Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Flare Acoustic Monitoring
Faster anomaly triage and event reconstruction
Acoustic
Quick Overview
| Problem | Flare systems in biogas and waste-to-energy plants are not always continuously monitored, limiting visibility on abnormal flow or venting events. |
| Solution | SENSAiO acoustic sensors monitor sound signatures generated by gas flow in flare lines. |
| Value | Improved detection of abnormal venting behavior and confirmation of flare activity through acoustic patterns. |
| ATEX | Designed for explosive gas atmospheres, compliant with ATEX / IECEx requirements typical of biogas installations. |
The Operational Challenge
Flare systems are critical components in biogas and waste-to-energy facilities. They are used to:
- Safely burn excess biogas
- Release gas during maintenance or upset conditions
- Prevent overpressure in digestion and storage systems
From a physical perspective:
- Gas flowing through a flare line generates turbulence
- Turbulent flow produces acoustic انرژی (sound waves)
- The intensity and frequency of this sound depend on flow rate, pressure, and flow regime
Typical operational situations include:
- Normal flaring during excess gas production
- Intermittent flaring during process fluctuations
- Emergency venting under abnormal conditions
However, several issues can occur:
- Unintended or continuous flaring
- Undetected gas release
- Intermittent venting not properly tracked
- Blockage or restriction affecting flare efficiency
Detection challenges include:
- Remote location of flare stacks
- Limited instrumentation on flare lines
- Lack of continuous monitoring
- Difficulty distinguishing between normal and abnormal events
As a result, flare activity may not be fully visible to operations teams.
Why Acoustic Monitoring Matters
Acoustic monitoring captures the sound generated by gas flow.
By analyzing acoustic signals:
- Presence or absence of flow can be detected
- Changes in flow intensity can be observed
- Intermittent or abnormal events can be identified
Typical interpretations include:
- Increased acoustic amplitude may indicate higher gas flow
- Sudden acoustic events may correlate with venting or release
- Absence of expected sound may indicate no flow or possible blockage
Acoustic data reflects the physical behavior of gas moving through the flare system.
SENSAiO Solution
SENSAiO deploys wireless acoustic sensors installed on:
- Flare lines
- Vent lines connected to digesters or storage systems
- points
- Flare activity visibility
- upstream of flare stacks
Sensors detect acoustic emissions generated by gas flow and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous acoustic monitoring
- Detection of flow-related sound patterns
- Alerts on abnormal acoustic activity
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control flaring operations
- It does not regulate gas flow or combustion
- It does not replace safety systems or flare control units
The system supports operational awareness and investigation.
Results and ROI
ATEX Compliance and Safety
Biogas environments contain flammable gas mixtures. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for explosive gas atmospheres
- Are designed for installation in hazardous zones
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace flare control systems, gas detection systems, or regulatory safety requirements.
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 flare and vent lines |
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.
Explore Our Sensors
Valve position
The SENSAiO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
Temperature
SENSAiO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
Acoustic
The SENSAiO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
