Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Wellhead Valve Position Verification (ESD & Production)
Faster confirmation of manual valve alignment; fewer “wrong lineup” investigations
Valve position
Quick Overview
| Problem | Manual or assumed valve states at wellheads can lead to uncertainty, especially in distributed assets where physical verification is infrequent. |
| Solution | SENSAiO valve position sensors provide continuous remote monitoring of valve open/closed status at wellheads. |
| Value | Improved operational visibility and reduced risk of incorrect valve state assumptions during production, shutdown, or intervention. |
| ATEX | Suitable for hazardous upstream environments (Zone 0–2), compatible with ATEX / IECEx deployment requirements. |
The Operational Challenge
Wellhead valves play a critical role in controlling production flow, isolating wells, and enabling safe intervention operations. Their correct position is essential for maintaining intended operating conditions.
In many upstream environments, especially in large or remote fields, valve position is not continuously monitored. Instead, operators rely on:
- Field operator rounds
- Control room assumptions based on prior actions
- Indirect indicators such as pressure or flow response
This creates several operational risks.
A valve that is partially open, unintentionally closed, or incorrectly configured can alter flow conditions. For example, a partially closed valve may introduce a restriction, generating pressure drop and turbulence. A closed valve assumed to be open may result in unexpected production loss. Conversely, an open valve assumed to be closed can create safety or operational concerns during maintenance activities.
Because valve position is a discrete mechanical state, it is not always reliably inferred from process variables alone. Pressure and flow may be influenced by multiple factors, making it difficult to isolate valve-related issues without direct position feedback.
Why Continuous Valve Position Monitoring Matters
Valve position represents a fundamental operational parameter. Continuous monitoring provides direct confirmation of the mechanical state of the valve rather than relying on indirect inference.
This enables:
- Verification that the valve position matches operational intent
- Detection of unintended changes in position
- Identification of discrepancies between field conditions and recorded status
- Improved coordination between field and control room operations
In distributed upstream assets, where physical inspection may be infrequent, continuous visibility on valve state reduces uncertainty and supports more reliable operations.
SENSAiO Solution
SENSAiO deploys wireless valve position sensors on wellhead valves to continuously monitor their open or closed state.
The sensors detect the mechanical position of the valve actuator or stem and transmit status data via LoRaWAN networks.
The system provides:
- Real-time valve state visibility (open / closed)
- Historical tracking of position changes
- Alerts in case of unexpected state transitions
It is important to note that:
- The system is monitoring-only
- It does not actuate or control valves
- It does not enforce safety interlocks or shutdown logic
It provides reliable field data to support operational awareness and decision-making.
Results and ROI
ATEX Compliance and Safety
Wellhead valves are typically located in hazardous areas requiring compliant instrumentation. SENSAiO valve position 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 design suitable for outdoor and harsh field conditions
Each device is provided with appropriate certification and installation documentation.
SENSAiO is a monitoring-only system. It does not perform valve actuation, safety shutdown, or control functions and must be used alongside existing safety and control systems.
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 manual or actuated wellhead valves; suitable for retrofit without process interruption |
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
Valve position
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.
