Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
< Industries/
upstream-oil-gas
Smart Monitoring for Upstream Oil & Gas Operations — ATEX-Certified Reliability
Quick Overview
| Problem | Limited visibility and manual inspection in hazardous upstream environments cause unplanned shutdowns and safety risks. |
| Solution | ATEX-certified LoRaWAN sensors for valves, pressure, differential pressure, temperature, vibration, and acoustic monitoring across wells and flowlines. |
| Value | ↑ Safety compliance ↑ Equipment uptime ↓ Maintenance cost (-30 %) ROI < 12 months |
| ATEX | Zones 0–2 |
The Operational Challenge in Upstream Production
Upstream oil and gas operations operate under extreme physical and regulatory constraints. Wellheads, separators, and injection lines are subject to high pressure, temperature variations, and explosive atmospheres. Even small deviations in pressure, flow, or valve position can trigger production losses or major incidents.
Every hour of unplanned shutdown can represent thousands of euros in lost output and several tonnes of unrecoverable hydrocarbons. Traditional inspection methods — manual gauge readings or periodic rounds — provide only a fragmented view of equipment status and expose personnel to unnecessary risk.
Visibility, safety, and efficiency are now inseparable pillars of upstream performance. Real-time monitoring through intrinsically safe sensors is the new foundation of operational excellence.
Why Atex and continous monitoring matter
The upstream segment is one of the most demanding ATEX environments in the industrial world. Zones 0, 1 and 2 require certified equipment that can function safely in the presence of explosive gases and vapours. Manual inspections in such conditions are time-consuming and potentially hazardous.
By deploying wireless ATEX-certified sensors, operators gain continuous data from critical points — without intrusive wiring or hot-work permits. Real-time visibility transforms maintenance from reactive to predictive, reducing both incident probability and field exposure.
60 % of safety-related events in upstream production originate from equipment not under active monitoring.
Core Use Cases for
Upstream Oil & Gas
Use Case
Sensor Type
ATEX
ROI/Value
Downhole Acoustic Anomaly Detection (Leak & Sand Noise) — ATEX
Acoustic
Early fault detection, protects downhole equipment
Produced Water Filtration ΔP Monitoring (Clogging Detection & Process Reliability)
Differential Pressure (ΔP)
Maintains process reliability, optimizes filter change cycles
Wellhead Structural Vibration Monitoring (Upstream Integrity & Casing Protection) — ATEX
Vibration
Identifies abnormal mechanical stress, prevents casing damage
Pump Vibration & Performance Monitoring (Early Fault Detection) — ATEX
Vibration
Prevents catastrophic failures, extends equipment life
Flare & Vent Line Acoustic Monitoring for Early Leak and Blockage Detection — ATEX
Acoustic
Detects leaks or unauthorized venting, improves safety
Flowline Temperature Monitoring for Hydrate & Wax Prevention — ATEX
Temperature
Prevents blockages, maintains flow assurance
Chemical Injection Skid Monitoring (Methanol & Inhibitors) — ATEX
Pressure
Valve position
Ensures consistent dosing, prevents corrosion and plugging
Separator Differential Pressure Monitoring (Filter Fouling & Process Stability) — ATEX
Differential Pressure (ΔP)
Avoids process upsets, reduces maintenance downtime
Gas & Water Injection Pressure Monitoring (Reservoir Integrity & Control) — ATEX
Pressure
Temperature
Maximizes reservoir efficiency, reduces over-injection risk
Tubing & Casing Pressure Monitoring (Well Integrity) — ATEX
Pressure
Detects leaks or blockages early, optimizes production
Wellhead Valve Position Monitoring (ESD & Production Valves) — ATEX
Valve position
Prevents blowouts, ensures ESD compliance, reduces manual inspections
Gas & Water Injection Pressure Monitoring (Reservoir Integrity & Control) — ATEX
Tubing & Casing Pressure Monitoring (Well Integrity) — ATEX
Wellhead Valve Position Monitoring (ESD & Production Valves) — ATEX
Chemical Injection Skid Monitoring (Methanol & Inhibitors) — ATEX
Flare & Vent Line Acoustic Monitoring for Early Leak and Blockage Detection — ATEX
Pump Vibration & Performance Monitoring (Early Fault Detection) — ATEX
Produced Water Filtration ΔP Monitoring (Clogging Detection & Process Reliability)
Downhole Acoustic Anomaly Detection (Leak & Sand Noise) — ATEX
Vibration
Acoustic
Differential Pressure (ΔP)
Temperature
Pressure
Valve position
How Sensa.io Technology Works
| Open Wireless Architecture | Sensa.io sensors are gateway-agnostic and fully compatible with all major LoRaWAN networks and industrial gateways on the market (Kerlink, MultiTech, Cisco, Milesight, etc.). They can also integrate via 4G/LTE or Ethernet backhaul for hybrid architectures. |
| Sensor Design |
|
| Integration | Sensors interface directly with any existing LoRaWAN Network Server, SCADA, or cloud platform through standard protocols (MQTT, Modbus, HTTP API). This open interoperability allows operators to integrate Sensa.io sensors seamlessly into their preferred infrastructure — no proprietary gateway required. |
| Data Intelligence | Continuous data streams are analysed to identify:
This transforms raw data into actionable maintenance insights. |
Proven ROI and Field Results
Operators who deployed Sensa.io in upstream fields typically achieved:
-30%
maintenance cost reduction within 12 months
+20%
increase in equipment availability
0
safety incidents related to manual gauge checks in ATEX zones
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 and ATEX Directive 2014/34/EU
Each shipment includes Declaration of Conformity, installation manual, and maintenance schedule. ATEX compliance ensures safe digitalisation of critical assets even in explosive atmospheres.
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/
Upstream Oil & Gas
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