Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Downhole Acoustic Anomaly Detection (Leak & Sand Noise) — ATEX
Early fault detection, protects downhole equipment
Acoustic
Quick Overview
| Problem | Downhole integrity issues such as tubing leaks, sand production, or annular gas migration often develop silently. Conventional detection methods are intermittent, reactive, and require intrusive well interventions in hazardous environments. |
| Solution | SENSAiO’s ATEX-certified acoustic sensors provide continuous, non-intrusive acoustic monitoring at the wellhead, detecting abnormal sound signatures associated with leaks, sand impact, and flow anomalies in real time. |
| Value | Improved well integrity • Earlier anomaly detection • Reduced unplanned interventions • Lower HSE exposure |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified sensors |
The Operational Challenge
Well integrity remains one of the most critical challenges in upstream oil and gas operations. Tubing leaks, casing communication, sand ingress, or annular gas migration can progressively degrade well performance while remaining undetected for extended periods.
Industry standards such as API RP 90 and API RP 14C highlight that many integrity incidents are identified only after pressure anomalies, production losses, or safety alarms occur — at a stage where corrective actions are costly, disruptive, and often require well intervention.
Traditional integrity monitoring relies on:
- Periodic wireline acoustic logging
- Pressure surveys during planned shutdowns
- Manual inspections at the wellhead
These approaches are:
- Intermittent, offering only snapshots in time
- Intrusive, requiring specialised crews and production interruption
- Reactive, detecting problems after degradation has progressed
In addition, manual operations increase personnel exposure to ATEX-classified zones, particularly on mature fields with a high number of producing wells. As a result, operators lack continuous visibility into early-stage mechanical or flow-related anomalies, increasing integrity risk, lifecycle cost, and HSE exposure.
Why Acoustic Monitoring Matters
Acoustic monitoring is a recognised technique in well integrity and sand management, widely documented in SPE technical literature and deployed by major operators as a complementary surveillance layer.
Abnormal acoustic signatures can indicate:
- High-frequency noise generated by gas or fluid leaks
- Broadband acoustic energy caused by sand particle impact on tubing, chokes, or restrictions
- Flow regime changes and turbulence
- Mechanical vibration transmitted through tubing and casing
Unlike pressure monitoring alone, acoustic monitoring captures physical phenomena that often occur before measurable pressure deviations.
Continuous acoustic data allows operators to:
- Detect integrity degradation earlier
- Identify abnormal trends rather than isolated events
- Correlate sound patterns with operating conditions and pressure data
In practice, acoustic monitoring does not replace pressure or temperature measurements, but significantly strengthens integrity surveillance when used alongside them, especially on mature or high-risk wells.
Sensa.io Solution
SENSAiO delivers a wireless, intrinsically safe acoustic monitoring solution engineered for upstream wellhead environments.
Core Components
Acoustic Sensor (ATEX Ex ia IIC T4 Gb)
The sensor captures wide-band acoustic and vibration signals transmitted through wellhead structures.Its stainless steel enclosure is designed for continuous outdoor exposure and hydrocarbon environments.
Wireless Communication
Compatible with LoRaWAN, Modbus, and MQTT, enabling seamless integration into existing SCADA, DCS, or well integrity platforms without proprietary constraints.
Installation & Power
Battery-powered and non-intrusive, the sensor is installed using clamp-on mounting — no well intervention, no production shutdown, no hot work.
Operational Benefits
- Continuous integrity surveillance without wireline operations
- Earlier detection of leaks and sand production
- Reduced reliance on manual inspections and logging campaigns
- Improved safety in hazardous ATEX zones
Results and ROI
ATEX Compliance and Safety
All sensors used for this application comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
Sensors are suitable for installation on live wells and are delivered with full ATEX documentation, supporting HSE procedures and regulatory audits.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, well integrity platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted transmission with VPN-secured data flows |
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.
