Sand Probes

Opera�on and Maintenance Manual

Metal Samples Company

A Division of Alabama Specialty Products, Inc.
152 Metal Samples Rd., Munford, AL 36268 Phone: (256) 358-4202 Fax: (256) 358-4515
E-mail: msc@alspi.com Internet: www.metalsamples.com
Houston Office: 6327 Teal Mist Lane, Fulshear, TX 77441 Phone: (832) 451-6825
Table of Contents

Safety Considera�ons.............................................................................................................................. 1

Introduc�on ............................................................................................................................................ 2

System Design ......................................................................................................................................... 4

Installa�on............................................................................................................................................... 8

Maintenance .........................................................................................................................................10

Appendix A: Common Accessory Items ................................................................................................11

Sand Probes

Safety Considera�ons
This document provides instruc�ons for installa�on and use of the Metal Samples SP7000 Sand Probe in a standard
two-inch high-pressure access system. Anyone atemp�ng to install, operate, or remove an SP7000 Sand Probe
should be trained and qualified in the use of two-inch high-pressure access systems, related tools such as the
Service Valve, Retrieval Tool, and Hot Tap Tool, as well as common piping components.

This document does not purport to address all the necessary safety considera�ons. It is the responsibility of the
user to ensure that all safety considera�ons are addressed, and that all your company, local, and governmental
requirements are met.

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Introduc�on
Many oil-producing wells also generate sand which can cause serious problems for pipeline operators. Sand in a
flow stream can cause erosion of the pipeline and connected hardware, leading to leaks and equipment failures.
Such events can have significant financial, safety, and environmental impact.

Sand Probes are mechanical sensors designed to gauge the severity of erosion in a flow line. When deployed and
used properly, Sand Probes give operators a way to predict failures before they happen.

A typical Sand Probe installa�on will consist of a Tee-Type Access Fi�ng with Cover, Solid Plug, Sand Probe Nut, the
Sand Probe, and a pressure-indica�ng device such as a pressure gauge or an electric pressure switch.

Figure 1. Typical Sand Probe Installa�on

The Sand Probe consists of a hollow probe body which has a sensing element on one end and terminates with 1/4"
male NPT threads on the other end. These male threads are used to install the Sand Probe into the Sand Probe
Nut.

Figure 2. Metal Samples SP7000 Sand Probe

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The Sand Probe element is a hollow, sacrificial tube which is capped and sealed on the end. When the Sand Probe
is properly installed in the flow stream, the element will be subjected to whatever erosion may occur in the line.
Over �me, erosion will cause a breach of the element allowing system pressure to enter the Sand Probe’s interior,
and in turn to be reflected on the pressure-indica�ng device connected to the tee of the Access Fi�ng. The
thickness of the element, coupled with the �me required for a breach to occur, indicates the rate of metal loss due
to erosion in the system.

It is important to note that the Sand Probe itself is consumable in nature and must be replaced once penetra�on of
the element has occurred. However, the remaining system components may be used repeatedly, assuming that
they have not become damaged, corroded, or fouled by sand.

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System Design
A typical Sand Probe installa�on will consist of the following components:

• Tee-Type Access Fi�ng

• Cover
• Solid Plug
• Sand Probe Nut
• Sand Probe
• Pressure-Indicator(s)

This sec�on will provide guidance in the proper selec�on and sizing of Sand Probe components for your
applica�on.

Placement
The first considera�on in your system design is placement. Proper placement of the Sand Probe is crucial to
ensuring that it provides meaningful informa�on. When designing a Sand Probe system, one must consider both
the loca�on along the line and the posi�on within the line, taking care to place the sensing element where the
sand flow is expected to be the greatest. In straight piping runs this may be in the center of the pipe, whereas the
sand may push towards the outer walls of bends and elbows.

