Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump & Agitator Vibration Monitoring (Predictive Maintenance & Asset Protection)
Avoids unplanned downtime
Vibration
Quick Overview
| Problem | Pumps and agitators are among the most failure-prone rotating assets in chemical and process plants. Bearing wear, cavitation, imbalance, or misalignment often develop silently and lead to seal failures, leaks, unplanned shutdowns, and safety incidents—particularly critical in hazardous or ATEX-adjacent environments. |
| Solution | Sensa.io’s wireless vibration sensors provide continuous monitoring of pumps and agitators, detecting early mechanical degradation and enabling predictive maintenance without wiring or production interruption. |
| Value | Reduced unplanned downtime • Extended asset lifetime • Lower maintenance cost • Improved process reliability |
| ATEX | ATEX-certified vibration sensor variants available for Zones 0–2 when required |
The Operational Challenge
Centrifugal pumps and agitators are used throughout chemical plants for:
- Fluid transfer and circulation
- Mixing and homogenisation
- Cooling and heating loops
- Dosing and recirculation
They operate under demanding conditions:
- Variable flow and pressure
- Corrosive or abrasive fluids
- Continuous or intermittent duty cycles
Typical failure mechanisms include:
- Bearing wear and lubrication breakdown
- Cavitation due to process instability
- Shaft misalignment or imbalance
- Progressive seal degradation
Traditional monitoring relies on:
- Periodic vibration surveys
- Motor current analysis
- Reactive repair after alarms or leaks
These approaches miss early-stage faults and expose operators to hazardous areas.
Why Continuous Vibration Monitoring Matters
Vibration is the earliest and most sensitive indicator of rotating equipment degradation.
Continuous vibration monitoring enables operators to:
- Detect bearing faults weeks before failure
- Identify cavitation and hydraulic instability
- Correlate vibration trends with process conditions
- Schedule maintenance during planned outages
Early detection protects seals, couplings, and downstream equipment.
Sensa.io Solution
Sensa.io delivers a wireless vibration monitoring solution tailored for chemical pumps and agitators.
Core Components
Vibration Sensor
Measures acceleration, RMS velocity, and frequency spectra to identify imbalance, misalignment, bearing wear, and cavitation.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with SCADA, DCS, and maintenance systems.
Installation & Power
Battery-powered clamp-on installation on pump or agitator bearing housings — no cabling, no hot work.
Operational Benefits
- Early fault detection
- Reduced seal and bearing failures
- Lower emergency maintenance
- Improved process availability
Results and ROI
ATEX Compliance and Safety
When deployed in hazardous areas, Sensa.io vibration sensors comply with:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
Intrinsically safe variants allow monitoring without shutdown or hot work.
Integration and compatibility
| Protocols | Protocols |
| Systems | DCS, SCADA, CMMS |
| Vendors | Siemens, Schneider Electric, ABB, Emerson |
| Cybersecurity | AES-128 encrypted communication |
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.
