Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump Vibration & Performance Monitoring (Early Fault Detection) — ATEX
Prevents catastrophic failures, extends equipment life
Vibration
Quick Overview
| Problem | Upstream pumps operate under harsh conditions and continuous load. Mechanical degradation such as bearing wear, cavitation, imbalance, or misalignment often develops gradually and remains undetected by traditional pressure or flow monitoring. Late detection leads to unplanned shutdowns, secondary damage, and production losses—especially in ATEX-classified environments. |
| Solution | SENSAiO’s ATEX-certified vibration sensors provide continuous, wireless monitoring of pump vibration behaviour, enabling early detection of mechanical faults and performance degradation before failure occurs. |
| Value | Early fault detection • Reduced unplanned downtime • Extended pump lifespan • Lower maintenance costs |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Pumps are among the most critical rotating assets in upstream oil & gas operations. They are exposed to fluctuating loads, abrasive fluids, and harsh environmental conditions.
Common risks include:
- Bearing degradation and lubrication failure
- Cavitation due to process instability
- Shaft misalignment and mechanical imbalance
- Progressive vibration leading to catastrophic failure
Operational challenges typically involve:
- Reliance on periodic manual vibration inspections
- Limited visibility between inspection intervals
- Reactive maintenance triggered only after alarms or failures
- High intervention cost in remote or hazardous locations
In ATEX-classified areas, frequent manual inspections increase safety risk and operational burden while still leaving long detection gaps.
Why Continuous Vibration Monitoring Matters
Pump failures rarely occur suddenly — they develop through identifiable vibration patterns over time.
Continuous vibration monitoring enables operators to:
- Detect early-stage mechanical degradation
- Identify abnormal vibration frequencies linked to specific faults
- Track performance deterioration trends
- Plan maintenance before failure impacts production
Unlike indirect indicators such as pressure or flow deviation, vibration data provides direct mechanical insight, making it one of the most reliable indicators of pump health. When applied continuously, vibration monitoring shifts maintenance from reactive to predictive, significantly reducing failure risk.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe vibration monitoring solution designed for upstream pump assets.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
High-sensitivity sensor capturing vibration magnitude and frequency. Suitable for centrifugal pumps, injection pumps, and transfer pumps
Wireless Communication
Compatible with LoRaWAN, Modbus, and MQTT, enabling integration into existing SCADA, DCS, or well integrity platforms without vendor lock-in.
Installation & Power
Battery-powered and non-intrusive, the sensor is installed on tubing or annulus lines without hot work or production shutdown.
Operational Benefits
- Early detection of pump mechanical issues
- Reduced unplanned shutdowns
- Lower maintenance and repair costs
- Improved asset reliability and availability
Results and ROI
ATEX Compliance and Safety
All vibration sensors for upstream 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 enables installation on live pump systems without shutdown, supporting safe monitoring in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, condition monitoring platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| 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.
