Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Tubing & Casing Pressure Monitoring (Well Integrity) — ATEX
Detects leaks or blockages early, optimizes production
Pressure
Quick Overview
| Problem | Undetected pressure variations in tubing and casing annuli can lead to integrity failures, fluid migration, or well control incidents. Manual readings and periodic checks provide limited visibility and increase personnel exposure in hazardous areas. |
| Solution | SENSAiO’s ATEX-certified wireless pressure sensors provide continuous monitoring of tubing and casing pressures, transmitting real-time data to SCADA or integrity systems for early anomaly detection. |
| Value | Improved well integrity • Reduced manual inspections • Earlier detection of leaks and communication • Lower HSE exposure |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified pressure sensors |
The Operational Challenge
Tubing and casing pressures are among the most critical indicators of well integrity in producing, injection, and shut-in wells. Abnormal pressure behaviour may indicate tubing leaks, packer failure, annular communication, gas migration, or changes in reservoir conditions. According to industry guidance such as API RP 90 and API RP 90-1, sustained or abnormal annular pressure is a key integrity risk that requires continuous surveillance and documented response procedures.
In many upstream assets, pressure monitoring still relies on:
- Manual gauge readings performed daily or weekly
- Periodic pressure surveys during well tests
- Wired transmitters installed only on selected wells
These approaches are:
- Risk-prone, especially in ATEX-classified wellhead areas
- Intermittent, missing transient or progressive events
- Labour-intensive, increasing field visits
As fields mature and the number of monitored annuli increases, manual approaches become increasingly difficult to scale and audit.
Why Continuous Pressure Monitoring Matters
Tubing and casing pressure trends provide direct insight into:
- The integrity of tubing, packers, and seals
- Annular communication or gas migration
- Reservoir behaviour and artificial lift performance
- Early signs of corrosion or mechanical degradation
Unlike single pressure readings, continuous monitoring captures trends, transients, and rate-of-change events that are critical for early diagnosis.
Pressure data supports:
- Faster identification of abnormal annular pressure
- Proactive integrity management rather than reactive response
- Improved compliance with integrity management programs
When combined with acoustic or temperature measurements, pressure monitoring forms the backbone of a comprehensive well surveillance strategy.
SENSAiO Solution
SENSAiO provides a wireless, intrinsically safe pressure monitoring solution designed for upstream wellhead environments.
Core Components
Pressure Sensor (ATEX Ex ia IIC T4 Gb)
High-accuracy pressure measurement suitable for tubing, casing, and annulus monitoring. The sensor housing is designed for long-term exposure to hydrocarbons and corrosive environments.
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
- Continuous pressure visibility on critical annuli
- Earlier detection of leaks or communication
- Reduced need for manual gauge readings
- Improved safety and audit readiness
Results and ROI
ATEX Compliance and Safety
All pressure sensors used for this application comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
Sensors are suitable for installation on live wells and are delivered with full ATEX documentation, supporting integrity audits and regulatory compliance.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, well integrity platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted data transmission with VPN-secured links |
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.
