3.1 Upstream: Wellhead and Production Monitoring

Upstream operations—exploration and production—represent the largest market segment for oil and gas sensors. Wireless transmitters are deployed extensively in this sector.

Wellhead Pressure and Temperature Monitoring

At each wellhead, operators need to monitor:

• Casing Pressure: Pressure in the annulus between the production tubing and the casing

• Tubing Pressure: Pressure inside the production tubing carrying hydrocarbons to the surface

• Flowline Pressure: Pressure in the pipeline transporting production from the wellhead

• Wellhead Temperature: Temperature of produced fluids

A typical installation might mount two wireless transmitters on each wellhead—one for pressure and one for temperature—with readings transmitted to a central gateway and then to the control room.

Real-World Example: Kuwait Oil Company deployed remote monitoring systems on 357 wellheads, with wireless transmitters measuring wellhead pressure and temperature, transmitting readings to the main control room.

Reservoir Management

Wireless downhole pressure gauges provide real-time data critical for informed reservoir management and field development decisions. In two onshore fields in Iraq, wireless downhole pressure gauges proved a valuable alternative to workover operations, transmitting data acoustically through production tubing to the surface in real time.

Waterflood and Enhanced Oil Recovery (EOR)

In waterflood operations, monitoring injection pressures and temperatures is essential for optimizing sweep efficiency and maximizing recovery.

3.2 Midstream: Pipeline and Storage Monitoring

Midstream operations—transportation and storage—present unique monitoring challenges due to the vast distances involved.

Pipeline Pressure Monitoring

Pipelines can stretch hundreds or thousands of kilometers across remote terrain. Wireless pressure transmitters placed at intervals along the pipeline provide:

• Real-time pressure profile: Identifying pressure drops that may indicate leaks or blockages

• Leak detection: Differential pressure monitoring can detect even small leaks

• Integrity management: Continuous monitoring supports pipeline integrity programs

A LoRa-based IoT system for crude oil pipeline monitoring demonstrated effectiveness for real-time, long-range pipeline monitoring and early leak detection.

Storage Tank Monitoring

Above-ground storage tanks at tank farms and terminals require:

• Pressure monitoring: Vapor pressure in fixed-roof tanks

• Level monitoring: Hydrocarbon liquid level (often using pressure transmitters configured for level measurement)

• Temperature monitoring: Product temperature for custody transfer calculations

Compressor Station and Pump Station Monitoring

Compressor stations on natural gas pipelines and pump stations on liquid pipelines require monitoring of suction and discharge pressures, as well as temperatures, to ensure efficient operation.

3.3 Downstream: Refinery and Processing

Downstream operations—refining and processing—involve the most complex and hazardous environments, with extreme temperatures, pressures, and corrosive media.

Process Control

Refineries have thousands of pressure and temperature measurement points across distillation columns, reactors, heat exchangers, and fired heaters. Wireless transmitters can supplement wired instrumentation in hard-to-reach or hazardous areas.

Safety Instrumented Systems

Wireless transmitters rated for use in Safety Integrity Level (SIL) loops enable critical safety monitoring without the wiring complexity.

Emissions Monitoring

With increasing regulatory focus on methane and VOC emissions, wireless temperature transmitters can monitor equipment for abnormal temperature conditions that may indicate leaks or equipment failure.