Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Gas Lift Line Pressure Monitoring
Identifies instability patterns; supports faster troubleshooting of lift performance changes
Pressure
Quick Overview
| Problem | Gas lift performance depends on stable injection pressure, but fluctuations, restrictions, or supply issues are not always continuously monitored at the well level. |
| Solution | SENSAiO wireless pressure sensors provide continuous monitoring of gas lift injection line pressure, enabling detection of deviations and instability. |
| Value | Improved visibility on gas lift efficiency, supporting optimization of injection conditions and earlier identification of abnormal behavior. |
| ATEX | Suitable for hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
Gas lift systems are widely used in upstream production to enhance hydrocarbon recovery by injecting gas into the production tubing. The effectiveness of this method depends strongly on maintaining stable and appropriate injection pressure.
Variations in gas lift line pressure can be associated with several physical conditions, including:
- Instability in gas supply from compressors
- Restrictions or partial blockage in injection lines
- Valve performance variations in the gas lift system
- Changes in well production behavior affecting injection dynamics
These variations may not always be immediately visible at the surface control level, especially when monitoring is centralized or limited to key nodes rather than individual wells.
At the well level, pressure behavior can fluctuate due to transient conditions. Without continuous measurement, short-duration events or gradual drifts may not be captured, making it difficult to understand injection efficiency or diagnose suboptimal performance.
Why Continuous Pressure Monitoring Matters
Gas lift performance is directly linked to the pressure conditions in the injection line. Continuous pressure monitoring provides visibility into dynamic behavior that cannot be captured through periodic readings.
This enables observation of:
- Pressure instability that may correlate with compressor cycling or supply fluctuations
- Gradual pressure drops that may indicate line restriction or leakage
- Transient pressure events linked to valve operation or flow regime changes
- Deviations from the expected pressure profile for a given operating condition
These insights help operators understand whether the injected gas is being delivered under consistent conditions and whether the system is operating within its intended envelope.
Continuous monitoring also allows comparison between wells, supporting identification of outliers or wells with abnormal injection behavior.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors on gas lift injection lines at or near the wellhead, capturing continuous pressure data without requiring extensive cabling.
The sensors measure line pressure and transmit data via LoRaWAN networks, enabling centralized access to distributed well data.
The monitoring provides:
- Continuous pressure trend analysis
- Identification of deviations from normal injection behavior
- Data that can be correlated with compressor operation, choke settings, and production performance
It is important to clarify that:
- The system is monitoring-only
- It does not regulate gas injection pressure
- It does not control compressors or valves
It provides data that supports operational decisions rather than executing them.
Results and ROI
ATEX Compliance and Safety
Gas lift systems are typically located in hazardous upstream environments requiring compliant instrumentation. SENSAiO pressure 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 robustness for vibration, pressure variation, and environmental exposure
Each sensor is supplied with appropriate certification and documentation.
The system is strictly monitoring-only. It does not perform safety shutdown, pressure control, or protective functions and must be used alongside existing safety systems and 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 (Emerson, Honeywell, Schneider, ABB) |
| Deployment | Installation on gas lift injection lines near wellheads; 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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Trusted by a Worldwide Network
With partners in over 20 countries, SENSAiO delivers rugged sensor solutions to the toughest environments — everywhere.
