Specific Procedure: Infrared Thermographic Inspection for Sand and

Sludge Deposits in Sand Separators

Document ID: SS-IRT-001

Revision: 4
Date: July 12, 2025
1.0 PURPOSE AND SCOPE

1.1 Purpose:
This procedure outlines the standardized method for using a FLIR E5 Pro thermal imaging
camera, or equivalent, to safely and accurately detect and quantify the accumulation of sand
and sludge deposits within operational sand separators in oil and gas fields. The objective is
to assess the internal condition of the separator without shutting down operations, enabling
proactive maintenance scheduling and preventing costly equipment failure.
1.2 Scope:
This procedure applies to all field personnel qualified in Level I Thermography or higher and
trained in site-specific safety protocols. It covers the inspection of horizontal and vertical
sand separators where sand/sludge accumulation is a known operational risk.
2.0 HEALTH, SAFETY, AND ENVIRONMENT (HSE)

2.1 Hazard Identification:

Personnel must be aware of potential hazards, including:
● Flammable/explosive atmospheres (hydrocarbon gases).
● High-pressure equipment.
● Hot surfaces.
● Uneven terrain and potential slip/trip hazards.
● Adverse weather conditions.
2.2 Required Personal Protective Equipment (PPE):
● Hard Hat
● Safety Glasses/Goggles
● Fire-Retardant Coveralls (FRC)
● Steel-Toed Safety Boots
● Impact-Resistant Gloves
● Personal H2S and 4-Gas Monitor
2.3 Safety Procedures:
● Obtain a valid Permit to Work (PTW) before commencing any work.
● Conduct a Job Safety Analysis (JSA) with all involved personnel.
● Confirm the thermal imaging camera is certified and rated as safe for use in the
specific hazardous area classification of the site.
● Ensure a clear escape route is always identified and accessible.
● Do not touch the separator or associated piping during operation.
3.0 REFERENCES

● ISO 18434-1: Condition monitoring and diagnostics of machines — Thermography

● ASTM E1934: Standard Guide for Examining Electrical and Mechanical Equipment with
Infrared Thermography
● ANSI/ISA-12.12.01: Electrical Equipment for Hazardous Locations
● Manufacturer’s Manual: FLIR E5 Pro or equivalent camera
4.0 EQUIPMENT

● Primary Imaging Device: FLIR E5 Pro Thermal Camera or Equivalent

● Support Equipment: Monopod or tripod for image stabilization.
● Ancillary Equipment:
○ Digital camera for visible light photos.
○ Notepad and pen or digital device for recording notes.
○ Separator identification list/drawing.
5.0 PRE-INSPECTION PROCEDURE

5.1 Operational State:

● Confirm that the sand separator is online and has been operating under normal, stable
conditions for a sufficient period to establish clear thermal patterns.
5.2 Environmental Conditions:
● Record the ambient temperature, wind speed, and solar loading (e.g., direct sun,
overcast).
● Crucial: Avoid performing inspections where direct solar radiation can heat the
vessel's surface, as this can mask the true thermal signature of internal deposits. If
unavoidable, survey the side of the separator that is in the shade.
5.3 FLIR E5 Pro Camera Setup:
1. Power On: Turn on the camera and allow it to stabilize for at least 5 minutes.
2. Mode Selection: Set the camera to Manual Mode. This is critical to lock the
temperature level and span, allowing for accurate comparison between different areas
of the separator and for future trend analysis.
3. Palette Selection: Select the "Rainbow" or "High-Contrast Rainbow" palette. This
provides the best visual differentiation for the temperature variations expected
between the hot process fluid and cooler sediment.
4. Emissivity (ε): Set the emissivity to 0.95. This is a standard value for painted metal
surfaces found on most separators.
5. Reflected Temperature: Measure the temperature of a non-reflective, diffuse surface
nearby (like a piece of crumpled paper) and input this value as the reflected
temperature in the camera settings.
6.0 INSPECTION EXECUTION
6.1 Establishing Thermal Baseline:
1. Position the camera at a distance that allows a clear view of a significant portion of the
separator. Use a monopod to keep the camera steady.
2. Aim the camera at the upper section of the separator, which should contain the hot
oil/gas/water mixture.
3. Manually adjust the Level (midpoint) and Span (range) of the thermal image so that
the hot fluid area is clearly visible and well-defined within the color palette. The typical
operating temperature of the fluid is between 32°C and 38°C.
4. Lock the settings. Do not change the Level and Span for the remainder of the
inspection on this specific vessel to ensure all images are directly comparable.
6.2 Scanning for Deposits:
1. Begin scanning from the top of the separator and move slowly downwards towards the
bottom.
2. Pay close attention to the thermal profile on the screen. The hot fluid will appear as hot
colors (red, orange, yellow), while cooler areas will appear as cool colors (blue, purple,
black).
3. Identify Sand/Sludge:
○ Sand: Sand is a poor heat conductor and will insulate the vessel shell from the
hot fluid. It will appear as a distinct, cooler region at the bottom of the separator.
The shape will typically be a layered, settled pattern. The temperature of this area
will be close to the ambient air temperature.
○ Sludge/Paraffin: Sludge or paraffin deposits can also appear as cooler regions
but may be found higher up on the vessel walls. Their patterns are often more
irregular or "jagged" compared to the smooth, settled profile of sand.
6.3 Image and Data Collection:
1. Capture multiple thermal images from different angles (front, back, sides) to build a
complete profile of the internal deposits. This helps to avoid misinterpretation due to
surface anomalies or solar reflections.
2. For each thermal image saved, also capture a corresponding visible light (digital) photo
from the same perspective.
3. Use the camera's measurement tools (e.g., Spotmeter) to record the temperature of:
○ The hot fluid section (T_hot).
○ The coolest part of the deposit section (T_cold).
○ The ambient air temperature (T_amb).
4. Create a sketch or use a diagram of the separator to mark the estimated height and
contour of the detected deposit line. Note the separator's unique identification
number.
8.0 INTERPRETATION OF RESULTS

