Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Tank Overpressure Monitoring
Early deviation visibility and improved event reconstruction
Pressure
Quick Overview
| Problem | Storage tanks may experience pressure build-up due to thermal expansion or process imbalance, which can be difficult to detect continuously. |
| Solution | SENSAiO pressure sensors monitor internal tank pressure trends to identify abnormal pressure increases. |
| Value | Improved visibility on tank pressure behavior, supporting earlier detection of overpressure conditions. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Storage tanks in refining and downstream facilities are used to contain hydrocarbons and process fluids.
These tanks are typically designed to operate within specific pressure ranges, often near atmospheric conditions.
Pressure inside a tank can increase due to several physical mechanisms:
- Thermal expansion of vapor due to temperature rise
- Vapor generation from volatile liquids
- Inadequate venting or restricted breather valves
- Process upsets such as overfilling or gas ingress
These conditions lead to:
- Increase in internal vapor pressure
- Stress on tank structure and sealing systems
- Activation of pressure relief or venting devices
Detecting overpressure conditions is challenging because:
- Pressure changes may be gradual
- Tanks are often distributed across large tank farms
- Instrumentation may be limited or not continuously monitored
- Manual checks are periodic
As a result, abnormal pressure build-up may not be identified early.
Why Pressure Monitoring Matters
Pressure is a direct physical indicator of tank internal conditions.
By continuously monitoring pressure:
- Normal operating pressure ranges can be established
- Deviations from baseline can be detected
- Pressure trends can be analyzed over time
Typical interpretations include:
- A gradual pressure increase may indicate thermal effects or vapor accumulation
- A rapid increase may correlate with process upset or restricted venting
- Pressure oscillations may reflect unstable venting behavior
Pressure monitoring provides a direct and measurable indication of tank situation.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors installed on tank vapor space or connected piping.
Sensors continuously measure pressure and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous pressure trend monitoring
- Detection of abnormal pressure deviations
- Alerts based on threshold exceedance or unusual trends
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not control tank pressure or venting systems
- It does not replace pressure relief devices or safety systems
- It does not guarantee prevention of overpressure events
The system supports operational awareness and early investigation.
Results and ROI
ATEX Compliance and Safety
Tank farms handling hydrocarbons are classified hazardous areas. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for installation in vapor-rich environments
- Can be deployed on tanks and associated piping
All equipment is provided with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace pressure relief valves, breather 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 tank monitoring and maintenance platforms |
| Deployment | Suitable for retrofit on existing storage tanks |
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.
