Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Downhole Acoustic Anomaly Detection (Leaks & Sand)
Surface acoustic anomalies may indicate sand/turbulence or leak-like behavior for investigation trigger
Acoustic
Quick Overview
| Problem | Early-stage tubing leaks and sand production generate subtle physical effects that are not immediately visible in pressure or flow measurements, making early detection difficult in producing wells. |
| Solution | SENSAiO acoustic sensors continuously monitor structure-borne acoustic activity at wellhead level, capturing deviations in flow-induced noise and particle impact signatures. |
| Value | Earlier identification of abnormal well behavior, supporting targeted inspection, reduced equipment degradation, and improved surveillance efficiency. |
| ATEX | Designed for deployment in hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx requirements depending on configuration. |
The Operational Challenge
In upstream oil and gas production, the wellbore is subject to complex multiphase flow conditions, pressure gradients, and mechanical constraints that can lead to progressive degradation mechanisms such as tubing leaks or sand production.
A tubing or casing leak introduces a localized flow path where fluid accelerates through a restriction. This generates turbulence and associated acoustic energy, but may initially produce only limited deviation in wellhead pressure or flow rate. As a result, early-stage leaks can remain undetected until they evolve into more severe integrity issues or crossflow conditions.
Sand production presents a different but equally critical challenge. When formation solids enter the production stream, particles interact with tubing walls, valves, and surface equipment. This interaction generates high-frequency acoustic emissions and can lead to erosion, loss of containment integrity, and equipment damage. However, early sand ingress may not significantly alter conventional process measurements.
In both cases, operators often rely on indirect indicators or periodic well interventions. This creates a gap between the onset of the phenomenon and its detection, particularly in wells without permanent downhole instrumentation.
Why Continuous Acoustic Monitoring Matters
Acoustic energy is directly linked to physical processes occurring inside the well. Turbulent flow, phase interactions, and particle impacts all generate measurable acoustic signatures that propagate through the well structure.
Continuous acoustic monitoring allows operators to observe:
- Changes in flow-induced noise that may correlate with turbulence or restriction
- High-frequency signals associated with particle impacts (sand movement)
- Deviations from the established acoustic baseline of a stable well
Unlike periodic diagnostics, continuous monitoring provides temporal resolution. This means that gradual changes, intermittent events, or early deviations can be identified as they develop rather than inferred after the fact.
This additional layer of observation supports earlier investigation, especially when correlated with pressure, temperature, or production data.
Sensa.io Solution
SENSAiO provides wireless acoustic monitoring using LoRaWAN-connected sensors installed on accessible external surfaces such as wellheads or connected production piping.
The sensors measure structure-borne acoustic signals transmitted through the metal. These signals reflect internal physical phenomena such as:
- Fluid turbulence due to flow restrictions or leak paths
- Multiphase flow regime changes
- Particle interaction and impact associated with sand production
The system continuously transmits acoustic data for trend analysis. A deviation in amplitude, frequency distribution, or signal pattern may indicate a change in well behavior.
It is important to note that:
- The system does not measure directly downhole
- It does not diagnose or confirm failure modes
- It does not perform control actions
Instead, it provides continuous monitoring data that supports engineering interpretation and earlier decision-making.
Results and ROI
ATEX Compliance and Safety
All acoustic sensors used in upstream environments are designed for operation in hazardous areas where explosive atmospheres may be present. Typical characteristics include:
- ATEX / IECEx compliant configurations for Zone 0, Zone 1, and Zone 2 depending on deployment
- Certification aligned with gas group and temperature class requirements (e.g., Ex ia / Ex ib concepts depending on model)
- Equipment designed to withstand harsh field conditions including vibration, corrosion, and wide temperature ranges
Each device is supplied with appropriate certification documentation and installation guidelines.
SENSAiO is a monitoring-only system. It is not a safety instrumented system and does not perform shutdown, isolation, or protection functions. It must be used alongside existing certified safety systems and operational procedures.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Interoperable with SCADA / DCS platforms (e.g., Emerson, Honeywell, Schneider, ABB) |
| Deployment | Retrofit or greenfield installation on wellheads or surface piping; adapted to field constraints |
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 SENSAiO 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
SENSAiO’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 SENSAiO 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, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
