Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Fuel Tank Pressure Monitoring
Improved overpressure event visibility
Pressure
Quick Overview
| Problem | Fuel tanks are subject to pressure variations due to filling, temperature changes, and vapor generation, but these variations are not always continuously monitored. |
| Solution | SENSAiO pressure sensors provide continuous monitoring of internal tank pressure. |
| Value | Improved visibility of pressure evolution, supporting earlier detection of abnormal conditions such as overpressure or vacuum formation. |
| ATEX | Available in ATEX / IECEx versions for hazardous fuel storage environments. |
The Operational Challenge
Fuel storage tanks in marine and port environments are exposed to dynamic conditions:
- Fuel loading and unloading operations
- Ambient temperature variations
- Vapor expansion and contraction
- Breathing through venting systems
From a physical standpoint:
- Liquid fuel and vapor coexist within the tank
- Temperature increases cause vapor expansion and pressure rise
- Cooling leads to pressure decrease and potential vacuum formation
Typical issues include:
- Overpressure due to excessive vapor generation or blocked venting
- Vacuum conditions during rapid unloading or cooling
- Malfunction or restriction in breather valves
- Undetected abnormal pressure fluctuations
Detection challenges:
- Pressure is often inferred rather than directly measured
- Venting issues may not be immediately visible
- Manual inspections do not capture transient pressure events
- Pressure excursions can occur between inspection intervals
As a result, tanks may operate outside optimal pressure ranges without clear indication.
Why Pressure Monitoring Matters
Pressure inside a fuel tank reflects the thermodynamic balance between liquid and vapor phases.
By continuously monitoring pressure:
- Pressure excursions can be detected in real time
- Venting system performance can be indirectly assessed
- Abnormal operating conditions can be identified earlier
Typical interpretations include:
- Gradual pressure increase may indicate normal thermal expansion
- Rapid pressure rise may indicate restricted venting
- Pressure drop below atmospheric may indicate vacuum conditions or excessive withdrawal
Pressure trends provide insight into tank breathing behavior and system integrity.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed on:
- Tank roof nozzles
- Vapor space access points
- Vent line connections
Sensors measure internal pressure and transmit data via LoRaWAN to a centralized platform.
The system enables:
- Continuous pressure monitoring
- Trend analysis of tank pressure behavior
- Alerts on deviations from expected ranges
Clarifications:
- SENSAiO is a monitoring-only system
- It does not control vent valves or pressure relief devices
- It does not regulate tank pressure
- It does not replace certified overpressure protection systems
It provides data to support operational awareness and investigation.
Results and ROI
ATEX Compliance and Safety
Fuel tanks are typically classified as hazardous areas due to the presence of flammable vapors. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Suitable for Zone 0 / Zone 1 / Zone 2 depending on installation design
- Designed for harsh marine and industrial environments
The system not act as a safety instrumented function (SIF) or trigger shutdown or relief actions but provides monitoring data to support safe operation practices
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard industrial LoRaWAN gateways |
| Systems | Integration with tank management and terminal systems |
| Deployment | Retrofit on existing tanks without process modification |
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.
