Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Refinery Pump Vibration Monitoring
Earlier mechanical degradation detection
Vibration
Quick Overview
| Problem | Mechanical degradation in refinery pumps can develop progressively and remain undetected between inspections. |
| Solution | SENSAiO vibration sensors continuously monitor dynamic behavior of pumps and associated rotating equipment. |
| Value | Improved visibility on mechanical condition, supporting earlier investigation of abnormal vibration patterns. |
| ATEX | Suitable for hazardous refinery environments (Zone 1–2), compliant with ATEX / IECEx requirements. |
The Operational Challenge
Pumps are critical assets in refinery operations, ensuring fluid transfer across process units such as:
- Crude distillation
- Hydrotreating
- Product blending
- Utility systems
These pumps operate under demanding conditions, including:
- High temperature and pressure
- Variable flow regimes
- Continuous or semi-continuous duty cycles
Mechanical degradation can occur progressively due to:
- Bearing wear
- Shaft misalignment
- Rotor imbalance
- Cavitation or hydraulic instability
From a physical standpoint, these issues generate changes in vibration behavior:
- Rotating imbalance produces periodic vibration at rotational frequency
- Misalignment introduces axial and radial vibration components
- Bearing defects generate high-frequency vibration energy
- Cavitation creates broadband vibration due to bubble collapse
Detecting these conditions is challenging because:
- Degradation often develops gradually
- Pumps may be distributed across large units
- Manual vibration measurements are periodic
- Early-stage faults may not trigger alarms in standard systems
As a result, anomalies may remain unnoticed until they become more severe.
Why Vibration Monitoring Matters
Vibration monitoring measures the dynamic response of rotating equipment.
By continuously tracking vibration signals, it is possible to:
- Establish baseline vibration signatures for each pump
- Detect deviations from normal operating conditions
- Observe trends over time
Typical interpretations include:
- An increase in overall vibration amplitude may indicate mechanical degradation
- Changes in frequency content can correlate with specific phenomena such as imbalance or bearing wear
- Intermittent vibration patterns may reflect unstable hydraulic conditions
It is important to note that:
- Vibration signals are indirect indicators of mechanical condition
- Interpretation requires engineering analysis and context
Continuous monitoring enhances the ability to detect subtle changes earlier.
SENSAiO Solution
SENSAiO deploys wireless vibration sensors mounted on pump housings or bearing locations.
Sensors continuously measure vibration levels and transmit data via LoRaWAN to a centralized platform.
The system provides:
- Continuous vibration trend monitoring
- Detection of deviations from baseline
- Alerting based on abnormal vibration behavior
It is important to clarify that:
- SENSAiO is a monitoring-only system
- It does not perform full vibration spectrum diagnostics equivalent to advanced analyzers
- It does not identify root cause automatically
- It does not replace protection systems or shutdown logic
The system supports condition awareness and maintenance planning.
Results and ROI
ATEX Compliance and Safety
Refinery environments are typically classified hazardous areas due to the presence of flammable hydrocarbons. SENSAiO sensors:
- Are available with ATEX / IECEx certification for Zone 1–2
- Are designed for installation on rotating equipment in process areas
- Withstand industrial तापमान and vibration conditions
All equipment is supplied with appropriate certification documentation.
SENSAiO systems are not safety systems and do not replace machinery protection systems or emergency shutdown systems.
Integration and compatibility
| Protocols | LoRaWAN, MQTT, REST API |
| Gateways | Compatible with standard LoRaWAN gateways (Kerlink, Multitech, Cisco, etc.) |
| Systems | Integration with maintenance and monitoring platforms |
| Deployment | Suitable for retrofit on existing pumps |
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.
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.
