Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Slurry Pipeline Pressure Monitoring
Blockage and erosion anomaly visibility
Pressure
Quick Overview
| Problem | Slurry transport pipelines operate under variable conditions, and pressure behavior is not always continuously monitored along the line. |
| Solution | SENSAiO pressure sensors provide continuous monitoring of slurry pipeline pressure. |
| Value | Improved visibility on flow conditions, supporting earlier detection of blockages, leaks, or abnormal hydraulic behavior. |
| ATEX | Suitable for hazardous mining environments where applicable, compliant with ATEX / IECEx requirements. |
The Operational Challenge
Slurry pipelines are used in mining operations to transport mixtures of:
- Water
- Fine ore particles
- Process residues
These pipelines operate under complex hydraulic conditions influenced by:
- Flow velocity
- Solid concentration
- Particle size distribution
- Pump performance
From a physical perspective:
- Pressure reflects the energy required to move slurry through the pipeline
- Friction, sedimentation, and geometry affect pressure loss
- Changes in flow regime directly impact pressure behavior
Typical issues include:
- Partial or complete blockage due to sedimentation
- Pipeline wear or internal buildup
- Pump performance degradation
- Leakage or rupture
Detection challenges include:
- Long pipeline distances with limited instrumentation points
- Harsh environments restricting sensor deployment
- Difficulty detecting gradual buildup or early-stage restriction
- Reliance on pump-level measurements rather than distributed monitoring
As a result, abnormal flow conditions may develop without immediate detection.
Why Pressure Monitoring Matters
Pressure is a key indicator of slurry flow behavior.
By continuously monitoring pressure:
- Hydraulic conditions along the pipeline can be observed
- Deviations from normal operating ranges can be detected
- Trends indicating gradual change can be identified
Typical interpretations include:
- Increasing pressure may indicate blockage, buildup, or increased resistance
- Decreasing pressure may indicate leakage or reduced flow
- Fluctuating pressure may correlate with unstable flow regimes or pump issues
Pressure data reflects the interaction between fluid movement and pipeline resistance.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed at strategic points along slurry pipelines, such as:
- Pump discharge points
- Intermediate sections
- Critical elevation changes
Sensors measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous pressure monitoring
- Trend analysis over time
- Alerts on abnormal pressure deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control pumps or flow rates
- It does not regulate pipeline operation
- It does not replace pipeline integrity management systems or safety protections
The system supports earlier investigation and operational decision-making.
Results and ROI
ATEX Compliance and Safety
Some slurry transport environments may be classified hazardous depending on materials and conditions. SENSAiO sensors:
- Are available with ATEX / IECEx certification where required
- Are designed for harsh industrial environments
- Can be installed on pipeline infrastructure
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace pipeline protection systems, leak detection 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 mining process and maintenance platforms |
| Deployment | Suitable for retrofit along existing slurry pipelines |
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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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
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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.
