Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
< Industries/
marine-ports-transport
Smart Monitoring for Marine, Ports & Transport — ATEX-Certified Reliability and Efficiency
Quick Overview
| Problem | Fuel handling, port pumping, and vessel operations involve flammable liquids, high mechanical stress, and complex logistics under strict ATEX constraints. Manual inspections expose operators to safety and downtime risks. |
| Solution | Sensa.io provides ATEX-certified wireless sensors for pressure, differential pressure, vibration, valve position, temperature, and acoustic monitoring — ensuring reliable, compliant, and efficient marine and port operations. |
| Value | ↑ Safety compliance • ↓ Downtime (−30 %) • ROI < 12 months |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified sensors for marine and fuel environments |
The Marine and Port Challenge
Marine, port, and transport infrastructures operate 24/7 under heavy mechanical load, variable temperatures, and vibration.
They move enormous volumes of fuel, water, and cargo — often through hazardous ATEX zones where ignition risk is constant.
Manual checks are still common, creating two major issues:
- Gaps in real-time visibility → undetected pressure drops or valve misalignments.
- Safety risks → human exposure during inspections in confined or explosive areas.
With wireless, intrinsically safe sensors, port authorities and ship operators can continuously monitor pressure, flow, and vibration — ensuring safety, reducing maintenance costs, and enabling predictive decision-making.
Why ATEX Monitoring Is Essential 🔥 ATEX
From ship bunkering lines to port fuel depots and engine rooms, flammable vapours and diesel fumes are ever-present.
Even a small spark from an uncertified sensor can trigger a catastrophic incident.
Sensa.io solves this by providing ATEX-certified wireless sensors designed specifically for marine and fuel-handling environments.
They enable continuous, non-intrusive data collection without cabling, welding, or hot-work permits.
Each unplanned hour of port equipment downtime can cost up to €25,000 in delayed loading and demurrage fees.
Core Use Cases for
Marine, Ports & Transport
Use Case
Sensor Type
ATEX
ROI/Value
Port Stormwater Pressure & Acoustic Monitoring (Flood & Environmental Protection)
Pressure
Acoustic
Prevents flooding, environmental compliance
Ballast Pump Temperature & Vibration Monitoring (Stability & Reliability Assurance)
Temperature
Vibration
Predictive maintenance
Acoustic Leak Detection in Marine Pipelines (Buried & Submerged Lines) — ATEX
Acoustic
Detects leaks in buried or submerged pipelines
Cargo Transfer Pressure & Valve Monitoring (Bunkering & Liquid Transfer Operations) — ATEX
Pressure
Valve position
Safety during transfer operations
Fuel Hydrant Valve & Pressure Monitoring (Airports & Aviation Fuel Systems) — ATEX
Valve position
Pressure
Prevents leaks, improves traceability
Pump Vibration Monitoring (Port Facilities & Marine Transfer Systems) — ATEX
Vibration
Prevents unplanned downtime
Marine Fuel Filter Differential Pressure Monitoring (Predictive Maintenance & Fuel Quality) — ATEX
Differential Pressure (ΔP)
Predicts maintenance, ensures clean fuel
Marine Fuel Filter Differential Pressure Monitoring (Predictive Maintenance & Fuel Quality) — ATEX
Pump Vibration Monitoring (Port Facilities & Marine Transfer Systems) — ATEX
Fuel Hydrant Valve & Pressure Monitoring (Airports & Aviation Fuel Systems) — ATEX
Cargo Transfer Pressure & Valve Monitoring (Bunkering & Liquid Transfer Operations) — ATEX
Acoustic Leak Detection in Marine Pipelines (Buried & Submerged Lines) — ATEX
Engine Vibration Monitoring (Ships & Marine Propulsion Systems)
Ballast Pump Temperature & Vibration Monitoring (Stability & Reliability Assurance)
Fuel Tank Pressure Monitoring (Ports & Ships) — ATEX
Fire Water System Valve Position Monitoring (Ports & Terminals)
Port Stormwater Pressure & Acoustic Monitoring (Flood & Environmental Protection)
Vibration
Acoustic
Differential Pressure (ΔP)
Temperature
Pressure
Valve position
How Sensa.io Technology Works
| Open Wireless Architecture | Sensa.io sensors are gateway-agnostic, connecting to any LoRaWAN or MQTT network and integrating with port SCADA or ship control systems. They operate independently of proprietary infrastructure — fully interoperable with Kerlink, Cisco, Milesight, or MultiTech gateways. |
| Marine-Grade Sensor Design |
|
| Data Intelligence |
All data are transmitted securely (AES-128 encryption) to SCADA or cloud dashboards for real-time diagnostics and predictive analytics. |
Proven ROI and Field Results
Operators who deployed Sensa.io in upstream fields typically achieved:
−30 %
Pump maintenance cost reduction
from hours to minutes
Leak detection time reduced
40 %
Fuel quality incidents reduced
Case Example
Acoustic & Vibration Detection of Rockfall or Structural Movement (Early Warning & Worker Protection)
Early warning to protect workers underground
Case Example
Gas Vent Line Acoustic & Pressure Anomaly Detection (Methane Hazard Early Warning)
Early detection of dangerous methane releases
ATEX Compliance and Safety
All Sensa.io sensors for upstream operations comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Gas Zones 0–1)
- Ex ia IIIC T135 °C Db (Dust Zones 20–21)
- IECEx certified and compliant with Directive 2014/34/EU
Every device includes Declaration of Conformity, ATEX label, and calibration certificate.
