Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Wellhead Valve Position Monitoring (ESD & Production Valves) — ATEX
Prevents blowouts, ensures ESD compliance, reduces manual inspections
Valve position
Quick Overview
| Problem | In upstream oil & gas operations, limited visibility on wellhead valve position (ESD, master, wing, choke) creates safety risks, compliance gaps, and operational uncertainty. Manual verification is infrequent and hazardous in ATEX zones. |
| Solution | SENSAiO’s ATEX-certified valve position sensors provide continuous, wireless feedback on wellhead valve status (open / closed / intermediate), enabling real-time visibility and remote verification via SCADA. |
| Value | Improved well safety • Verified ESD readiness • Reduced site visits • Faster incident response |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified valve position sensors |
The Operational Challenge
Wellhead valves are among the most safety-critical components in upstream production. They control flow, isolate wells in emergencies, and ensure regulatory compliance.
However, many upstream sites still rely on:
- Manual valve position checks
- Visual confirmation during site visits
- Indirect assumptions based on pressure readings
This creates several operational risks:
- Uncertainty on actual valve state after intervention
- Inability to remotely verify ESD valve readiness
- Delayed response during abnormal events
- Increased personnel exposure in hazardous areas
In multi-well fields or remote locations, valve verification may occur only weekly or monthly, leaving long periods without confirmation of safe operating conditions.
Why Valve Position Monitoring Matters
Valve position is a binary but critical parameter.
Continuous monitoring allows operators to:
- Confirm ESD valves are fully closed when commanded
- Detect partially closed or stuck valves
- Verify valve actuation after remote or manual operation
- Maintain an auditable record of valve movements
Relying solely on pressure data is insufficient — pressure may stabilise even if a valve is not fully seated. Valve position feedback provides direct, unambiguous confirmation of mechanical status, which is essential for safety and compliance.
SENSAiO Solution
SENSAiO delivers a non-intrusive, wireless valve position monitoring solution designed for upstream wellhead environments.
Core Components
Valve Position Sensor (ATEX Ex ia IIC T4 Gb)
Detects valve state using magnetic or mechanical position sensing. Suitable for gate, ball, and choke valves.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling direct integration with SCADA and safety systems.
Installation & Power
Clamp-on or bracket-mounted design with internal battery power. No cabling, no hot work, no production interruption.
Operational Benefits
- Continuous verification of valve status
- Immediate detection of misalignment or incomplete closure
- Reduced need for manual inspections
- Improved emergency response readiness
Results and ROI
Title
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ATEX Compliance and Safety
All valve position sensors for wellhead applications 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 allows installation on live wellheads without shutdown, supporting safe operations in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, DCS, safety systems (SIS read-only integration) |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted data transmission |
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.
