Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Tubing & Casing Pressure Monitoring (Well Integrity)
Earlier visibility of sustained drift/variability; supports integrity follow-up prioritization
Pressure
Quick Overview
| Problem | Pressure variations in tubing and casing annuli can indicate integrity issues or abnormal flow conditions, but are often monitored intermittently or with limited visibility. |
| Solution | SENSAiO wireless pressure sensors provide continuous monitoring of tubing and casing pressure, enabling real-time trend analysis and deviation detection. |
| Value | Improved visibility on well integrity conditions, supporting earlier investigation and better prioritization of field interventions. |
| ATEX | Designed for hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
In upstream wells, maintaining control and understanding of pressure conditions within tubing and casing annuli is essential for well integrity management.
Pressure behavior reflects the balance between reservoir inflow, production conditions, and mechanical integrity of the well structure. Abnormal pressure evolution in the tubing or casing can be associated with several physical phenomena, including:
- Communication between annuli
- Tubing or packer integrity degradation
- Gas migration or buildup in confined spaces
- Thermal expansion effects during injection or shut-in conditions
These pressure changes may develop progressively and can remain within acceptable operating ranges in early stages. As a result, they are not always immediately identified as abnormal.
In many field configurations, pressure readings are collected manually or at low frequency. This limits the ability to detect transient events, gradual drifts, or intermittent anomalies that may indicate evolving well integrity issues.
Why Continuous Pressure Monitoring Matters
Pressure is a primary indicator of mechanical and flow conditions within the well system. Continuous monitoring provides time-resolved data that enables detection of patterns not visible through periodic measurements.
Key observations enabled by continuous monitoring include:
- Gradual pressure build-up that may indicate gas accumulation or restricted flow
- Pressure communication between annuli that may suggest loss of isolation
- Transient pressure events associated with operational changes or integrity issues
- Deviation from established baseline pressure profiles
By tracking these variations over time, operators gain a clearer understanding of well behavior and can identify conditions that warrant further investigation.
This is particularly relevant in wells where annular pressure management is critical for regulatory compliance and long-term asset integrity.
SENSAiO Solution
SENSAiO deploys wireless pressure sensors on wellheads and accessible connection points to continuously measure tubing and casing pressure.
The sensors capture real-time pressure data and transmit it via LoRaWAN networks, enabling centralized monitoring of distributed well assets.
The measurement provides:
- Continuous pressure trends rather than isolated readings
- Detection of deviations from expected operating conditions
- Data that can be correlated with operational parameters such as production rate, injection cycles, or shut-in periods
It is important to note that:
- The system provides measurement and monitoring only
- It does not control pressure or regulate the process
- It does not diagnose specific integrity failures
Instead, it supports engineering analysis by providing reliable and continuous pressure data.
Results and ROI
ATEX Compliance and Safety
Pressure monitoring in upstream environments requires equipment compatible with hazardous area classifications. SENSAiO pressure sensors are designed to operate in such environments, with:
- ATEX / IECEx compliant configurations for Zones 0–2
- Certification aligned with applicable gas groups and temperature classes
- Robust design for exposure to pressure, vibration, and environmental conditions
Each device is delivered with appropriate certification and documentation.
SENSAiO is a monitoring-only system. It does not provide pressure relief, shutdown, or safety barrier functions and must be used alongside certified safety systems and well integrity 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 wellheads, annulus ports, or pressure access points; retrofit or greenfield |
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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