Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Gas Valve Position Monitoring
Reduced misrouting risk during maintenance or feedstock changes
Valve position
Quick Overview
| Problem | Gas valve positions in biogas plants are not always continuously verified, especially for manually operated or remotely located valves. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of valve open/closed status. |
| Value | Improved visibility on gas routing configuration, supporting detection of incorrect or unexpected valve positions. |
| ATEX | Designed for biogas environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Gas valves in biogas and waste-to-energy plants are used to:
- Control flow between digesters, storage, upgrading, and flare systems
- Isolate equipment during maintenance
- Manage gas routing under varying operating conditions
From a physical perspective:
- A valve’s position directly determines whether gas can flow
- An open valve allows pressure and flow continuity
- A closed valve isolates sections and prevents gas movement
In distributed biogas systems, valves are often:
- Manually operated
- Located in remote or hazardous areas
- Not instrumented with position feedback
Typical issues include:
- Valve left in incorrect position after intervention
- Partial or unintended opening/closing
- Mismatch between assumed and actual configuration
- Lack of traceability of valve operations
Detection challenges include:
- Dependence on manual checks
- Limited real-time visibility
- Infrequent verification in remote locations
- No centralized monitoring of valve states
As a result, incorrect valve configurations may persist undetected.
Why Valve Position Monitoring Matters
Valve position defines the physical configuration of the gas network.
By continuously monitoring valve status:
- Flow paths can be verified in real time
- Isolation conditions can be confirmed
- Unexpected changes can be detected
Typical interpretations include:
- Unexpected open valve may allow unintended gas flow
- Unexpected closed valve may restrict gas movement or cause pressure buildup
- Inconsistent state may indicate operational or mechanical issues
Valve position data reflects how gas is routed through the system.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors installed on:
- Manual gas valves
- Isolation valves
- Critical routing points within the plant
Sensors detect valve position (open/closed) and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous valve position monitoring
- Remote verification of valve states
- Alerts on unexpected position changes
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not enforce process logic or interlocks
- It does not replace safety or control systems
The system supports operational awareness and verification.
Results and ROI
ATEX Compliance and Safety
Biogas plants operate in explosive gas environments. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Are suitable for hazardous gas atmospheres
- Are designed for industrial classified zones
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace emergency shutdown systems, interlocks, 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 biogas plant monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing gas valves |
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.
