Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump Station Pressure & Vibration Monitoring (Mining Dewatering Pumps)
Prevents flooding incidents, reduces pump failures
Pressure
Vibration
Quick Overview
| Problem | Dewatering pump stations are critical for keeping open-pit and underground mines operational. Pressure instability, cavitation, or mechanical degradation can rapidly lead to pump failure, flooding incidents, equipment damage, and forced production shutdowns. Manual inspections provide limited visibility and are often unsafe in wet or confined environments. |
| Solution | Sensa.io’s wireless pressure and vibration sensors continuously monitor dewatering pump performance, detecting hydraulic and mechanical anomalies early to prevent flooding and unplanned downtime. |
| Value | Flooding risk reduction • Higher pump availability • Lower maintenance cost • Safer operations |
| ATEX | Wet and gas-prone zones may apply • ATEX-certified pressure & vibration sensor variants available |
The Operational Challenge
Mining dewatering systems operate continuously to manage:
- Groundwater ingress in underground workings
- Rainwater accumulation in open pits
- Process water circulation and recovery
- Tailings and slurry drainage
They face severe operating conditions:
- Continuous duty cycles
- Abrasive particles causing wear
- Variable flow and suction conditions
- Remote or confined installation locations
Common failure modes include:
- Cavitation due to suction issues
- Bearing wear and imbalance
- Seal degradation and leakage
- Sudden loss of pressure or flow
Traditional monitoring relies on:
- Manual pressure gauge readings
- Visual inspection of pumps and motors
- Reactive intervention after alarms or flooding
These approaches often detect issues only after damage or operational impact has occurred.
Why Pressure & Vibration Monitoring Matter
Pressure and vibration together provide a complete picture of pump health.
Continuous monitoring enables operators to:
- Detect cavitation through pressure fluctuation patterns
- Identify bearing wear weeks before failure
- Monitor pump load and hydraulic efficiency
- Prevent sudden pump trips and flooding events
Reliable dewatering is essential to mine safety and production continuity.
Sensa.io Solution
Sensa.io delivers a wireless monitoring solution designed for mining dewatering pump stations.
Core Components
Pressure Sensor
Monitors suction and discharge pressure to detect cavitation, blockage, or loss of hydraulic performance.
Vibration Sensor
Measures acceleration and frequency spectra to detect bearing wear, imbalance, and misalignment.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, suitable for underground shafts and remote pump stations.
Installation & Power
Battery-powered clamp-on or threaded installation — no cabling, no shutdown required.
Operational Benefits
- Early detection of pump degradation
- Reduced flooding and safety incidents
- Predictable maintenance planning
- Improved pump efficiency and uptime
Results and ROI
ATEX Compliance and Safety
Where required, Sensa.io sensors support:
- ATEX Directive 2014/34/EU
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
This enables safe monitoring in confined, gas-prone, or hazardous mine environments.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Mine SCADA, pumping control systems, CMMS |
| Deployment | Underground pump stations or surface control rooms |
| 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.
