Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump Vibration Monitoring (Port Facilities & Marine Transfer Systems) — ATEX
Prevents unplanned downtime
Vibration
Quick Overview
| Problem | Pumps used in port terminals and marine transfer systems operate continuously under variable loads. Bearing wear, cavitation, misalignment, or imbalance often develop silently until sudden failure causes fuel transfer interruption, environmental risk, or safety incidents in ATEX-classified zones. |
| Solution | SENSAiO’s ATEX-certified vibration sensors provide continuous monitoring of pump vibration behaviour, enabling early detection of mechanical degradation and predictive maintenance in port and marine environments. |
| Value | Reduced pump failures • Lower maintenance OPEX • Improved transfer reliability • Enhanced safety |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Port and marine transfer pumps are used for:
- Fuel and chemical loading/unloading
- Bunkering operations
- Ballast and utility pumping
- Emergency and firewater systems
These pumps are exposed to:
- Variable flow rates and pressure conditions
- Abrasive or contaminated fluids
- Corrosive marine environments
- Continuous duty cycles
Common failure mechanisms include:
- Bearing wear and lubrication loss
- Cavitation due to suction issues
- Shaft misalignment
- Rotor imbalance
- Progressive seal degradation
Traditional monitoring typically involves:
- Periodic vibration measurements
- Manual inspections
- Reactive repairs after alarms or breakdowns
This approach leads to unplanned downtime and increased safety risk.
Why Vibration Monitoring Matters
Vibration analysis is the most effective method for early detection of rotating equipment faults.
Continuous vibration monitoring enables operators to:
- Detect bearing defects before failure
- Identify cavitation and hydraulic instability
- Detect misalignment and imbalance
- Monitor degradation trends over time
Early detection prevents catastrophic pump failure, reduces environmental exposure during transfer operations, and improves operational continuity in ports.
SENSAiO Solution
SENSAiO delivers a wireless vibration monitoring solution optimised for port and marine pump applications.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
High-sensitivity vibration measurement capturing acceleration and frequency patterns relevant to pump health.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with port SCADA, terminal management systems, and CMMS platforms.
Installation & Power
Battery-powered magnetic or bolted installation on pump housings — no cabling or shutdown required.
Operational Benefits
- Early detection of mechanical faults
- Reduced unplanned pump failures
- Improved maintenance planning
- Increased availability of transfer systems
Results and ROI
ATEX Compliance and Safety
All vibration sensors for port pump 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 safe deployment in fuel and chemical handling areas without operational disruption.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Port SCADA, terminal automation, CMMS |
| Vendors | ABB Marine, Siemens, Kongsberg, Emerson |
| 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.
