Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Hydrogen Valve Position Verification
Reduced misalignment risk in high-pressure routing
Valve position
Quick Overview
| Problem | The actual position of hydrogen valves (open/closed) is not always continuously monitored, especially in distributed or hazardous areas. |
| Solution | SENSAiO valve position sensors provide continuous verification of valve status. |
| Value | Improved operational visibility, supporting confirmation of valve state and detection of unexpected or inconsistent positions. |
| ATEX | Designed for hydrogen environments, compliant with ATEX / IECEx requirements for explosive gas atmospheres. |
The Operational Challenge
Hydrogen infrastructure relies on valves to:
- Isolate sections of the network
- Control flow routing
- Enable maintenance operations
- Ensure process segmentation
From a physical perspective:
- A valve position directly determines whether gas flow is allowed or blocked
- An open valve enables pressure and flow continuity
- A closed valve isolates pressure and stops flow
In hydrogen systems, valve status is critical due to:
- High diffusivity of hydrogen gas
- Sensitivity to leakage and pressure imbalance
- Strict operational procedures for isolation
Typical issues include:
- Valve left partially open or closed
- Manual operation not correctly executed
- Mismatch between expected and actual valve position
- Lack of feedback from remote or inaccessible valves
Detection challenges include:
- Manual verification requirements
- Limited instrumentation on field valves
- Inaccessible or hazardous locations
- Lack of centralized visibility
As a result, valve position inconsistencies may remain unnoticed.
Why Valve Position Monitoring Matters
Valve position is a binary but critical operational parameter.
By continuously monitoring valve status:
- The actual state of the system can be confirmed
- Isolation conditions can be verified
- Unexpected changes can be detected
Typical interpretations include:
- Unexpected open valve may allow unintended flow
- Unexpected closed valve may restrict flow or create pressure buildup
- Inconsistent position may indicate mechanical or operational issues
Valve position data reflects the physical configuration of the system at any time.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors installed on:
- Manual valves
- Isolation valves
- Critical hydrogen line valves
Sensors detect valve position (open/closed state) and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous valve state monitoring
- Remote verification of valve positions
- Alerts on unexpected state 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 verification and field awareness.
Results and ROI
ATEX Compliance and Safety
Hydrogen environments are classified hazardous due to flammable gas presence. SENSAiO sensors:
- Are available with ATEX / IECEx certification for gas zones
- Are suitable for hydrogen installations
- Are designed for use in explosive atmospheres
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 hydrogen operation and maintenance platforms |
| Deployment | Suitable for retrofit on existing valves without major 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.