ATEX compliance ensures safety even in confined engine rooms, fuel depots, and refuelling stations.
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.
General & Functionality
What is the typical ROI when deploying sensors in upstream production?
Depending on asset criticality and scope, operators generally achieve payback within 6 to 12 months, driven by reduced downtime, lower maintenance overhead, and improved safety compliance.
How are calibration and maintenance handled in ATEX zones?
Sensors are factory-calibrated and include internal digital calibration tables. No field recalibration is required for 5–10 years; visual inspection every 3 years is sufficient.
How are data transmissions secured in remote fields?
All data packets are encrypted end-to-end with AES-128, and communication can run over private LoRaWAN or VPN-secured 4G networks. This guarantees industrial-grade cybersecurity and compliance with IT/OT segmentation policies.
Can Sensa.io sensors monitor hydrate or wax formation in flowlines?
Yes. Temperature sensors placed along the flowline detect critical cooling patterns leading to hydrate or wax build-up. Real-time data allows proactive heating or chemical injection, avoiding costly blockages.
How does acoustic leak detection work in upstream applications?
Acoustic sensors detect high-frequency sound anomalies generated by gas or fluid leaks. When combined with pressure readings, they localise the leak within ±10 m, reducing detection time from hours to minutes.
Can sensors remain active during well interventions or shutdowns?
Yes. Thanks to intrinsically safe (Ex ia) design, sensors can operate continuously in Zone 0 even during interventions, without hot-work permits or risk of ignition.
How do pressure sensors resist sand abrasion and high vibration in wellheads?
Each pressure module uses 316L stainless-steel diaphragms and vibration-proof electronics (rated up to 20 g RMS) with conformal coating. This ensures long-term stability in abrasive and high-shock environments typical of wellhead zones.
How does predictive maintenance with Sensa.io actually reduce OPEX?
By analysing vibration, pressure, or ΔP trends, the system detects anomalies before they escalate. This reduces emergency interventions by 30–40 %, extends equipment lifetime, and lowers energy consumption by 10–15 %.
How can Sensa.io sensors be integrated into our SCADA or DCS system?
Integration is immediate through standard industrial protocols: LoRaWAN, Modbus RTU/TCP, MQTT, or REST API. Data can feed directly into Honeywell, Emerson, Schneider, or ABB SCADA platforms without middleware.
How long do the batteries last in upstream operations?
Up to 10 years depending on the transmission interval and signal quality. The adaptive power management system automatically adjusts the sending frequency according to the measured parameter’s variability.
What ATEX certifications cover Sensa.io sensors?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb (Gas Zones 0–2) and Ex ia IIIC T135°C Db (Dust Zones 20–21). They are also IECEx approved and comply with the European Directive 2014/34/EU.
Are Sensa.io sensors compatible with any LoRaWAN gateway or network?
Yes. Sensa.io sensors are fully gateway-agnostic and connect seamlessly to any LoRaWAN or MQTT-compatible infrastructure — including Kerlink, Cisco, Milesight, MultiTech, or private industrial networks. This ensures flexible integration with existing SCADA or IoT systems.
Specific Technical Questions/
Marine, Ports & Transport
What ROI can be expected from port-wide deployment?
Typically 6–10 months, due to high cost of unplanned pump failures and demurrage savings.
Are sensors certified for ship classification compliance (BV, DNV)?
Yes, Sensa.io sensors are compatible with marine standards and can be integrated into class-approved automation systems.
What maintenance is required?
None for 5–10 years beyond visual inspection. Sensors are self-calibrated and conformally coated to resist humidity and salt ingress.
Can vibration sensors differentiate between cavitation and normal operation?
Yes. Sensa.io’s vibration analytics distinguish harmonic signatures of cavitation from standard vibration profiles, reducing false alarms.
How do sensors resist corrosion from seawater and fuel?
Marine-grade 316L or duplex stainless-steel bodies and PTFE seals prevent corrosion and ensure long-term reliability.
How does acoustic leak detection work in submerged lines?
Acoustic sensors identify ultrasonic leak patterns through pipelines or ballast lines, correlating noise with pressure variations to localise leaks.
Can sensors operate during fuel transfer or bunkering?
Yes, intrinsically safe design allows use during loading/unloading without risk of ignition, even in Zone 0 environments.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
