Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Filter / Strainer Differential Pressure Monitoring
Restriction progression tracking
Differential Pressure (ΔP)
Quick Overview
| Problem | Pipeline filters and strainers progressively accumulate debris, but clogging is not always detected before it impacts flow or equipment. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across filters and strainers. |
| Value | Improved visibility of fouling progression, supporting earlier maintenance decisions. |
| ATEX | Available in ATEX / IECEx versions for hazardous marine and fuel transfer environments. |
The Operational Challenge
Pipeline filters and strainers are installed to:
- Protect downstream equipment (pumps, valves, meters)
- Remove particulates and debris from fluid streams
- Maintain process reliability in fuel and cargo transfer systems
From a physical perspective:
- Fluid flows through a filtering element
- Particles accumulate over time
- This creates resistance to flow
As fouling increases:
- The pressure upstream of the filter rises
- The pressure downstream decreases or remains stable
- The differential pressure (ΔP) increases
Typical issues include:
- Progressive clogging due to debris accumulation
- Sudden blockage from large particles
- Reduced flow efficiency
- Increased stress on upstream pumps
Detection challenges:
- Filters are often inspected on a schedule, not condition
- Pressure drop is not continuously measured
- Flow reduction may be attributed to other causes
- Early-stage clogging may not be visible
As a result, filters may operate in degraded conditions without detection.
Why Differential Pressure Monitoring Matters
Differential pressure is a direct indicator of flow resistance across the filter.
By measuring ΔP:
- Fouling progression can be tracked over time
- Abnormal blockage events can be identified
- Cleaning or replacement can be scheduled based on condition
Typical interpretations include:
- Gradual increase in ΔP may indicate normal fouling buildup
- Rapid increase may indicate sudden blockage
- Stable low ΔP indicates clean or low-resistance condition
This measurement reflects the physical interaction between fluid and filtering element.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across:
- Inlet and outlet of filters or strainers
- Accessible pressure tapping points
Sensors measure upstream and downstream pressure to calculate ΔP and transmit data via LoRaWAN.
The system provides:
- Continuous differential pressure monitoring
- Trend analysis over time
- Alerts on abnormal deviations
Clarifications:
- SENSAiO is a monitoring-only system
- It does not clean or backflush filters
- It does not regulate flow or pressure
- It does not determine exact clogging composition
It supports operational visibility and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Pipeline filtration systems in marine and fuel transfer environments may be located in hazardous areas. SENSAiO sensors:
- Are available with ATEX / IECEx certification
- Suitable for Zone 1 / Zone 2 installations depending on configuration
- Designed for harsh industrial and marine environments
The system does not act as a safety barrier or trigger shutdown systems but provides monitoring data to support safe operation practices
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN infrastructure |
| Systems | Integration with SCADA, terminal management, and maintenance platforms |
| Deployment | Retrofit on existing filters without process interruption |
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
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Vibration
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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.
