Sand production and erosion pose significant challenges in the oil and gas industry, leading to equipment damage, production loss, and costly repairs. Existing sand control techniques such as well completion, sand screens, sand separation, or predictive models for sand production are not 100% effective. This paper presents a comprehensive approach to sand management utilizing complimentary non-intrusive erosion monitoring solutions. The focus is on the integration of acoustic sensors and ultrasonic thickness sensors to detect and assess sand particles in pipelines and process equipment. The use of acoustic sensors enables the detection and characterization of particles, including sand, through their unique acoustic signatures. These sensors provide real-time data, allowing for proactive monitoring of sand production and erosion. In combination with ultrasonic thickness sensors, which provide accurate measurements of material thickness, a risk and impact calculation can be derived. By analysing the risk value obtained from the acoustic sensor and the impact value obtained from the thickness sensor, an overall assessment of asset health can be determined. To facilitate effective sand management, the proposed solution incorporates the integration of these sensors into a single package, accompanied by specialised software. The software allows for comprehensive data analysis, trending, and future predictions. By utilising this integrated system, operators can gain actionable insights into the condition of their assets, enabling timely intervention and mitigation strategies. The benefits of this approach include enhanced asset integrity, reduced downtime, and improved maintenance planning. Additionally, the ability to monitor sand production and erosion in real-time empowers operators to optimize production rates while ensuring the integrity of their infrastructure. This paper presents a practical and cost-effective solution for effective sand management in the oil and gas industry. By leveraging complimentary non-intrusive erosion monitoring solutions, operators can mitigate risks associated with sand production, extend the operational life of their equipment, and optimize production efficiency.

The Bureau of Reclamation has encountered challenges with coatings on pump casings. The casings are exposed to aggressive erosion conditions due to the suspended solids such as sand and debris in the water.