Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump & Motor Vibration Monitoring (Topside Predictive Maintenance) — ATEX
Prevents failures under harsh conditions
Vibration
Quick Overview
| Problem | Offshore pumps and electric motors operate continuously under harsh conditions. Progressive vibration-related faults often go unnoticed until failure causes production loss, safety incidents, or emergency shutdowns in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified vibration sensors continuously monitor pumps and motors topside, detecting early mechanical degradation and enabling predictive maintenance. |
| Value | Reduced unplanned downtime • Lower maintenance OPEX • Improved asset reliability • Safer offshore operations |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Offshore platforms and FPSOs rely on pumps and motors for:
- Seawater cooling
- Produced water handling
- Crude transfer
- Utility and firewater systems
These assets are exposed to:
- Salt corrosion and humidity
- Variable load and flow conditions
- Continuous operation with limited maintenance windows
- Restricted access and high intervention costs
Typical failure modes include:
- Bearing wear and lubrication failure
- Shaft misalignment
- Hydraulic imbalance and cavitation
- Motor electrical-mechanical coupling issues
Traditional monitoring approaches often rely on:
- Periodic vibration surveys during maintenance windows
- Reactive alarms after vibration exceeds limits
- Manual inspection requiring offshore personnel exposure
This results in late fault detection and costly emergency interventions.
Why Continuous Vibration Monitoring Matters
Vibration patterns provide early insight into rotating equipment health.
Continuous monitoring enables operators to:
- Detect bearing degradation weeks in advance
- Identify cavitation and hydraulic imbalance
- Monitor vibration trends under changing process conditions
- Prioritise maintenance based on asset condition
Early intervention prevents secondary damage and extends asset lifetime. Wireless monitoring also reduces the need for routine manual inspection in hazardous offshore environments.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe vibration monitoring solution for offshore pumps and motors.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, velocity, and frequency spectra to identify early-stage faults.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with offshore SCADA, CMMS, and reliability platforms.
Installation & Power
Battery-powered magnetic or bolted installation on bearing housings allows rapid retrofit without shutdown.
Operational Benefits
- Early fault detection and diagnosis
- Reduced unplanned shutdowns
- Optimised maintenance scheduling
- Improved equipment availability
Results and ROI
ATEX Compliance and Safety
All vibration sensors for offshore pump and motor 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 equipment 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.
