Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Flare & Vent Line Acoustic Monitoring
Flags unusual discharge acoustics; supports faster event triage and follow-up
Acoustic
Quick Overview
| Problem | Undetected gas flow, leaks, or abnormal discharge in flare and vent lines may not be continuously visible, especially at low flow rates or during intermittent events. |
| Solution | SENSAiO acoustic sensors continuously monitor sound signatures in flare and vent lines to detect flow-related anomalies and acoustic activity. |
| Value | Improved visibility on flare and vent activity, supporting earlier identification of abnormal flow conditions and reduced undetected emissions. |
| ATEX | Suitable for hazardous environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
Flare and vent systems are critical for handling excess gas, pressure relief, and controlled release in upstream facilities. Under normal operation, these systems may remain inactive or operate intermittently depending on process conditions.
However, unintended or continuous gas flow can occur due to:
- Valve leakage or improper sealing
- Pressure relief valve passing or partial opening
- Process imbalance leading to unexpected venting
- Small leaks in connected piping
These flows may be low in magnitude or intermittent, making them difficult to detect using conventional instrumentation. Pressure measurements may remain within normal ranges, and flow meters are not always installed or sensitive enough for low-flow detection.
As a result, undetected venting or flaring can persist, leading to:
- Product loss
- Increased emissions
- Reduced process efficiency
- Potential regulatory concerns
Detecting these events early is challenging without a direct measurement of flow or a proxy signal sensitive to small changes.
Why Continuous Acoustic Monitoring Matters
Gas flow through pipes and valves generates acoustic energy due to turbulence, friction, and pressure gradients. Even low flow rates can produce detectable acoustic signatures, especially when passing through restrictions or leak paths.
Continuous acoustic monitoring enables detection of:
- Persistent low-level flow that may not be visible through pressure data
- Intermittent venting events
- Changes in acoustic intensity that may correlate with increasing or decreasing flow
- Deviations from baseline acoustic conditions during nominally inactive periods
Because acoustic signals respond directly to flow-induced turbulence, they provide a sensitive indicator of gas movement, even when other measurements remain stable.
This makes acoustic monitoring particularly relevant for flare and vent systems where early detection of unintended flow is important.
SENSAiO Solution
SENSAiO deploys wireless acoustic sensors on flare and vent lines to monitor structure-borne sound generated by gas flow.
The sensors are installed externally on the pipe and measure acoustic vibrations transmitted through the structure. These signals reflect internal flow behavior such as turbulence or leakage.
The system provides:
- Continuous acoustic trend monitoring
- Detection of deviations from baseline (e.g., silent vs active line)
- Identification of intermittent or continuous acoustic activity
It is important to clarify that:
- The system is monitoring-only
- It does not measure flow rate directly
- It does not confirm leak presence with certainty
- It does not perform control or shutdown actions
It provides a sensitive proxy measurement that supports detection of abnormal flow conditions.
Results and ROI
ATEX Compliance and Safety
Flare and vent systems operate in hazardous areas where gas presence is expected, requiring compliant instrumentation. SENSAiO acoustic sensors are designed for such environments, with:
- ATEX / IECEx compliant configurations for Zone 0–2
- Certification aligned with gas group and temperature class requirements
- Robust design for outdoor exposure, temperature variation, and vibration
Each sensor is supplied with appropriate certification and installation documentation.
SENSAiO is a monitoring-only system. It does not perform safety, shutdown, or emission control functions and must be used alongside existing safety and environmental management systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Interoperable with SCADA / DCS platforms (Emerson, Honeywell, Schneider, ABB) |
| Deployment | Installation on flare or vent lines; suitable for retrofit without process interruption |
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.
