Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Ballast Pump Temperature & Vibration Monitoring (Stability & Reliability Assurance)
Predictive maintenance
Temperature
Vibration
Quick Overview
| Problem | Ballast pumps are critical for vessel stability, trim, and safety. Overheating, bearing wear, cavitation, or vibration issues often develop unnoticed until pump failure compromises ballast operations, manoeuvrability, or compliance with maritime safety regulations. |
| Solution | SENSAiO’s wireless temperature and vibration sensors continuously monitor ballast pump health, detecting thermal and mechanical anomalies early to ensure reliable ballast operations. |
| Value | Improved vessel stability • Reduced pump failures • Lower maintenance OPEX • Enhanced operational safety |
| ATEX | Not required in most ballast systems; ATEX-certified sensor versions available when installed near fuel or hazardous zones |
The Operational Challenge
Ballast pumps are used for:
- Vessel stability and trim control
- Cargo loading and unloading operations
- Compliance with ballast water management regulations
- Emergency stability correction
These pumps operate under challenging conditions:
- Variable flow rates and frequent start/stop cycles
- Exposure to seawater corrosion and debris
- Limited redundancy during operations
- High consequence of failure during manoeuvring
Common failure modes include:
- Motor overheating due to overload or cooling issues
- Bearing wear and lubrication degradation
- Cavitation caused by suction restrictions
- Vibration from misalignment or imbalance
Traditional monitoring typically involves:
- Manual temperature checks
- Periodic inspection during port calls
- Reactive repairs after alarms
This results in late detection and increased operational risk.
Why Temperature & Vibration Monitoring Matters
Temperature and vibration are the earliest indicators of pump health.
Continuous monitoring enables operators to:
- Detect overheating before motor damage occurs
- Identify bearing and mechanical degradation early
- Detect cavitation and hydraulic instability
- Maintain reliable ballast operations
Early fault detection ensures vessel stability is maintained at all times, especially during critical manoeuvres.
SENSAiO Solution
SENSAiO delivers a wireless pump condition monitoring solution for marine ballast systems.
Core Components
Temperature Sensor
Measures motor and bearing housing temperature to detect overheating and abnormal load.
Vibration Sensor
Captures vibration patterns indicating bearing wear, imbalance, misalignment, or cavitation.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with ship automation systems and maintenance platforms.
Installation & Power
Battery-powered magnetic or bolted installation on pump motor and housing — no cabling required.
Operational Benefits
- Reduced risk of ballast pump failure
- Improved vessel stability and safety
- Optimised maintenance scheduling
- Lower emergency repair costs
Results and ROI
ATEX Compliance and Safety
Ballast pump monitoring supports compliance with:
- IMO Ballast Water Management Convention
- Classification society requirements
- Vessel safety management systems
ATEX-certified sensor versions are available when sensors are installed in hazardous zones.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Ship automation, ballast management, CMMS |
| Vendors | ABB Marine, Wärtsilä, Siemens, Kongsberg |
| 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.