8.1 Interpretation Table

Observation Indication
Uniform high temperature Normal operation (no sand/sludge detected)
Cooler regions at bottom (localized) Potential sand/sludge accumulation
Cooler regions mid-height Possible paraffin build-up
Irregular patterns with sharp edges External surface anomalies or artifacts

8.2 Visual Reference Examples

The following reference images illustrate the difference between a separator with normal
operating levels and one with significant sand accumulation.
Figure 1: Example of Low Sand Levels (Normal Operation)
[cite_start][Insert your image showing LOW sand levels here] [cite: 2]
● Description: This thermal image shows a separator with minimal sand accumulation,
which is considered acceptable. Note the hot thermal signature (red/yellow) is
dominant and extends towards the base of the vessel, indicating it is primarily filled
with process fluid. [cite_start]The small cooler signature at the very bottom is minimal.
[cite: 2]
Figure 2: Example of High Sand Accumulation (Action Required)
[cite_start][Insert your image showing HIGH sand levels here] [cite: 1]
● Description: This thermal image clearly shows a significant level of sand accumulation
requiring maintenance. The distinct and large cooler region (blue/black) at the bottom
represents the sand pile insulating the vessel shell from the hot fluid above.
[cite_start]The clear transition line between the hot and cool colors indicates a sand
height that could endanger the internal fire tube. [cite: 1]
9.0 ACCEPTANCE CRITERIA

● No significant cooler regions (ΔT ≤ 3°C between oil bath and suspected deposit zones).
● Areas with ΔT > 3°C and consistent cooler patterns at the separator base indicate
probable sand/sludge build-up requiring maintenance.
10.0 REPORTING

Prepare a formal inspection report for each separator, which must include:
● Inspector's Name and Certification Level.
● Date and Time of Inspection.
● Site and specific Equipment ID (e.g., Separator Serial Number).
● The make and model of the IR camera used.
● Camera settings used (Emissivity, Manual Level/Span).
● Recorded environmental conditions (Ambient Temp, Wind, Solar Load).
● A summary of findings, stating the estimated level of sand/sludge.
● Paired thermal and digital photographs, clearly annotated to show the deposit level.
● Recommendations based on the Acceptance Criteria (e.g., "No action required,"
"Continue to monitor," or "Schedule for clean-out").
11.0 FREQUENCY OF INSPECTION

● Newly Fracked Wells: Inspect monthly for the first 6 months.

● Routine Monitoring: Quarterly inspections for all separators in service.
● Post-Cleanout Verification: Inspect after maintenance to ensure complete removal of
deposits.
12.0 POST-INSPECTION

● Clean and properly store all equipment.

● Close out the Permit to Work (PTW).
● Distribute the final report to relevant personnel (Maintenance, Operations,
Engineering).