Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Compressor & Fan Vibration Tracking (Predictive Maintenance & Energy Efficiency) — ATEX
Reduces energy waste, maintenance costs
Vibration
Quick Overview
| Problem | Compressors and large fans are among the most energy-intensive and failure-prone assets in refineries. Progressive mechanical degradation often remains undetected until vibration levels trigger trips, unplanned shutdowns, or safety incidents in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified vibration sensors continuously monitor compressors and fans, detecting early mechanical anomalies and enabling predictive maintenance before failures occur. |
| Value | Reduced unplanned downtime • Lower maintenance OPEX • Improved energy efficiency • Enhanced asset reliability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Downstream refineries rely on compressors and fans for:
- Process gas compression
- Air supply for furnaces and utilities
- Flue gas and exhaust handling
- Cooling and ventilation systems
These rotating assets operate continuously under harsh conditions, including:
- High rotational speeds
- Variable loads and process fluctuations
- Elevated temperatures
- Dust and corrosive atmospheres
Typical failure modes include:
- Bearing wear and lubrication failure
- Shaft misalignment
- Rotor imbalance
- Blade fouling or damage
- Structural resonance
Traditional monitoring approaches often consist of:
- Periodic handheld vibration surveys
- Alarm-based monitoring reacting only at high thresholds
- Reactive maintenance after trips
Such approaches provide limited early warning and often result in avoidable downtime and excess energy consumption.
Why Continuous Vibration Monitoring Matters
Vibration behaviour is a direct indicator of rotating equipment health.
Continuous vibration monitoring enables operators to:
- Detect bearing degradation weeks before failure
- Identify imbalance and misalignment early
- Monitor vibration trends under varying load conditions
- Correlate vibration with energy consumption and efficiency
Mechanical degradation increases friction and energy demand long before failure occurs. By addressing issues early, operators reduce both failure risk and energy waste.
In ATEX zones, continuous wireless monitoring also reduces the need for manual inspection near rotating and hazardous equipment.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe vibration monitoring solution for downstream compressors and fans.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, velocity, and frequency spectra to identify early-stage mechanical faults.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with refinery SCADA, CMMS, and energy management systems.
Installation & Power
Battery-powered magnetic or bolted installation on bearing housings or structural supports enables fast retrofit without shutdown.
Operational Benefits
- Early fault detection and diagnosis
- Reduced unplanned shutdowns
- Optimised maintenance scheduling
- Improved energy efficiency
Results and ROI
ATEX Compliance and Safety
All vibration sensors for compressor and fan 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 supports installation on live rotating equipment without shutdown, ensuring safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, CMMS, asset performance management 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.
