Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Pressure Transient & Surge Monitoring
Improved reconstruction of surge events and hydraulic stress analysis
Pressure
Quick Overview
| Problem | Pressure transients in pipelines are often not fully captured, despite their impact on mechanical integrity and operational stability. |
| Solution | SENSAiO pressure sensors continuously monitor pressure variations to detect transient events and abnormal behaviors. |
| Value | Improved understanding of pipeline dynamics, supporting earlier investigation of potentially damaging conditions. |
| ATEX | Suitable for hazardous pipeline environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pipeline systems are subject to dynamic operating conditions.
Pressure transients can occur due to:
- Rapid valve closures or openings
- Pump start-up or shutdown sequences
- Flow regime changes
- Emergency shutdown events
These transients propagate as pressure waves along the pipeline and may result in:
- Short-duration overpressure or underpressure events
- Mechanical stress on pipes, joints, and fittings
- Fatigue accumulation over time
- In extreme cases, conditions associated with hydraulic shock (water hammer)
In many installations, pressure measurements are limited to steady-state monitoring, with low sampling rates or insufficient spatial coverage.
As a result:
- Short-duration transients may not be recorded
- Pressure peaks may remain undetected
- Root cause analysis of mechanical issues becomes more difficult
Why Pressure Transient Monitoring Matters
Pressure transient monitoring focuses on capturing the dynamic behavior of the system rather than only steady-state values.
Continuous pressure measurement enables:
- Detection of rapid pressure changes associated with operational events
- Identification of pressure spikes that may exceed normal operating ranges
- Observation of pressure wave propagation patterns
- Correlation between transient events and equipment operation
Typical interpretations include:
- Repeated pressure spikes may indicate frequent hydraulic stress conditions
- Sudden pressure drops may correlate with rapid flow changes or system disturbances
- Oscillating pressure signals may reflect unstable flow regimes
These observations help engineers understand how the pipeline responds to real operating conditions.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors along pipelines, particularly at:
- Pump stations
- Valve stations
- Critical segments prone to transient events
Sensors continuously measure pressure and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous pressure trend monitoring
- Detection of deviations from typical pressure behavior
- Historical data for transient event analysis
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform hydraulic modeling or simulation
- It does not control pipeline operation
- It does not replace surge protection systems
The data supports engineering analysis and operational awareness.
Results and ROI
ATEX Compliance and Safety
Pipeline environments handling hydrocarbons or gases are typically classified hazardous areas. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for outdoor and remote installations
- Are designed to withstand harsh environmental conditions
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace protective measures such as surge relief systems or emergency shutdown systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with SCADA and pipeline monitoring systems |
| Deployment | Suitable for retrofit or new pipeline installations |
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.
