Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Wellhead Structural Vibration Monitoring (Upstream Integrity & Casing Protection) — ATEX
Identifies abnormal mechanical stress, prevents casing damage
Vibration
Quick Overview
| Problem | Wellheads are exposed to continuous mechanical stress from flow turbulence, pressure fluctuations, thermal cycling, and external vibration sources. Excessive or abnormal vibration can lead to casing fatigue, flange loosening, seal degradation, or structural damage—often developing unnoticed in remote, ATEX-classified upstream environments until a leak, integrity failure, or shutdown occurs. |
| Solution | Sensa.io’s ATEX-certified wireless vibration sensors continuously monitor wellhead structural behaviour, detecting abnormal mechanical stress and vibration patterns early to protect casing integrity and ensure safe upstream operation. |
| Value | Protected wellhead integrity • Reduced leak risk • Lower intervention cost • Improved upstream safety |
| ATEX | Not always required (safe area buildings) • ATEX sensor variants available for classified zonesZones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Wellheads are critical assets in upstream operations, including:
- Oil and gas production wells
- Gas lift and injection wells
- Hydrogen-ready or renewable gas upstream infrastructure
- Onshore and remote well pads
They operate under challenging mechanical conditions:
- High-pressure flow-induced vibration
- Cyclic loading from start/stop operations
- Thermal expansion and contraction
- Wind, equipment-induced, or ground-borne vibration
Common integrity risks include:
- Excessive vibration leading to casing fatigue
- Flange bolt loosening and seal degradation
- Structural resonance amplifying mechanical stress
- Progressive damage undetected between inspections
Traditional monitoring approaches rely on:
- Periodic visual inspections
- Manual integrity checks during site visits
- Reactive investigation after alarms or leaks
This leaves long periods with no visibility into wellhead mechanical health.
Why Structural Vibration Monitoring Matters
Vibration is an early indicator of abnormal mechanical stress and structural degradation.
Continuous vibration monitoring enables operators to:
- Detect abnormal stress before casing damage occurs
- Identify vibration patterns linked to flow or pressure changes
- Prevent progressive fatigue and structural failure
- Reduce exposure of personnel to hazardous areas
For remote and ATEX-classified well sites, continuous monitoring provides critical early warning without frequent site access.
Sensa.io Solution
Sensa.io delivers a wireless, intrinsically safe vibration monitoring solution designed for upstream wellhead integrity.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, velocity, and frequency signatures to identify abnormal structural vibration and mechanical stress on wellhead assemblies.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT for integration with upstream SCADA, integrity management, and condition monitoring platforms.
Installation & Power
Battery-powered clamp-on installation on wellhead structures, casing heads, or support frames — no cabling, no hot work, no production interruption.
Operational Benefits
- Early detection of abnormal mechanical stress
- Reduced risk of casing and flange damage
- Fewer manual inspections in ATEX zones
- Improved integrity assurance for remote wells
Results and ROI
ATEX Compliance and Safety
All vibration sensors for wellhead 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 continuous monitoring on live wellheads in hazardous upstream environments.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | Upstream SCADA, integrity management systems, CMMS |
| Vendors | Siemens Energy, ABB, Schneider Electric, Honeywell |
| 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
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Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
