Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Compressor Vibration Monitoring (Predictive Maintenance & Uptime) — ATEX
Avoids breakdowns, reduces OPEX, improves uptime
Vibration
Quick Overview
| Problem | Midstream compressors operate under high mechanical and thermal stress. Bearing wear, imbalance, or misalignment can escalate rapidly into catastrophic failures, unplanned shutdowns, and safety incidents. Periodic inspections often detect issues too late, especially in ATEX-classified compressor stations. |
| Solution | SENSAiO’s ATEX-certified vibration sensors provide continuous, wireless monitoring of compressor mechanical health, detecting early vibration anomalies and enabling predictive maintenance strategies. |
| Value | Reduced unplanned shutdowns • Extended equipment life • Lower maintenance OPEX • Improved availability |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Compressors are among the most critical assets in midstream operations, used for gas transportation, boosting, and processing. Their reliability directly impacts throughput, contractual delivery obligations, and energy efficiency.
Common compressor failure mechanisms include:
- Bearing wear and lubrication degradation
- Rotor imbalance or misalignment
- Mechanical looseness and coupling defects
- Structural resonance and fatigue
Traditional monitoring approaches often rely on:
- Periodic vibration surveys
- Motor current or performance indicators
- Reactive maintenance after alarms or trips
These approaches provide intermittent snapshots, missing gradual degradation or transient vibration events that precede major failures. In ATEX environments, frequent manual inspection increases personnel exposure and operational risk.
Why Continuous Vibration Monitoring Matters
Vibration is one of the earliest and most reliable indicators of rotating machinery health.
Continuous monitoring allows operators to:
- Detect bearing defects at an early stage
- Identify imbalance or misalignment trends
- Monitor changes in operating regime or load
- Prevent secondary damage caused by progressive vibration
For compressors, early vibration anomalies often precede:
- Seal failure
- Rotor contact or rubbing
- Emergency shutdowns
By trending vibration data continuously, operators move from corrective to predictive maintenance, improving reliability and reducing lifecycle cost.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe vibration monitoring solution designed for midstream compressor stations.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures vibration levels and patterns relevant to rotating machinery health. Suitable for continuous monitoring in harsh industrial environments.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with SCADA and condition monitoring systems.
Installation & Power
Battery-powered and compact. Magnetic or bolted mounting on compressor casings, bearing housings, or structural supports.
Operational Benefits
- Early detection of mechanical degradation
- Reduced unplanned compressor trips
- Improved maintenance planning
- Extended service intervals
Results and ROI
ATEX Compliance and Safety
All vibration sensors for 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 enables installation on live compressor equipment without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, condition monitoring, asset management platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Security | 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.
