Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Leak Monitoring (Pressure & Acoustic)
Faster anomaly investigation trigger and correlation support
Acoustic
Quick Overview
| Problem | Pipeline leaks can be difficult to detect early, especially in remote or buried sections where instrumentation is limited. |
| Solution | SENSAiO combines pressure and acoustic monitoring to detect anomalies that may correlate with leak events. |
| Value | Improved visibility on pipeline integrity, supporting earlier investigation of abnormal conditions. |
| ATEX | Designed for hazardous pipeline environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pipelines transport fluids over long distances under varying pressure and flow conditions.
A leak in a pipeline results in a loss of containment, which physically manifests through:
- A local pressure drop due to fluid escape
- Generation of acoustic energy caused by turbulent flow through the leak point
- Possible pressure transients propagating along the line
Detecting leaks is challenging because:
- Pressure variations may also be caused by operational changes (pump start/stop, valve movement)
- Small leaks may generate limited pressure deviation at remote measurement points
- Acoustic signals attenuate with distance and depend on pipeline material and fluid properties
- Many pipeline sections lack continuous instrumentation coverage
As a result, early-stage leaks may remain undetected or require manual inspection.
Why Combined Pressure and Acoustic Monitoring Matters
Pressure and acoustic measurements capture complementary physical phenomena.
Pressure monitoring provides:
- Detection of gradual or sudden pressure drops
- Identification of abnormal pressure profiles along the pipeline
- Insight into transient hydraulic behavior
Acoustic monitoring provides:
- Detection of high-frequency signals generated by fluid escaping through a restriction
- Sensitivity to localized turbulence and leak-induced noise
Typical interpretations include:
- A pressure drop combined with acoustic activity may indicate a potential leak location
- Acoustic anomalies without significant pressure change may correspond to early-stage or small leaks
- Pressure transients without acoustic signature may be linked to operational events
Combining both measurements improves the ability to distinguish between operational events and potential leak conditions.
SENSAiO Solution
SENSAiO deploys wireless pressure and acoustic sensors along pipelines at strategic locations such as:
- Valve stations
- Critical segments
- High-risk areas (corrosion zones, crossings, connections)
These sensors continuously collect data and transmit it via LoRaWAN to a centralized monitoring platform.
The system enables:
- Continuous pressure and acoustic trend analysis
- Detection of deviations from normal operating conditions
- Correlation of multi-parameter data for improved interpretation
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform automatic leak confirmation
- It does not replace dedicated leak detection systems or safety systems
- It does not control pipeline operation
The data supports engineering analysis and field investigation.
Results and ROI
ATEX Compliance and Safety
Pipeline environments often fall under hazardous area classification due to the presence of flammable fluids. SENSAiO sensors:
- Are available in ATEX / IECEx certified versions for Zone 1–2
- Are designed for outdoor and remote environments
- Can operate under harsh environmental conditions (temperature, humidity, vibration)
Certification documentation is provided for compliance with applicable regulations.
SENSAiO systems are not safety systems and do not replace pipeline protection measures such as emergency shutdown systems or certified leak detection systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with pipeline SCADA and integrity management systems |
| Deployment | Suitable for retrofit on existing pipelines or integration into new infrastructure |
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.
