Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Gas Storage Overpressure Monitoring
Improved event visibility and response coordination
Pressure
Quick Overview
| Problem | Gas storage systems in biogas plants are not always continuously monitored for pressure buildup, limiting visibility on abnormal accumulation. |
| Solution | SENSAiO pressure sensors provide continuous monitoring of gas storage pressure. |
| Value | Improved detection of abnormal pressure increase, supporting earlier identification of imbalance between gas production and consumption. |
| ATEX | Designed for biogas environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Biogas storage systems (e.g., gas holders, membranes, or tanks) are used to:
- Buffer fluctuations between production and consumption
- Maintain stable supply to downstream systems
- Prevent continuous flaring or gas loss
From a physical perspective:
- Gas accumulation increases internal pressure
- Pressure depends on stored volume, temperature, and system flexibility
- Membrane or storage systems have defined pressure operating ranges
Typical operational situations include:
- Variable gas production from digesters
- Intermittent consumption by engines or upgrading units
- External factors such as temperature variation
Common issues include:
- Overpressure due to excess gas production
- Insufficient gas withdrawal downstream
- Malfunction of pressure control or relief systems
- Restricted flow between storage and consumption units
Detection challenges include:
- Limited continuous instrumentation on storage units
- Reliance on local gauges or manual checks
- Difficulty detecting gradual pressure increase
- Lack of centralized monitoring
As a result, abnormal pressure buildup may not be immediately identified.
Why Pressure Monitoring Matters
Pressure is a key indicator of storage system behavior.
By continuously monitoring pressure:
- Gas balance between production and consumption can be assessed
- Deviations from normal operating ranges can be detected
- Trends in pressure buildup can be analyzed
Typical interpretations include:
- Increasing pressure may indicate gas accumulation
- Stable high pressure may indicate limited consumption capacity
- Sudden pressure rise may correlate with process imbalance
Pressure data reflects the dynamic equilibrium of the biogas system.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed on:
- Gas holders
- Storage membranes
- Buffer tanks and associated piping
Sensors measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous pressure monitoring
- Trend analysis over time
- Alerts on abnormal pressure deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control gas pressure or flow
- It does not regulate storage systems
- It does not replace safety devices such as pressure relief valves
The system supports operational awareness and early investigation.
Results and ROI
ATEX Compliance and Safety
Biogas storage systems operate in explosive gas atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for hazardous gas environments
- Are designed for industrial classified zones
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace pressure relief systems, gas safety systems, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with biogas monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing storage systems |
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.
