Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Heat Exchanger Temperature Monitoring
Earlier fouling detection and thermal efficiency tracking
Temperature
Quick Overview
| Problem | Heat exchanger performance degradation is often gradual and difficult to detect between inspections. |
| Solution | SENSAiO temperature sensors continuously monitor thermal conditions at key points of the exchanger. |
| Value | Improved visibility on heat transfer behavior, supporting earlier detection of fouling or process deviations. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Heat exchangers are critical assets in refining processes, enabling heat transfer between fluids for:
- Heating or cooling process streams
- Energy recovery and efficiency optimization
- Temperature control of reactions and separations
Their performance depends on efficient heat transfer across surfaces separating two fluids.
Over time, degradation mechanisms may affect performance:
- Fouling due to scaling, deposition, or corrosion
- Reduced heat transfer coefficient
- Flow maldistribution inside the exchanger
- Partial blockage or channel restriction
From a physical perspective, these issues manifest as:
- Reduced temperature difference between inlet and outlet
- Changes in thermal gradients across the exchanger
- Deviation from expected heat transfer profiles
Detecting these changes is challenging because:
- Fouling develops progressively
- Process variability can mask early symptoms
- Manual measurements are intermittent
- Many exchangers are distributed across large units
As a result, performance losses may remain unnoticed until they impact efficiency.
Why Temperature Monitoring Matters
Temperature is a direct indicator of heat transfer performance.
By continuously measuring temperatures at strategic points:
- Inlet and outlet temperatures can be trended
- Thermal performance baselines can be established
- Deviations from expected behavior can be detected
Typical interpretations include:
- A decrease in temperature difference may indicate reduced heat transfer efficiency
- An increasing temperature approach may correlate with fouling
- Asymmetrical temperature patterns may suggest flow maldistribution
Temperature data provides a direct and physically meaningful insight into exchanger behavior.
SENSAiO Solution
SENSAiO deploys wireless temperature sensors installed on process lines at exchanger inlet and outlet points.
Sensors continuously measure temperature and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous temperature trend monitoring
- Detection of deviations from expected thermal profiles
- Alerts based on abnormal temperature behavior
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not calculate full heat exchanger efficiency or duty automatically
- It does not diagnose fouling mechanisms
- It does not control process conditions
The system supports operational monitoring and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Heat exchangers in refineries are commonly located in hazardous areas due to hydrocarbon presence. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for industrial environments with temperature constraints
- Can be installed on process piping close the exchanger
All equipment is provided with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace process protection or thermal control systems.
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 heat exchangers |
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.