Access Fi�ng, Solid Plug, and Cover

The SP7000 Sand Probe is compa�ble with all two-inch, high-pressure Access Fi�ng systems including the Metal
Samples HP, MH, and Hydraulic fi�ng systems, as well those of most other manufacturers. However, the SP7000
must be used with a tee-type fi�ng to provide an outlet path for pressure once penetra�on of the Sand Probe
element has occurred.

This manual assumes that a suitable Tee-Type Access Fi�ng is already installed and available for use. If fi�ng
installa�on and/or hot-tapping is required, please refer to the appropriate product manual(s) for further
instruc�ons on those opera�ons.

It is important to know the size and type of the Access Fi�ng in use, as this will determine the length of the Sand
Probe Nut. If you do not know the size and type of the Access Fi�ng being used for your Sand Probe installa�on,
contact your Metal Samples sales representa�ve for support.

The SP7000 Sand Probe and Sand Probe Nut are designed to mount on a standard Solid Plug assembly. The
materials of the Solid Plug and seals should be selected to ensure op�mum performance, taking into considera�on
things such as chemical compa�bility with the system, maximum opera�ng temperature, and poten�al galling
issues between the plug and fi�ng.

It is recommended to use a Cover with any Access Fi�ng system. However, the cover has no real impact on Sand
Probe opera�on so it should be selected based on the applica�on and site requirements.

Sand Probe Nut

The Sand Probe Nut is used to direct pressure between the Sand Probe and the pressure indicator, once the Sand
Probe element has been penetrated. When selec�ng a Sand Probe Nut there are three primary considera�ons:

• The length
• The seal material
• The alloy

The length of the Sand Probe Nut is based on the type and height of the Access Fi�ng in which it is being installed.
Table 1 below provides guidance on selec�ng the correct length for your applica�on.

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 Model
IQN Sand Probe Nut
Length
1 1.75” for HP Fi�ng, 5.25” Standard Height
2 2.75” for HP Fi�ng, 6.25” Standard Height
3 3.75” for HP Fi�ng, 7.25” Standard Height
4 4.75”
5 5.50” for HP Fi�ng, 8.25” Standard Height
6 3.50” for MH Fi�ngs, All Heights
Sand Probe End Thread
2 1/4"-18 NPT
Seal Material
0 N/A
1 Viton® O-ring with Teflon® Backing Ring
2 Ethylene Propylene O-ring with Teflon® Backing Ring
3 Kalrez O-ring with Teflon® Backing Ring
4 Hydrin O-ring with Teflon® Backing Ring
5 Nitrile O-ring with Teflon® Backing Ring
6 Teflon® O-ring with Teflon® Backing Ring
Alloy Code
158 316 Stainless Steel
A12 C276
IQN 1 2 1 158 ← Example Part Number
Table 1. Sand Probe Nut Ordering Chart

The alloy of the Sand Probe Nut should be selected to offer sufficient corrosion resistance to the process medium.
316 Stainless Steel is suitable for most applica�ons, but C276 offers superior corrosion resistance where 316 may
be insufficient. Other alloys are available as well.

The seal material should be selected to offer good chemical resistance to the process medium, and to meet the
service temperature of the system. A variety of available seal materials are listed in Table 1, and other materials
can be provided upon request.

Sand Probe
As previously discussed, the Sand Probe is a sacrificial device used to detect erosion in the system. There are four
things to consider when selec�ng a Sand Probe:

• The body material

• The element material
• The element wall thickness
• The length

The body material should be chosen to offer good corrosion resistance to the process medium. The Sand Probe
element is also typically made of a corrosion-resistant alloy to help to minimize the effects of corrosion and provide
a more accurate representa�on of erosion within the stream. Common alloys for the body and element include
316 Stainless Steel, 2205 Duplex Stainless Steel, and C276, all of which offer varying degrees of corrosion
resistance. Other alloys are available upon request.

Sand Probe elements are available in several wall thicknesses to suit different applica�ons. Standard sizes are
shown in Table 2 below. A thickness should be selected that gives good sensi�vity. A general rule of thumb is to
select a Sand Probe element that is approximately 10% of the pipe wall thickness.

