Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Reactor Valve Position Monitoring
Reduced misrouting risk and faster transition verification
Valve position
Quick Overview
| Problem | Reactor valve positions are not always continuously verified, especially for manual or remotely located valves. |
| Solution | SENSAiO valve position sensors provide continuous monitoring of valve open/closed status. |
| Value | Improved visibility on reactor configuration, supporting earlier detection of incorrect or unexpected valve states. |
| ATEX | Suitable for hazardous chemical environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Valves around chemical reactors are critical for controlling:
- Feed injection
- Product exit
- Recirculation loops
- Isolation during maintenance or shutdown
Correct valve positioning is essential to maintain:
- Proper flow paths
- Reaction stability
- Safe isolation conditions
However, several operational challenges exist:
- Many valves are manually operated
- Remote or hard-to-access locations limit direct verification
- Process changes require frequent valve adjustments
- Documentation may not reflect real-time valve state
From a physical perspective:
- A closed valve blocks flow, potentially leading to upstream pressure buildup
- A partially open valve introduces flow restriction and pressure drop
- Incorrect valve alignment can alter residence time or mixing conditions
Detection challenges include:
- Lack of real-time feedback on valve position
- Dependence on manual checks or operator reporting
- Inability to quickly confirm valve configuration during process upsets
As a result, discrepancies between intended and actual valve position may persist unnoticed.
Why Valve Position Monitoring Matters
Valve position is a discrete but critical parameter in reactor operation.
By continuously monitoring valve state:
- Operators can verify process configuration in real time
- Unexpected valve changes can be detected
- Operational sequences can be validated
Typical interpretations include:
- A valve expected to be open but detected closed may indicate operational error
- A partially actuated valve may correlate with abnormal flow or pressure conditions
- Unexpected position change may indicate mechanical or human intervention
Valve position data provides direct insight into how the process is configured.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors mounted directly on reactor valves.
Sensors detect valve state (open / closed or position change) and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous valve position monitoring
- Real-time visibility across reactor systems
- Alerts on unexpected position changes
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not actuate or control valves
- It does not enforce process interlocks or safety logic
- It does not replace control systems or safety systems
The system supports verification and operational awareness.
Results and ROI
ATEX Compliance and Safety
Reactor environments often involve flammable or hazardous substances. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for installation on process valves in chemical plants
- Are designed for industrial hazardous environments
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace interlocks, 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 reactor 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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Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
