Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Filter Train Differential Pressure Monitoring
Progressive restriction tracking and optimized changeout timing
Differential Pressure (ΔP)
Quick Overview
| Problem | Progressive fouling in filter trains increases flow resistance and may go unnoticed between inspections. |
| Solution | SENSAiO differential pressure sensors continuously monitor pressure drop across filter stages. |
| Value | Improved visibility on filter loading, supporting earlier intervention and optimized maintenance. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Filter trains are used in refining processes to remove particulates and contaminants from process streams.
They are typically installed in series and may include:
- Coarse filters
- Fine filtration stages
- Polishing filters
During operation, solid particles accumulate on filter media, progressively restricting flow.
This results in a physical phenomenon:
- Increase in pressure upstream of the filter
- Decrease in pressure downstream
- Growth of differential pressure (ΔP) across the filter
Key degradation mechanisms include:
- Particle loading and cake formation
- Fouling due to chemical deposition
- Filter media saturation or blockage
Detecting these conditions is challenging because:
- Fouling develops gradually
- Manual pressure readings are intermittent
- Filters may be located across large units
- Early-stage restriction may not impact process conditions immediately
As a result, filters may operate beyond optimal conditions or be replaced too early.
Why Differential Pressure Monitoring Matters
Differential pressure (ΔP) is a direct indicator of flow resistance through a filter.
By continuously measuring ΔP:
- Baseline conditions can be established for clean filters
- Progressive increases can be tracked over time
- Abnormal deviations can be identified
Typical interpretations include:
- A gradual increase in ΔP may indicate normal particle accumulation
- A rapid increase may suggest accelerated fouling or blockage
- A sudden drop in ΔP may indicate filter bypass or media failure
Differential pressure monitoring provides a direct and physically meaningful signal of filter condition.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across filter inlet and outlet points.
Sensors continuously measure ΔP and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous tracking of differential pressure trends
- Detection of deviations from expected behavior
- Alerts when ΔP exceeds defined thresholds or patterns
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not determine optimal replacement timing automatically
- It does not control process flow or filtration systems
- It does not diagnose root causes of fouling
The system supports maintenance planning and operational awareness.
Results and ROI
ATEX Compliance and Safety
Filter trains in refining environments are often located in classified hazardous areas. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for installation in process environments with pressure and तापमान constraints
- Can be deployed directly on process piping
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace process protection or filtration integrity safeguards.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with plant monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing filter trains |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
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Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
