The client reported high sand production from one of their remote wellhead platforms (WHP). Local monitoring systems for sand (Acoustic Sand Monitoring) and wall thickness (Corrosion Erosion Monitoring) were either offline or unreliable; all were obsolete. The threat of pipeline erosion and potential loss of primary containment (LOPC) was great enough to prompt an urgent overhaul of the systems in-situ.

A pilot project was awarded to SMS to commission a new sand and erosion monitoring system on one of the known sand producing wells – this comprised a single Acoustic Sand Detector and five (5) sensor Wireless Ultrasonic Thickness (UT) Monitoring array on a 90- degree bend. The system was tied into a local EEx d interface enclsoure which handled local power and commmunication, as well as data I/O with the field Process Control System (PCS). As a result of this installation, the client now has full surveillence on well sanding tendencies and the resultant impact on pipeline wall thickness. With the system infrastrcutre already in place, and proof of reliability verified, the client opted to replicate the monitoring arrays across the remaining four (4) wells on the WHP.

Challenges:

• Depleting sandstone reservoir with confirmed onset of sand production across multiple wells
• Acoustic Sand Monitoring and Corrosion Erosion Monitoring systems in-situ were obsolete / unserviceable
• Requirement for real-time monitoring with integrated alarms
• Normally Unmanned Installation with no Safe Area
• Infrequent visits to platform – system robustness paramount
• Limited availability of Process Control System integration architecture

Solution:

• Wireless wall thickness sensor array (5 x UT sensors) installed at high-risk location on well flowline
• Single Acoustic Sand monitor installed on 90-degree elbow for instantaneous sand indication
• EEx d control panel designed and assembled with integrated Wireless Gateway and Sand Erosion CPU – facilitates
  real-time data handoff to Process Control System via MODBUS
• Sand PC configured with SMS SMART software for data acquisition and MODBUS read-write capability
• All Sand and Erosion data recorded at Normally Unmanned Installation made available for review at manned hub (CCR)

Results:

• Sand PC successfully integrated with client PCS
• System fully commissioned and site acceptance tested within the allocated timeframe
• Training and handover to site reps with the provision of health checklists, SOPs, and software familiarisation
• Sand and Erosion data for remote wells trending and logging both at Sand PC CPU and client PCS
• Client provided with full coverage and visibility of pipe wall thickness, well sanding tendencies, clean-up duration, critical
  drawdown, and Maximum Sand Free Rates (MSFR)

Value to Client:

Remote Location Monitoring
Early identification of sanding events from remote wells.

Real-Time
Immediate data availability, for dynamic and informed decision making.

Reduced Cost
Minimal personnel and maintenance required.

Repeatable and Reliable
Reliable method of tracking sand production.