Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Pump Station Vibration Monitoring
Earlier identification of mechanical degradation trends
Vibration
Quick Overview
| Problem | Pump stations are critical assets, but vibration behavior is not always continuously monitored, especially in remote installations. |
| Solution | SENSAiO vibration sensors provide continuous monitoring of mechanical vibration on pumps and associated equipment. |
| Value | Improved visibility on mechanical condition, supporting earlier investigation of abnormal vibration patterns. |
| ATEX | Suitable for hazardous environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pump stations are essential for maintaining flow and pressure in pipeline systems.
Rotating equipment such as pumps and motors generate vibration as part of normal operation. However, changes in vibration behavior may indicate evolving mechanical issues.
Common sources of abnormal vibration include:
- Imbalance in rotating components
- Misalignment between pump and motor
- Bearing wear or degradation
- Cavitation due to inadequate suction conditions
- Hydraulic instability
These issues physically manifest as changes in vibration amplitude, frequency, or pattern.
Challenges in monitoring include:
- Limited instrumentation on secondary or remote pump stations
- Periodic inspections rather than continuous monitoring
- Difficulty correlating vibration events with operating conditions
As a result, early signs of mechanical degradation may not be captured.
Why Vibration Monitoring Matters
Vibration is a direct indicator of mechanical behavior in rotating equipment.
Continuous monitoring enables:
- Detection of changes in vibration amplitude over time
- Identification of abnormal vibration signatures
- Correlation between vibration patterns and operating conditions
Typical interpretations include:
- Increasing vibration amplitude may indicate progressive wear or imbalance
- High-frequency vibration may correlate with bearing-related issues
- Irregular vibration patterns may reflect hydraulic phenomena such as cavitation
It is important to note that vibration data indicates mechanical behavior but does not directly diagnose specific failure modes without detailed analysis.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors installed on pump casings or associated structures.
These sensors continuously measure vibration levels and transmit data via LoRaWAN to a centralized monitoring platform.
The system provides:
- Continuous vibration trend monitoring
- Detection of deviations from baseline vibration behavior
- Historical data for analysis and comparison
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform detailed vibration diagnostics
- It does not control or shut down equipment
- It does not replace condition monitoring systems designed for detailed spectral analysis
The system provides indicative data to support maintenance decisions and further investigation.
Results and ROI
ATEX Compliance and Safety
Pump stations handling hydrocarbons or flammable fluids are typically classified hazardous areas. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are suitable for outdoor and industrial environments
- Are designed to withstand vibration and environmental stress
All equipment is supplied with certification documentation.
SENSAiO systems are not safety systems and do not replace protective systems such as vibration trip systems or emergency shutdown mechanisms.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with SCADA and maintenance management systems |
| Deployment | Suitable for retrofit on existing pump stations 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.
