Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Separator Differential Pressure Monitoring (Fouling)
Tracks restriction progression; improves timing of cleaning/element changeout
Differential Pressure (ΔP)
Quick Overview
| Problem | Separator performance depends on stable internal flow and phase separation, but fouling, liquid carryover, or restriction may not be immediately visible through standard instrumentation. |
| Solution | SENSAiO differential pressure sensors continuously monitor pressure drop across separators or internal elements to track evolving flow conditions. |
| Value | Improved visibility on separator condition and performance, supporting earlier detection of fouling or abnormal flow behavior. |
| ATEX | Suitable for hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
Separators are critical components in upstream production, ensuring proper phase separation between oil, gas, and water before further processing or export.
Their performance depends on stable flow conditions and unobstructed internal elements such as inlet devices, mist extractors, and internals designed to promote separation. Over time, several physical phenomena can degrade separator efficiency:
- Fouling or accumulation on internal elements
- Liquid carryover into gas streams
- Gas entrainment in liquid phases
- Partial blockage or restriction within the vessel
These conditions affect pressure distribution inside the separator. A restriction or fouling layer increases resistance to flow, while abnormal phase behavior can alter internal pressure dynamics.
However, these changes are not always immediately visible through standard process measurements such as inlet/outlet pressure or flow rates. In many cases, degradation develops progressively and remains undetected until separation efficiency drops or downstream equipment is impacted.
Why Continuous Differential Pressure Monitoring Matters
Differential pressure (ΔP) across a separator or across specific internal sections reflects the resistance to flow within the system.
Continuous monitoring enables operators to observe:
- Gradual increase in differential pressure that may indicate fouling or buildup
- Sudden changes in ΔP that may correlate with operational disturbances
- Deviations from baseline ΔP under similar flow conditions
- Instability that may indicate changing phase behavior or flow regime
Because ΔP is directly linked to flow resistance, it provides a sensitive indicator of internal condition, even when overall system pressure remains within normal limits.
Tracking ΔP over time allows operators to distinguish between stable operation and evolving degradation.
SENSAiO Solution
SENSAiO deploys wireless differential pressure sensors across separators or across selected points of interest (e.g., inlet to outlet, across internals, or across filters integrated within the system).
The sensors measure pressure difference between two points and transmit data via LoRaWAN networks.
This provides:
- Continuous ΔP trend monitoring
- Detection of deviations from expected operating conditions
- Data that can be correlated with flow rate, fluid composition, and operational changes
It is important to clarify that:
- The system is monitoring-only
- It does not control separator operation
- It does not diagnose specific internal failures
It provides measurable indicators that support interpretation of separator performance.
Results and ROI
ATEX Compliance and Safety
Separators are typically located in hazardous production areas requiring compliant instrumentation. SENSAiO differential pressure sensors are designed for such environments, with:
- ATEX / IECEx compliant configurations for Zone 0–2
- Certification aligned with gas group and temperature class requirements
- Mechanical robustness for exposure to pressure variation, vibration, and process conditions
Each device is delivered with certification documentation and installation guidelines.
SENSAiO is a monitoring-only system. It does not perform control, shutdown, or safety barrier functions and must be used alongside existing safety and process control systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Interoperable with SCADA / DCS platforms (Emerson, Honeywell, Schneider, ABB) |
| Deployment | Installation across separator pressure taps or connected lines; suitable for retrofit or new 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.