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 Model
SP Sand Probe for High Pressure (HPTM and MHTM) Access Systems
Body Material
2 316
4 C276
U Duplex 2205
Element Material
2 316
4 C276
U Duplex 2205
Element Wall Thickness
1 .016” (41 mm)
2 .028” (71 mm)
3 .035” (89 mm)
Length (Round calculated length down to the nearest 1/4")
XXXX Length in inches, stated in 2 decimal place format
(Ex: 6 1/4" = 0625)
SP 2 2 3 0625 ← Example Part Number
Table 2. Sand Probe Ordering Chart

In service, the Sand Probe Element should be posi�oned in the most erosive part of the flow stream. To facilitate
this, Sand Probes can be manufactured in prac�cally any user-specified length. The formulas below provide
guidance in calcula�ng the correct Sand Probe length for either a flanged or non-flanged Access Fi�ng.

Non-Flanged Access Fi�ng

L = (FH + PD/2) - (2.04 + N)

Flanged Access Fi�ng

L = (FH + PD/2 + MF) - (2.04 + N)

Where:
FH = Access Fi�ng Height
N = Sand Probe Nut Length
L = Sand Probe Length3
MF = Ma�ng Flange Height
PD = Pipe Outer Diameter
Round calculated length down to the nearest 1/4" (6.35 mm) increment. Minimum length is 3.75” (95.25 mm.)
3

Pressure Indicator
The Pressure Indicator alerts the user that penetra�on of the Sand Probe Element has occurred. The Pressure
Indicator can be a mechanical pressure gauge, or an electrical pressure switch or transducer. One or more of these
devices can be connected directly to the tee of the Access Fi�ng using standard piping components such as a pipe
nipple and pipe tee (see Figure 1 above.)

Components that are connected directly to the tee of the Access Fi�ng will be exposed directly to process
medium, including sand or other abrasives, so care should be taken in their material selec�on. Make sure that they
are of suitable construc�on to withstand exposure to the system medium, pressure, and temperature.

The Model PR6573158 Remote Alarm Actuator and Indicator (RAAI) can be used to isolate sensi�ve devices such as
pressure gauges and transducers from harsh process medium, and it provides a local indica�on that erosion has
penetrated the Sand Probe. Once penetra�on has occurred, system pressure travels through the sand probe body
and into the RAAI Adapter Stem, which pushes out the End Knob to its extended posi�on, revealing a red indicator

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on the RAAI Body Stem. This ac�on also actuates an internal valve mechanism which can be used to switch clean
instrument-air for devices such as pressure gauges, switches, or transducers.

A B

Figure 3. Sand Probe with Remote Alarm Actuator / Indicator before (A) and a�er (B) Sand Probe Penetra�on

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Installa�on
The SP7000 Sand Probe is installed into a two-inch high-pressure Access Fi�ng using a standard Solid Plug. To
begin installa�on, you must first fit the Solid Plug with a Sand Probe Nut. Once this has been done, the Sand Probe
will thread directly into the female threads on the botom of the Sand Probe Nut. The general procedure is as
follows:

1) Begin by inspec�ng all components to make sure that they are in good condi�on, are made of the correct
materials, and that all piece-parts such as seals, set screws, and so forth are in place.
2) Remove the set screw from the Solid Plug Nut on the base of the Solid Plug. Retain the set screw for use
in a later step below.

3) Unthread the Solid Plug Nut from the Solid Plug, being sure to leave the Primary Packing in place.
NOTE: The Solid Plug Nut and Sand Probe Nut u�lize le�-handed ma�ng threads. Be sure to turn in the
proper direc�on when loosening and �ghtening.

4) Thread the Sand Probe Nut onto the Solid Plug, being sure to turn in the proper direc�on. Tighten the
Sand Probe Nut un�l it contacts the Primary Packing, and then �ghten an addi�onal quarter-turn.

5) Insert the set screw and �ghten it to lock the Sand Probe Nut in place.

