Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Safety Relief Valve Acoustic Monitoring
Early chatter detection and discharge anomaly visibility
Acoustic
Quick Overview
| Problem | Safety relief valve (SRV) releases are not always continuously detected, especially when discharge is intermittent or routed to closed systems. |
| Solution | SENSAiO acoustic sensors monitor sound signatures associated with SRV discharge events. |
| Value | Improved visibility on relief activity, supporting earlier identification of unexpected valve operation. |
| ATEX | Suitable for hazardous chemical environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Safety relief valves (SRVs) are critical protective devices designed to release pressure when system limits are exceeded.
They are commonly installed on:
- Reactors
- Pressure vessels
- Storage tanks
- Process lines
Under normal conditions, SRVs remain closed. When activated:
- Pressurized fluid is discharged
- Flow through the valve generates high-velocity turbulence
- This produces characteristic acoustic emissions
Operational challenges arise because:
- SRV discharges can be short-duration or intermittent
- Discharge may be routed to flare systems or closed headers
- Events are not always visible from control rooms
- Multiple valves may operate within the same system
From a physical perspective:
- Flow through a relief valve generates broadband acoustic الطاقة due to turbulence
- Acoustic intensity correlates with flow velocity and discharge conditions
- Repeated or sustained acoustic activity may indicate frequent relief events
Detection challenges include:
- Lack of continuous monitoring on all valves
- Difficulty distinguishing between normal and abnormal activation patterns
- Limited feedback unless pressure excursions are recorded simultaneously
As a result, some relief events may go unnoticed or be identified only after analysis.
Why Acoustic Monitoring Matters
Acoustic monitoring provides a direct way to detect flow events through SRVs.
By continuously measuring acoustic signals:
- Baseline noise conditions can be established
- Acoustic deviations can be detected in real time
- Event frequency and duration can be analyzed
Typical interpretations include:
- Sudden increase in acoustic amplitude may indicate valve opening
- Repeated acoustic bursts may correlate with cycling or unstable pressure conditions
- Sustained acoustic signal may indicate continuous discharge
Acoustic data reflects the physical presence of flow through the valve.
SENSAiO Solution
SENSAiO deploys wireless acoustic sensors installed near safety relief valves or on associated piping.
Sensors capture acoustic energy generated during valve discharge and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous acoustic trend monitoring
- Detection of abnormal acoustic events
- Alerts based on signal thresholds or pattern deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not detect pressure directly
- It does not control or actuate safety relief valves
- It does not replace certified safety or pressure protection systems
The system supports event visibility and post-event analysis.
Results and ROI
ATEX Compliance and Safety
SRVs operate in hazardous environments with flammable or reactive media. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for installation near pressurized process equipment
- Are designed for chemical and petrochemical environments
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace SRVs, pressure relief design, 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 plant monitoring and asset management platforms |
| Deployment | Suitable for retrofit on existing SRV 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.
