Steam exchangers are extensively used in oil and gas processing operations to transfer thermal energy from steam to various process fluids, including water, gas, oil, or chemicals.

Key processes such as distillation, refining, oil heating and viscosity reduction, steam injection for enhanced oil recovery (EOR), gas treatment and processing, as well as utility and energy systems, can suffer efficiency losses due to the accumulation of fine particulates, debris, or corrosion products within the exchanger’s tubes and shells. Even minimal ingress of particulates can increase operational energy consumption, lower heat transfer efficiency, and cause costly maintenance or unexpected downtime for cleaning.

Reliance solely on conventional scheduled maintenance without real-time data can lead to undetected performance degradation and hidden equipment damage until failures manifest.

To effectively monitor complex multiphase streams such as water-in-oil or oil-in-water emulsions, a real-time particle size analyser delivers continuous, precise measurements of particle size distribution (PSD) and concentration. It detects abnormal particulate matter including solids, dispersed oil droplets, water droplets, and gas bubbles without the need for manual sample extraction or minimum sample volume constraints.

This automated monitoring system ensures real-time acquisition of multi-phase PSD data from critical online processes, including those with inherent health and safety risks (e.g., mercury contamination, Naturally Occurring Radioactive Materials (NORM), hydrogen sulfide (H₂S), and elevated carbon dioxide (CO₂) concentrations).

Industry Applications:

1. Steam Exchanger to Boiler 
   Ensuring oil-in-water content stays below 20 ppm for optimal operation and equipment protection.
2. Completion Services  
   Verifying Total Suspended Solids (TSS) levels are under 0.5% to guarantee clean discharge and environmental compliance.
3. UBD / MPD Water Filtration
   Precise monitoring to maintain TSS levels below 1%, ensuring superior water quality and process efficiency.
4. Oil in Water Monitoring 
   Reliable detection and control to keep oil concentrations below 20 ppm before overboarding, fully compliant with regulatory standards.

Benefits

• Early detection: Detect unusual particles before they turn into permanent deposits.
• Predictive maintenance: Cleans or intervenes only when necessary.
• Higher efficiency: Maintain optimal heat transfer for longer periods.
• Reduced costs: Less downtime, fewer unplanned cleanings, and extended exchanger service intervals.
• Data-driven decisions: Supports proactive maintenance strategies based on real-time data.
• Improved Safety & HSE Compliance: Minimises manual handling and sample exposure to harmful substances while ensures environmental regulations are met