Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Artificial Lift Vibration Monitoring
Earlier visibility of vibration growth for maintenance planning (site dependent)
Vibration
Quick Overview
| Problem | Artificial lift systems generate mechanical vibrations that may indicate imbalance, wear, or abnormal operating conditions, but are not always continuously monitored at the well level. |
| Solution | SENSAiO vibration sensors provide continuous monitoring of mechanical vibration on artificial lift equipment, enabling detection of deviations from normal operating patterns. |
| Value | Improved visibility on equipment condition, supporting earlier investigation of abnormal behavior and reducing risk of unplanned failure. |
| ATEX | Suitable for hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
Artificial lift systems such as rod pumps, electric submersible pumps (ESP), or surface-driven pumping units are widely used to maintain production in wells where natural flow is insufficient.
These systems involve rotating and reciprocating mechanical components operating under load. Over time, mechanical degradation may occur due to:
- Imbalance in rotating elements
- Misalignment or mechanical looseness
- Bearing wear or lubrication issues
- Changing load conditions linked to reservoir or flow behavior
These conditions affect the vibration profile of the equipment. For example, imbalance or misalignment can increase vibration amplitude at specific frequencies, while mechanical wear may introduce irregular or broadband vibration patterns.
In many cases, vibration monitoring is not deployed systematically at the well level, especially across large and distributed assets. As a result, early-stage degradation may not be detected until it leads to reduced efficiency, equipment damage, or failure.
Why Continuous Vibration Monitoring Matters
Vibration is directly linked to mechanical behavior. Continuous monitoring allows operators to observe how vibration characteristics evolve over time under real operating conditions.
This enables detection of:
- Increases in vibration amplitude that may indicate imbalance or load variation
- Changes in frequency content associated with mechanical defects
- Intermittent vibration events that may be missed during periodic inspection
- Deviations from baseline vibration profiles for a given operating regime
Because mechanical degradation often develops progressively, continuous monitoring provides early indication of abnormal behavior before failure occurs.
This is particularly valuable for distributed assets where manual inspection frequency is limited.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors on artificial lift equipment such as pump structures, motors, or associated mechanical components.
The sensors measure vibration signals and transmit data via LoRaWAN networks, enabling centralized monitoring across multiple wells.
The system provides:
- Continuous vibration trend data
- Detection of deviations from normal operating patterns
- Data that can be correlated with operating conditions such as production rate or load
It is important to clarify that:
- The system is monitoring-only
- It does not perform predictive diagnosis automatically
- It does not control or shut down equipment
It provides data that supports condition monitoring and engineering interpretation.
Results and ROI
ATEX Compliance and Safety
Artificial lift equipment is typically installed in hazardous upstream environments requiring compliant instrumentation. SENSAiO vibration sensors are designed for such environments, with:
- ATEX / IECEx compliant configurations for Zone 0–2
- Certification aligned with gas group and temperature class requirements
- Mechanical design suitable for vibration exposure and harsh outdoor conditions
Each device is supplied with certification documentation and installation guidance.
SENSAiO is a monitoring-only system. It does not perform protective shutdown, control actions, or safety functions and must be used alongside certified safety and control systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Interoperable with SCADA / DCS platforms (Emerson, Honeywell, Schneider, ABB) |
| Deployment | Installation on pump structures, motors, or mechanical frames; suitable for retrofit or new installations |
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.
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