From particle detection to metal loss

Efficient and safe production in the oil and gas industry depends on accurate insight into how sand and erosion develop over time. Flow conditions in pipelines and wells are not static, and even small changes in velocity, flow regime or particle size can influence where erosion occurs and how sand moves through the system. ClampOn has developed monitoring technologies that allow operators to understand these processes in real time and make informed decisions based on reliable data.

Experience gathered through long term cooperation with engineering groups and operators shows that erosion does not occur in a single predictable pattern. Gas flow, liquid flow and multiphase flow each create different conditions in a pipeline, and the point of maximum erosion shifts accordingly. Particle size also plays a significant role. These variations make it challenging to identify the correct installation point for an erosion monitor, and underline the importance of combining field knowledge, modelling and practical experience during planning.

The ClampOn Sand Monitor is designed to provide a stable and repeatable response to sand impacts. The sensor utilizes advanced Digital Signal Processing (DSP) technology, which incorporates a unique filtering technique to effectively minimize interference from other noise sources. This technology allows the sensor to discriminate between the sound generated by sand particles and background noise from liquid/gas mixtures, mechanical vibrations, and other equipment.

By processing the signal internally, the sensor enhances the signal-to-noise ratio, ensuring that the pattern of sound made by the sand is clearly illustrated in the monitoring software. This capability is crucial for accurately detecting sand production and optimizing production rates while minimizing the risk of damage to the equipment

The most preferable installation point is typically where a vertical pipe transitions into a horizontal section. In this zone, the particles are lifted by the flow and strike the upper pipe wall with similar velocity, which gives a predictable acoustic response.

For long term integrity management, erosion monitoring offers an additional layer of security. The ClampOn Erosion Monitor measures both average and minimum wall thickness, allowing operators to detect changes at an early stage. It uses active ultrasound and exploits the properties of Acoustic Guided Lamb Waves to detect the changes in wall thickness relative to the reference values obtained during the installation of the system. Up to 16 transducers transmit and receive signals to and from each other to form a grid of signal paths over a defined area, and this is used to monitor any changes in pipe wall thickness. The coverage area and the accuracy / sensitivity depend on the number of transducers installed / pipe-size. With the right number of transducers up to 100 percent coverage of a given area can be obtained. As little as 0.1% change in wall thickness can be measured in real-time. These values can be integrated directly into the control system as simple numerical outputs, while detailed tomography data is available through the dedicated software. This gives engineers the possibility to analyze specific paths and compare results with intelligent pigging data over time.

ClampOn has supplied monitoring systems for a wide range of subsea and topside applications, including manifolds and brownfield fields that have passed their original design life. Some installations have been adapted for diver operations in shallow water, while others have been designed for ROV installation. In every case, correct installation and commissioning are essential. ClampOn recommends that its own service personnel perform the commissioning to ensure proper configuration and avoid false alarms in the control system.

Close cooperation with the operator remains the key to successful monitoring. When installation, configuration and operational conditions are well understood, the instruments provide valuable information that supports safer operation and improved field management throughout the lifetime of the asset.