Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump & Agitator Vibration Monitoring
Earlier mechanical degradation detection
Vibration
Quick Overview
| Problem | Mechanical degradation in pumps and agitators develops progressively but is not always continuously monitored. |
| Solution | SENSAiO vibration sensors monitor mechanical vibration behavior in real time. |
| Value | Improved visibility on equipment condition, supporting earlier identification of abnormal mechanical behavior. |
| ATEX | Suitable for hazardous chemical environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pumps and agitators are critical rotating equipment in chemical and petrochemical processes.
They are used for:
- Fluid transfer
- Mixing and reaction homogenization
- Maintaining process consistency
These machines operate under continuous mechanical stress, which can lead to:
- Bearing wear
- Shaft misalignment
- Imbalance of rotating components
- Cavitation in pumps
From a physical perspective:
- Vibration is the result of dynamic forces generated by rotating elements
- Changes in vibration amplitude or frequency content reflect changes in mechanical condition
- Mechanical defects introduce characteristic vibration patterns
Typical manifestations include:
- Increased vibration amplitude due to imbalance or wear
- Irregular vibration patterns due to misalignment
- High-frequency vibration components associated with bearing degradation
Detection challenges include:
- Equipment distributed across large installations
- Limited permanent instrumentation on secondary assets
- Intermittent manual measurements
- Lack of continuous trend data
As a result, degradation may progress without early detection.
Why Vibration Monitoring Matters
Vibration is a direct indicator of mechanical behavior in rotating equipment.
By continuously monitoring vibration:
- Baseline operating conditions can be established
- Deviations from normal vibration patterns can be detected
- Trends can be analyzed over time
Typical interpretations include:
- A gradual increase in vibration may indicate progressive wear
- Sudden changes may correlate with mechanical disturbance or damage
- Frequency changes may reflect specific mechanical phenomena
Vibration data provides insight into equipment condition based on physical movement dynamics.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors mounted on pumps and agitators.
Sensors continuously measure vibration levels and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous vibration trend monitoring
- Detection of abnormal vibration behavior
- Alerts based on thresholds or deviations
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform detailed vibration spectrum diagnostics
- It does not identify specific failure modes automatically
- It does not replace condition monitoring specialists or safety systems
The system supports early awareness and investigation.
Results and ROI
ATEX Compliance and Safety
Pumps and agitators often operate in hazardous areas with flammable substances. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for installation on rotating equipment in chemical environments
- Are designed for industrial operating conditions
All equipment is delivered with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace protective systems such as shutdown interlocks or mechanical safeguards.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with maintenance and reliability platforms |
| Deployment | Suitable for retrofit on existing rotating equipment |
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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The SENSAiO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
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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.
