Wellhead Sensor Design

Engineers who work with AltaSim Technologies bring their products to market more rapidly, at a lower cost, and with an optimized design by leveraging our guidance for implementing Multiphysics simulations. To help see the impact we have on our clients, we have put together a brief case study of a unique solution our simulation experts produced on a recent project.


A client of AltaSim’s was using electromagnetic fields to develop a new sensor design to measure the oil, water and gas in a fluid flowing through a wellhead. Understanding that the oil and gas industry needed better measurement capabilities, our client’s technology could address this market need, but testing of their prototypes produced data that did not meet their expectations. Our client was concerned that delays in getting their sensors to market would enable their competitors to gain an advantage.


AltaSim developed simulations of the current electromagnetic sensor design and used these simulations to demonstrate that most of the electromagnetic energy produced by the sensor reflected instead of transmitted through the flowing fluid. The reflected energy reduced the effectiveness of the sensors and produced erroneous data in testing. AltaSim worked with our client to redesign the sensor to increase the electromagnetic energy that transmitted through the fluid. The simulations of this new sensor design were then used to assess how the electromagnetic energy would interact with different mixtures of oil, water and gas. The new sensor design proved to be effective, and our client was able to get their product to market ahead of the competition.


Through working with AltaSim, our client was able to develop an improved sensor design that measured constituents of a flowing fluid. After three months developing these simulations and an investment by our client of $25,000, they were able to eliminate the bottleneck in their technology development and grow their new product line generating critical data for the oil and gas industry.

AltaSim partners with companies to provide simulations that increase the knowledge and understanding of our clients’ engineering staff. Through these simulations, we work with our clients to develop actionable plans to solve their engineering challenges. To better understand our simulation services, visit our website for an overview. To contact us directly, please visit our Contact Us page.

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April 2023 Case Study