Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Valve Position Verification
Faster confirmation of valve alignment during unit transitions
Valve position
Quick Overview
| Problem | The actual position of pipeline valves is not always continuously verified, especially in remote or unmanned locations. |
| Solution | SENSAiO valve position sensors monitor and transmit the open/closed state of valves in real time. |
| Value | Improved visibility on valve status, supporting operational verification and reducing uncertainty. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pipeline networks rely on valves to control, isolate, or redirect flow.
These valves are critical for:
- Section isolation during maintenance
- Flow routing across network segments
- Emergency shutdown procedures
- Operational configuration management
In practice, several issues may arise:
- Valve position not matching recorded status
- Partial opening or incomplete closure
- Human error during manual operation
- Lack of feedback from non-instrumented valves
From a physical standpoint:
- A valve that is partially open introduces flow restriction
- A valve that remains open when expected closed allows unintended flow
- A closed valve in an active line can cause pressure buildup upstream
Detecting these conditions is challenging because:
- Many valves are manually operated and not instrumented
- Pipelines can extend over large and remote areas
- Verification often requires physical inspection
- SCADA systems may not have real-time feedback for all assets
As a result, uncertainty around valve position can impact operations and maintenance.
Why Valve Position Monitoring Matters
Valve position is a discrete but critical parameter.
By continuously monitoring valve position:
- The actual state (open/closed) can be verified
- Changes in position can be tracked over time
- Discrepancies between expected and actual state can be identified
Typical interpretations include:
- A mismatch between commanded and measured position may indicate operational inconsistency
- Unexpected position changes may reflect unintended intervention
- Lack of position change during operation may indicate mechanical issues
Valve position data provides a direct indication of mechanical state.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors mounted on manual or automated valves.
Sensors detect valve state (e.g., open or closed) and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous monitoring of valve position
- Event-based tracking of position changes
- Alerts when unexpected position states are detected
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not verify sealing integrity or leakage
- It does not replace safety shutdown systems
The system supports operational visibility and verification.
Results and ROI
ATEX Compliance and Safety
Pipeline valves are often located in hazardous areas with flammable fluids. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for outdoor and industrial environments
- Can be installed on both manual and actuated valves
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace emergency shutdown systems or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with SCADA, asset management, and maintenance systems |
| Deployment | Suitable for retrofit on existing pipeline valves |
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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The SENSAiO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
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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.
