Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Compressor Vibration & ΔP Filtration Monitoring (FPSO Process Reliability) — ATEX
Predictive maintenance, uptime ↑
Vibration
Differential Pressure (ΔP)
Quick Overview
| Problem | Offshore compressors are mission-critical assets on FPSOs and platforms. Progressive mechanical degradation and filter clogging often go undetected until performance drops, trips occur, or safety margins are compromised in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified vibration and differential pressure (ΔP) sensors provide continuous monitoring of compressor health and filtration condition, enabling predictive maintenance and stable offshore operations. |
| Value | Reduced unplanned trips • Improved compressor availability • Lower maintenance OPEX • Enhanced safety |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration & ΔP sensors |
The Operational Challenge
Compressors on FPSOs and offshore platforms are used for:
- Gas compression and export
- Gas lift and reinjection
- Fuel gas supply
- Process and utility services
These systems operate under:
- Continuous duty cycles
- Variable pressure and flow conditions
- High vibration and mechanical stress
- Limited maintenance access offshore
Two major degradation drivers are often linked:
Mechanical degradation
- Bearing wear and lubrication issues
- Rotor imbalance and misalignment
- Surge or unstable operating regimes
Filtration degradation
- Suction filter clogging
- Discharge filter fouling
- Progressive pressure losses affecting efficiency
Traditional monitoring typically relies on:
- Periodic vibration surveys
- Local ΔP gauges checked manually
- Compressor trips as the first failure indicator
This reactive approach leads to avoidable downtime and costly offshore interventions.
Why Combined Vibration & ΔP Monitoring Matters
Vibration and differential pressure together provide a complete picture of compressor health.
Continuous vibration monitoring enables operators to:
- Detect bearing wear and imbalance early
- Identify surge-related vibration patterns
- Monitor mechanical stability under load changes
Continuous ΔP monitoring enables operators to:
- Detect progressive filter clogging
- Prevent suction starvation or discharge restriction
- Maintain stable compressor performance
By correlating vibration trends with ΔP evolution, operators can distinguish mechanical faults from process-induced issues, enabling faster and more accurate diagnosis.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe compressor monitoring solution combining vibration and filtration condition monitoring.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, velocity, and frequency spectra to detect early mechanical faults.
Differential Pressure Sensor (ATEX Ex ia IIC T4 Gb)
Monitors pressure drop across suction or discharge filters to identify fouling trends.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with offshore SCADA, CMMS, and reliability platforms.
Installation & Power
Battery-powered, clamp-on or threaded installation — no cabling or shutdown required.
Operational Benefits
- Early detection of compressor mechanical faults
- Prevention of performance loss due to filter clogging
- Reduced emergency shutdowns
- Optimised offshore maintenance planning
Results and ROI
ATEX Compliance and Safety
All sensors for offshore compressor 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 allows safe deployment in explosive offshore environments without shutdown.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, CMMS, asset performance management |
| Vendors | Honeywell, ABB, Emerson, Siemens |
| 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.