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6) Apply a suitable thread lubricant/sealant to the 1/4" male NPT threads on the Sand Probe.

7) Thread the Sand Probe into the 1/4" female NPT threads on the end of the Sand Probe Nut. Using two
adjustable wrenches and the wrench flats on the Sand Probe and Sand Probe Nut, �ghten the NPT threads
un�l a reliable seal is achieved.

8) Inspect the Primary Packing, O-rings, and Backing Rings to ensure that they are seated properly and free
of any damage or defects.

9) Once assembly is completed, the Solid Plug, Sand Probe Nut, and Sand Probe can be installed into the
Access Fi�ng. This should be done only by qualified personnel who have been trained in the use of high-
pressure access systems and the related tools.

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Inspec�on and Maintenance
Sand Probes are consumable in nature and do not require maintenance. However, other system components can
be reused and should be inspected regularly. Table 3 provides recommended inspec�on points and intervals for
Sand Probe components.

NOTE: Inspec�on and maintenance of the Access Fi�ng and Cover are beyond the scope of this document. Refer
to the High Pressure Access Systems Manual for inspec�on and maintenance instruc�ons of these items.

NOTE: Inspec�on of electrical wiring and equipment such as pressure switches or transducers are beyond the
scope of this document. Refer to the manufacturer's literature for maintenance instruc�ons on these items.

Frequency During Replacement Of Sand Probe

Item: Inspect For: Correc�ve Ac�on:
Sand Probe Nut
Cuts Or Tears
O-Ring Degrada�on Of The Material Replace O-Ring
Compression Se�ng
Cuts, Tears, Or Deforma�on
Backing Rings Replace Backing Rings
Degrada�on Of The Material
Dings Or Torn Threads
Female NPT Threads Galling Replace Sand Probe Nut
Excessive Wear
Loose Set Screw Tighten Set Screw
Set Screw
Missing Set Screw Replace Set Screw
Solid Plug
Dings Or Torn Threads
Male Threads Galling Replace Solid Plug
Excessive Wear
Tears Or Deforma�on
Primary Packing Replace Primary Packing
Degrada�on Of The Material
Cuts Or Tears
Backup O-Ring Degrada�on Of The Material Replace O-Ring
Compression Se�ng
General
Tighten Leaking Component, Or Replace If
External Pipe Connec�ons Leaks
Necessary
Remote Alarm Leaks
Replace Remote Alarm Actuator/Indicator
Actuator/Indicator (If Used) Mechanical Binding
Frequency During Replacement Of Primary Packing
Item Inspect For: Correc�ve Ac�on:
Sand Probe Nut
Dings Or Torn Threads
Le�-Handed Female Threads Galling Replace Sand Probe Nut
Excessive Wear
Solid Plug
Dings Or Torn Threads
Le�-Handed Male Threads Galling Replace Solid Plug
Excessive Wear
Table 3. Recommended inspec�on points and intervals

Considera�on should also be given to lubrica�on of items such as threads and O-rings, although the requirements
for such depend on the type of service and the materials in use. The user should determine what, if any,
lubrica�on is needed for the materials in use and reapply each �me the Solid Plug is pulled from the system.

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Appendix A: Common Accessory Items
Common Sand Probe System Components
Descrip�on Part#
Pressure Gauge, 316 SS, 0 to 10,000 psi HA700603158
HP Solid Plug, 316 SS HA700644158
MH Solid Plug, 316 SS HA700645158
Remote Alarm Actuator / Indicator PR6573158
Replacement Seal Kit for Remote Alarm Actuator/Indicator KR1012834

Nipple and Valve Ordering Chart

Access Fi�ng Valve Nipple, 4 in (100 mm)
Tee Size 316 SS 316 SS Sch. 80
Part No. Part No.
1/4" HA700022158 HA700018158
1/2" HA700023158 HA700019158
3/4" HA700027158 HA700020158
1" HA700029158 HA700021158

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