Published on 01-Nov-2023

Remote desktop monitoring of Shell wellheads with HotSense™

Remote desktop monitoring of Shell wellheads with HotSense™

Ionix HotSense™ has been successfully deployed with a CALIPERAY wireless system and a field communication kit to monitor erosion rates in a remote upstream Shell facility as an alternative to manual inspection with X-ray RT profiling.

Key Benefits:

o    Maximising well productivity, based on known erosion rates

o    Increasing safety, reduced site activity & exposure to X-ray

o    Reducing costs by automating data collection remotely


The Application:

Ionix HotSense™ sensors were connected to a Mistras WirelessHART CALIPERAY™ ultrasonic monitoring system to make automated, accurate, precise and reliable thickness measurements.

The system is intrinsically safe certified for use in FM Class 1 Div 1 and ATEX & IECEx Zone 0 applications.

HotSense™ sensors were attached to the NPS 2” pipes using the non-intrusive clamp deployment system during live operation of the well.

A Field Communication Kit was installed based on a WirelessHART gateway, power supply and cellular modem to provide direct data transfer to a remote server.

Advanced software for wall thickness data analysis and graphical visualisation (WAMP) was installed on the server for data collection and analysis

Measurements collected from the UT system over a 6 month period were successfully validated against RT profile images


Key Outputs:

Thickness measurements can be automatically collected and uploaded via the cellular enabled field deployment kit.

Frequent, consistent and high-quality wall thickness data collection enables the customer to maximise well productivity and increase safety.

The measurement was validated as an upper operating threshold, risk mitigation strategy compared to the costly alternative – RT profiling.

Process and Production engineers have desktop access to integrity data from the remote site allowing production optimisation and profitable decisions based on measurable data.

 Reduced inspection costs avoiding travel and eliminating hot work permits

Continuous monitoring from remote and hazardous locations delivered reduced exposure of staff to hazardous environments


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Application Notes