The iicorr solids & erosion monitoring system integrates with surface test equipment and utilises inline erosion probes, online data loggers and data interpretation software.

The same system can be applied to permanent process systems where standard corrosion fitting are present

Connections are to client specification but we also hold a large stock of standard WECO and flanged fittings. Maximum pressure rating of 10,000 PSI

The operating principles of the ER erosion probe are based on the simple electrical resistance technique, which has been used extensively for corrosion monitoring probes over many years.

It relies on the erosive effects of solid particle impingement on thin elements mounted on a probe inserted into the pipe and is dependent upon the mass and velocity of solids flowing past the probe. The erosion reduces the element thickness, and accordingly increases its resistance value, which is measured accurately by the SandLog mounted on the probe. The change in resistance (metal loss) over time can be converted to a sand production rate derived from a computer model containing extensive calibration data stored in the PC.

It and can be operated in single or multiphase flow conditions, independent of acoustic noise or vibrations and has been demonstrated in the field to indicate low levels of solids production of far less than 1PPTB (Part per thousand barrel) during oil/gas well test.

Due to the design of the elements placed on the intrusive probe, direct metal loss values are recorded, which reflect the effect of erosion on the worst case condition in the pipe work, e.g. at a 90 ° elbow, or valve.

No on-site calibration is required.

It is envisaged that the erosion/solids monitoring carried out during the well operations phase will establish whether a particular well produces sand and erosion, and to what extent. It will also establish how prone the wells are to formation breakdown when there are changes in production rates.

The pipe spool can be manufactured to any pipe specification with end fittings to suit the desired well test facility. 4" and 5" Ø spool pieces are readily available in the following specification:

• 4", 5" or 6" Ø spool, schedule XXS, material AISI 4130, length 3', with 3" 1502 / 602 / 1002 Weco fittings and 3" Grayloc clamped fittings.
• Two off 2" hydraulic access fittings flare welded to the pipe and set 90° apart, material ASTM A350 LF2 (mod) with 6090 PSI working pressure rating.
• Hollow and solid plug assemblies in AISI 316L with Viton seals. The solid plug can be used for seal and pressure test purposes prior to the installation of the sand probe.
• Heavy duty cover, with hole.

The above are tested and certified to Bureau Veritas SI 289 sour gas service, with a maximum operating pressure of 6090 PSI. This spool can be installed at any convenient location downstream of the choke valve, e.g. after the data collection spool.

The SandLog electronics are inside an IP65 housing, certified by NEMKO to EEx ib IIc T3 code for intrinsic safety operation in Zone 1, with a temperature rating of -20 to 70°C.

Power requirements:

The MultiTrend software package will provide on line monitoring of the metal loss against time of the probe elements which can be converted to a solids production rate, viewed via a real time erosion or solids production plot, and event log print out.

Real time filtering and cross correlation of all probe elements will provide a responsive and accurate assessment of the solids/erosion conditions through the spool. Manual data input will consist of the following:- the average particle size; the flow velocity of the oil, gas, and water to the separator; the operating pressure and temperature which are obtained from the test log.

The historical data of the complete well test can be stored for subsequent analysis and correlation with the production conditions. From this data, it will be possible to determine the optimum flow rate at a given minimum acceptable solids production rate. The raw data can also be post processed to recalculate solids production rates from corrected flow rates or particle sizes.

The metal loss data can be utilised to provide an indication of the wall thickness reduction within well testing spread pipe work.

The Electrical Resistance (ER) sand probe is a simple and robust device. The standard probe incorporates thin elements of a material selected with similar hardness properties to that of normal carbon steel. However, the elements are not prone to corrosion in produced fluids. The probe has been calibrated after extensive testing in variable flow / sand conditions to provide a reliable and sensitive solids detection tool.

The probe is installed in a 2" hydraulic access fitting, thus providing a safe and flexible system for probe installation and also optional retrieval under pressure. The probe has to be aligned with the elements facing the direction of flow, and this is simply achieved in the hydraulic access fitting with a special orientation tool.

Two access fittings welded at 90° to each other, with a separation of approximately 25cm, provide optimum cover of the internal pipe area. In velocity flow conditions (>10m/s), it is possible to gain sufficient information from only one sand probe, however, the use of two sand probes provides better response characteristics at lower velocity flow conditions.

This is a useful commodity, often utilised during the well test programmes or extended flow periods that cannot be interrupted.

The system comprises of a service valve (double isolation ball valve) and a hydraulic retrieval tool and pump.

The hydraulic retrieval system is an option provided at the request of the client.

The engineer installs all erosion monitoring equipment prior to the pressure testing of the complete system, and then provides "on the spot" analysis during the well test. The engineer is required to update the MultiTrend PC with particle size and production data as, and when, it becomes available during the testing period.

Furthermore, the engineer is trained to interpret the data and to assist the reservoir engineer in ascertaining "sand free" production rates. After each test is completed, an interim report is presented to the client, and a final report is produced following completion of all the drill stem tests in the programme.