Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Hydrogen Purification Filter Differential Pressure Monitoring
Restriction progression tracking
Differential Pressure (ΔP)
Quick Overview
| Problem | Filtration stages in hydrogen purification systems are not always continuously monitored, making it difficult to detect gradual clogging or filter degradation. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across purification filters. |
| Value | Improved visibility on filtration performance, supporting earlier detection of abnormal flow resistance or filter condition changes. |
| ATEX | Designed for hydrogen environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Hydrogen purification systems include filtration stages used to:
- Remove particulates
- Protect downstream equipment
- Ensure gas quality
These filters operate under controlled flow conditions where pressure behavior is critical.
From a physical perspective:
- Gas flowing through a filter creates a pressure drop due to resistance
- As contaminants accumulate, resistance increases, leading to higher differential pressure
- Filter degradation or rupture may reduce resistance, lowering differential pressure
Typical issues include:
- Progressive filter clogging
- Filter media degradation
- Channeling or bypass within the filter
- Inefficient filtration due to damage
Detection challenges include:
- Lack of continuous monitoring across distributed filtration stages
- Reliance on periodic inspection or manual gauges
- Difficulty detecting early-stage fouling
- Limited visibility on real-time gas flow resistance
As a result, filtration inefficiencies may develop without immediate detection.
Why Differential Pressure Monitoring Matters
Differential pressure is a direct indicator of filter condition.
By continuously monitoring differential pressure:
- Filter loading trends can be tracked
- Deviations from expected performance can be identified
- Abnormal conditions can be detected earlier
Typical interpretations include:
- Increasing differential pressure may indicate clogging or fouling
- Sudden decrease in differential pressure may indicate filter damage or bypass
- Stable but elevated pressure may indicate end-of-life filter condition
Differential pressure reflects the resistance encountered by gas flowing through the filter.
Sensa.io Solution
SENSAiO deploys wireless differential pressure sensors installed across:
- Filter inlet and outlet points
- Critical filtration stages in purification systems
Sensors measure pressure difference and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous differential 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 filtration systems
- It does not regulate gas flow
- It does not replace purification control systems or safety devices
The system supports maintenance planning and operational awareness.
Results and ROI
ATEX Compliance and Safety
Hydrogen purification systems operate in explosive gas atmospheres. SENSAiO sensors:
- Are available with ATEX / IECEx certification for gas zones
- Are suitable for hydrogen infrastructure
- Are designed for hazardous industrial environments
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace gas safety systems, pressure protection devices, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with hydrogen processing and maintenance platforms |
| Deployment | Suitable for retrofit on existing filtration 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.
