Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pipeline Acoustic & Vibration Monitoring (Early Leak & Anomaly Detection) — ATEX
Early anomaly alerts, reduces inspection frequency
Acoustic
Vibration
Quick Overview
| Problem | Small pipeline leaks, mechanical defects, or external interference often generate acoustic or vibration signatures long before pressure loss becomes visible. These early signals are rarely detected by conventional monitoring, allowing leaks to grow into major incidents. |
| Solution | SENSAiO’s ATEX-certified acoustic and vibration sensors continuously monitor pipelines to detect abnormal sound and vibration patterns associated with leaks, mechanical damage, or third-party interference — in real time. |
| Value | Early leak detection • Reduced spill impact • Fewer inspections • Improved pipeline integrity |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified acoustic & vibration sensors |
The Operational Challenge
Midstream pipelines extend over long distances and are exposed to multiple risk factors:
- Progressive corrosion or pinhole leaks
- Mechanical damage from ground movement or vibration
- Third-party interference (excavation, vehicle impact)
- Fatigue at welds, bends, or supports
Traditional detection methods typically rely on:
- Pressure balance or flow discrepancy analysis
- Periodic patrols and visual inspection
- Post-event investigation after alarms or spills
These methods often detect leaks late, especially when leakage rates are small or transient. In ATEX environments, frequent physical inspection also increases personnel exposure and operational cost.
Why Acoustic & Vibration Monitoring Matters
Leaks and mechanical anomalies generate distinct acoustic and vibration signatures before they cause measurable pressure loss.
Continuous monitoring enables operators to:
- Detect pinhole leaks and micro-fractures early
- Identify abnormal vibration from pipe movement or fatigue
- Detect third-party interference near buried or exposed pipelines
- Localise anomaly zones for targeted inspection
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Unlike pressure-based methods, acoustic and vibration monitoring focuses on mechanical behaviour, enabling detection at a much earlier stage.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe acoustic and vibration monitoring solution for midstream pipelines.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
Captures a wide frequency range to detect leak noise, flow anomalies, and mechanical sounds transmitted through the pipe wall.
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures vibration amplitude and frequency to detect abnormal mechanical behaviour.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling real-time integration with pipeline SCADA and integrity platforms.
Installation & Power
Battery-powered clamp-on installation suitable for exposed pipelines, supports, and valve stations.
Operational Benefits
- Early detection of small leaks
- Reduced spill volume and environmental impact
- Fewer routine patrols and inspections
- Faster localisation of problem areas
Results and ROI
ATEX Compliance and Safety
All acoustic and vibration sensors for pipeline monitoring comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
The intrinsically safe design enables installation on live pipelines without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, pipeline integrity, leak detection platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted communication with secure transport |
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 Sensa iO 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
Sensa iO’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 Sensa iO 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, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
