Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Steam Leak Acoustic Detection
Faster identification of high-energy steam anomalies
Acoustic
Quick Overview
| Problem | Steam leaks can be difficult to detect early, especially in complex piping networks where visual inspection is limited. |
| Solution | SENSAiO acoustic sensors continuously monitor high-frequency sound signatures associated with steam leakage. |
| Value | Improved detection of abnormal acoustic activity, supporting earlier investigation of potential steam leaks. |
| ATEX | Suitable for industrial environments; ATEX / IECEx versions available for classified areas (Zone 1–2). |
The Operational Challenge
Steam systems are widely used in industrial facilities for heating, processing, and energy transfer.
Steam is typically transported under pressure through extensive piping networks. A leak occurs when steam escapes through a defect such as:
- Flange gasket degradation
- Valve packing wear
- Pipe corrosion or cracking
- Failed connections or fittings
Physically, a steam leak generates:
- A rapid expansion of pressurized vapor
- Turbulent flow at the leak point
- High-frequency acoustic emissions
Detecting steam leaks is challenging because:
- Steam is often invisible, especially at high pressure
- Leaks may occur in inaccessible or insulated areas
- Background noise in industrial environments can mask early-stage leaks
- Detection often relies on manual inspection or audible identification
As a result, small leaks may persist undetected and evolve over time.
Why Acoustic Monitoring Matters
Acoustic monitoring focuses on detecting the sound energy generated by turbulent fluid flow through a leak.
When steam escapes through a restriction:
- The pressure differential creates high-velocity flow
- This flow generates broadband acoustic emissions, often in ultrasonic or high-frequency ranges
Continuous acoustic monitoring enables:
- Detection of abnormal sound patterns associated with leaks
- Identification of changes in acoustic intensity over time
- Monitoring of areas where visual inspection is not feasible
Typical interpretations include:
- A persistent high-frequency acoustic signal may indicate continuous leakage
- An increase in acoustic intensity may correlate with leak growth
- Intermittent acoustic signals may reflect variable operating conditions
Acoustic data provides an indirect but sensitive indication of leak-related phenomena.
SENSAiO Solution
SENSAiO deploys wireless acoustic sensors installed on or near steam lines, valves, or fittings.
These sensors continuously measure acoustic activity and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous acoustic trend monitoring
- Detection of deviations from baseline noise levels
- Alerts based on abnormal acoustic patterns
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not confirm the presence of a leak with certainty
- It does not quantify leak rate or size
- It does not replace inspection or maintenance procedures
The system supports early detection and prioritization of field investigation.
Results and ROI
ATEX Compliance and Safety
Steam systems may be located in both non-classified and hazardous industrial environments. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Can be deployed in areas where flammable gases may be present
- Are designed for industrial conditions including temperature and vibration
All equipment is provided with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace leak detection systems required for safety-critical applications.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with plant monitoring and maintenance systems |
| Deployment | Suitable for retrofit on existing steam networks |
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.
