Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
< Industries/
offshore-oil-gas
Smart Monitoring for Offshore Oil & Gas — ATEX-Certified Safety and Reliability
Quick Overview
| Problem | Offshore platforms and FPSOs face harsh marine conditions, complex process systems, and strict ATEX safety requirements. Failures or leaks can lead to costly shutdowns and environmental incidents. |
| Solution | Sensa.io provides ATEX-certified wireless sensors for valves, pressure, differential pressure, vibration, temperature, and acoustic monitoring, ensuring real-time reliability in offshore environments. |
| Value | ↑ Equipment uptime • ↓ Maintenance cost (−35 %) • Typical ROI < 12 months |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified sensors for marine and hazardous environments |
The Offshore Challenge
Offshore production is among the most demanding industrial environments:
exposure to salt spray, vibration, humidity, high temperatures, and explosive gases.
Manual inspections and wired instrumentation are costly, complex, and often unsafe.
Operators face a triple challenge:
- Maintaining equipment uptime despite harsh conditions.
- Ensuring ATEX compliance across hundreds of sensors and junctions.
- Reducing OPEX while guaranteeing personnel safety.
Wireless ATEX-certified sensing from Sensa.io brings a simple solution: continuous visibility of pumps, compressors, valves, and pipelines — without compromising safety or requiring heavy cabling.
Why ATEX and Wireless Monitoring Are Essential 🔥 ATEX
Most offshore facilities include large ATEX Zones (0, 1, and 2) across topsides, manifolds, and cargo decks.
Running cables through pressurised rooms or hazardous decks adds complexity and cost.
By adopting intrinsically safe wireless sensors, operators can:
- Remove the need for hard-wired installations.
- Collect continuous data from critical points (pressure, vibration, ΔP).
- Reduce offshore man-hours (no routine rounds in risky areas).
One offshore inspection avoided per week saves 60+ man-hours and €40,000 yearly per platform.
Core Use Cases for
Offshore Oil & Gas
Use Case
Sensor Type
ATEX
ROI/Value
Subsea Acoustic Anomaly Detection (Early Leak & Structural Event Detection) — ATEX
Acoustic
Fast underwater leak localization
Seawater Cooling Pressure & Temperature Monitoring (Cooling Reliability & Asset Protection) — Offshore / ATEX
Pressure
Temperature
Ensures cooling reliability, uptime
Structural Vibration Monitoring (Platform Integrity & Fatigue Detection)
Vibration
Prevents fatigue damage, compliance
Lube Oil Temperature Monitoring (Rotating Equipment Protection) — ATEX
Temperature
Prevents overheating, protects assets
Compressor Vibration & ΔP Filtration Monitoring (FPSO Process Reliability) — ATEX
Vibration
Differential Pressure (ΔP)
Predictive maintenance, uptime ↑
Acoustic Monitoring of Flare & Vent Stacks (Abnormal Venting & Leak Detection) — ATEX
Acoustic
Detects abnormal venting or leaks
Fuel Transfer Pressure Monitoring (FPSO Bunkering & Transfer Safety) — ATEX
Pressure
Prevents leaks, ensures safe bunkering
Ballast Tank Valve Position Monitoring (FPSO & Platform Stability) — ATEX
Valve position
Avoids ballast imbalance, safety-critical
Pump & Motor Vibration Monitoring (Topside Predictive Maintenance) — ATEX
Vibration
Prevents failures under harsh conditions
Pipeline Leak Detection (Topside & Subsea) Using Acoustic & Pressure Monitoring — ATEX
Acoustic
Pressure
Detects leaks within minutes, reduces spill risk
Pipeline Leak Detection (Topside & Subsea) Using Acoustic & Pressure Monitoring — ATEX
Pump & Motor Vibration Monitoring (Topside Predictive Maintenance) — ATEX
Ballast Tank Valve Position Monitoring (FPSO & Platform Stability) — ATEX
Fuel Transfer Pressure Monitoring (FPSO Bunkering & Transfer Safety) — ATEX
Acoustic Monitoring of Flare & Vent Stacks (Abnormal Venting & Leak Detection) — ATEX
Compressor Vibration & ΔP Filtration Monitoring (FPSO Process Reliability) — ATEX
Lube Oil Temperature Monitoring (Rotating Equipment Protection) — ATEX
Structural Vibration Monitoring (Platform Integrity & Fatigue Detection)
Seawater Cooling Pressure & Temperature Monitoring (Cooling Reliability & Asset Protection) — Offshore / ATEX
Subsea Acoustic Anomaly Detection (Early Leak & Structural Event Detection) — ATEX
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, MQTT, or 4–20 mA infrastructure. They integrate seamlessly with offshore SCADA/DCS (Honeywell, Emerson, Yokogawa, ABB, Schneider). Data flows securely via on-board network or satellite uplink. |
| Sensor Engineering |
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| Data Analytics |
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Proven ROI and Field Results
Operators who deployed Sensa.io in upstream fields typically achieved:
30–40 %
Unplanned downtime reduced
up to 25 %
Maintenance workload reduced
−60 %
Safety incidents related to manual rounds
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 ATEX Directive 2014/34/EU
Each device is delivered with a Declaration of Conformity, installation manual, and safety certificate.
The design guarantees zero ignition risk and long-term corrosion resistance under marine exposure.
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/
Offshore Oil & Gas
What is the typical ROI for offshore deployments?
6–12 months. Offshore environments offer the fastest ROI due to high intervention costs and downtime savings.
Do sensors interfere with cathodic protection systems?
No. All units are electrically isolated and designed to avoid galvanic coupling.
How is data transmitted from offshore to onshore?
Via LoRaWAN to local gateways, then through satellite or VPN-secured fibre backhaul to the onshore control room.
> Can sensors operate under cryogenic or high-temperature conditions? > > >
Yes. Models are available for −196 °C (LNG) to +125 °C environments.
How does subsea acoustic leak detection work?
Acoustic sensors detect high-frequency sound from escaping gas or oil. Algorithms correlate acoustic amplitude and frequency to localise leaks with ±10 m accuracy.
Are sensors affected by vibration from engines or waves?
No. They are vibration-rated up to 20 g RMS, tested under marine vibration profiles.
How do sensors resist corrosion and saltwater exposure?
All housings use marine-grade 316L, duplex stainless steel, or titanium with PTFE seals. Electronics are fully encapsulated and IP68/IP69K rated.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
