Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Structural Vibration Monitoring (Platform Integrity & Fatigue Detection)
Prevents fatigue damage, compliance
Vibration
Quick Overview
| Problem | Offshore platforms and FPSOs are exposed to continuous dynamic loads from waves, wind, rotating equipment, and vessel motions. Progressive structural fatigue or resonance can remain undetected until cracks, deformation, or safety-critical failures occur. |
| Solution | SENSAiO’s wireless vibration sensors provide continuous structural vibration monitoring to detect abnormal dynamic behaviour, resonance, and early signs of fatigue on offshore structures. |
| Value | Early fatigue detection • Improved structural integrity • Reduced inspection cost • Enhanced offshore safety |
| ATEX | Not required for structural steel in most cases; ATEX-certified vibration sensors available when installed in hazardous zones |
The Operational Challenge
Offshore structures are subject to complex mechanical stresses, including:
- Wave-induced cyclic loading
- Wind and weather excitation
- Vibration from rotating equipment
- Vessel impact and mooring forces
Over time, these stresses can lead to:
- Structural fatigue and crack initiation
- Local resonance amplifying stress
- Progressive degradation of joints and supports
- Reduced structural safety margins
Traditional monitoring relies on:
- Periodic visual inspections
- Non-destructive testing campaigns
- Manual surveys during planned shutdowns
These methods are expensive, intermittent, and often detect issues after damage has already developed.
Why Structural Vibration Monitoring Matters
Structural vibration behaviour is a direct indicator of integrity and fatigue state.
Continuous monitoring enables operators to:
- Detect changes in natural frequencies indicating stiffness loss
- Identify resonance conditions under specific sea states
- Monitor fatigue accumulation over time
- Correlate vibration levels with operational conditions
By tracking vibration trends, operators gain early warning of structural degradation—well before visible damage occurs.
SENSAiO Solution
SENSAiO delivers a wireless structural vibration monitoring solution for offshore platforms and FPSOs.
Core Components
Vibration Sensor
High-sensitivity vibration measurement capturing acceleration and frequency spectra relevant to structural dynamics.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with offshore SCADA, integrity management, or digital twin platforms.
Installation & Power
Battery-powered magnetic or bolted installation on beams, decks, supports, or modules — no cabling required.
Operational Benefits
- Early detection of fatigue and resonance
- Reduced reliance on costly inspection campaigns
- Improved structural integrity assurance
- Enhanced offshore safety
Results and ROI
ATEX Compliance and Safety
Structural monitoring supports compliance with offshore integrity standards such as:
- ISO 19901 (Offshore structures)
- API RP 2A (Planning, Designing, and Constructing Fixed Offshore Platforms)
ATEX-certified versions are available when sensors are installed in hazardous areas.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Structural integrity management, digital twin platforms, SCADA |
| Vendors | ABB, Siemens, Bentley Systems |
| 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.
