Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Process Filter Differential Pressure Monitoring
Restriction tracking and optimized maintenance timing
Differential Pressure (ΔP)
Quick Overview
| Problem | Process filters progressively foul during operation, but differential pressure is not always continuously monitored across all units. |
| Solution | SENSAiO differential pressure sensors monitor pressure drop across process filters in real time. |
| Value | Improved visibility on filter condition, supporting earlier detection of clogging or abnormal filtration behavior. |
| ATEX | Suitable for hazardous chemical environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Process filters are widely used in chemical and petrochemical plants to:
- Remove particles or contaminants from fluids
- Protect downstream equipment
- Maintain product quality
During operation, filters accumulate solids, which leads to:
- Increasing resistance to flow
- Rising pressure drop across the filter
- Reduced effective throughput
From a physical perspective:
- Differential pressure (ΔP) reflects the المقاومة to fluid flow across the filter media
- As fouling increases, ΔP increases
- Changes in flow regime or fluid properties also influence ΔP
Typical issues include:
- Gradual clogging reducing process efficiency
- Sudden blockage due to particle accumulation
- Filter media damage leading to bypass or reduced filtration
Detection challenges include:
- Limited instrumentation on secondary or distributed filters
- Manual inspection intervals
- Lack of continuous performance tracking
- Difficulty correlating process issues with filter condition
As a result, filter degradation or failure may not be identified early.
Why Differential Pressure Monitoring Matters
Differential pressure is the primary measurable indicator of filter performance.
By continuously monitoring ΔP:
- Clean filter baseline conditions can be established
- Fouling trends can be tracked over time
- Abnormal behavior can be detected
Typical interpretations include:
- Gradual ΔP increase may indicate normal fouling
- Rapid ΔP rise may correlate with process upset or contamination spike
- Sudden ΔP drop may indicate filter rupture or bypass
Differential pressure provides a direct measurement of hydraulic resistance across the filter.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors installed across process filters.
Sensors measure upstream and downstream pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous ΔP trend monitoring
- Detection of abnormal pressure behavior
- Alerts based on thresholds or deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control filtration or cleaning systems
- It does not automatically diagnose filter condition
- It does not replace process control or safety systems
The system supports operational visibility and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Process filters are often installed in hazardous chemical environments. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for installation on pressurized process lines
- Are designed for industrial chemical applications
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace process protection, filtration safeguards, or regulatory requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with plant monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing filtration systems |
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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A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
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.
