Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Reactor Temperature Monitoring
Early detection of abnormal thermal drift
Temperature
Quick Overview
| Problem | Temperature variations inside or around reactors are not always continuously monitored at all critical points. |
| Solution | SENSAiO temperature sensors monitor reactor temperature trends in real time. |
| Value | Improved visibility on thermal behavior, supporting earlier detection of abnormal temperature deviations. |
| ATEX | Suitable for hazardous chemical environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Chemical reactors operate under controlled temperature conditions to ensure:
- Reaction stability
- Product quality
- Safe operating conditions
Temperature directly influences:
- Reaction kinetics
- Heat generation or absorption
- Phase behavior of reactants and products
From a physical perspective:
- Exothermic reactions generate heat, increasing temperature
- Endothermic reactions absorb heat, reducing temperature
- Heat transfer limitations may create temperature gradients
Typical issues include:
- Localized overheating due to reaction hotspots
- Insufficient cooling leading to gradual temperature rise
- Unstable temperature control during process transitions
- Thermal stratification within large vessels
Detection challenges include:
- Limited number of installed temperature points
- Incomplete coverage of reactor surfaces or zones
- Delay between temperature deviation and detection
- Difficulty capturing localized thermal effects
As a result, abnormal thermal behavior may develop without immediate visibility.
Why Temperature Monitoring Matters
Temperature is one of the most critical parameters in reactor operation.
By continuously monitoring temperature:
- Baseline operating conditions can be established
- Deviations from expected temperature ranges can be detected
- Trends over time can be analyzed
Typical interpretations include:
- A gradual temperature increase may indicate insufficient cooling or increased reaction rate
- Sudden temperature rise may correlate with reaction instability
- Temperature fluctuations may reflect process variability
Temperature data provides direct insight into reaction thermal dynamics.
SENSAiO Solution
SENSAiO deploys wireless temperature sensors installed on reactor الخارجية surfaces or associated piping.
Sensors continuously measure temperature and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous temperature trend monitoring
- Detection of abnormal temperature deviations
- Alerts based on thresholds or unusual patterns
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control reactor temperature or cooling systems
- It does not model reaction kinetics or predict runaway reactions
- It does not replace process control or safety systems
The system supports operational awareness and investigation.
Results and ROI
ATEX Compliance and Safety
Reactor environments may involve flammable or hazardous chemicals. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for installation in chemical processing environments
- Are designed for industrial temperature monitoring applications
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace reactor protection systems, emergency shutdown systems, or regulatory safety requirements.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with process monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing reactors |
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.
