The subsea sensor is a self-powered, externally mounted smart clamp that harvests thermal energy directly from the pipeline and eliminates the need for batteries, cables or pressure penetrations. The technology continuously monitors pipeline thermal behavior and detects the formation of wax and other flow assurance deposits from outside the pipe.

Data is then communicated optically and can be read using standard ROV cameras, with AI-based analytics converting the measurements into actionable insights for operators.

"The device 'reads' how heat is escaping from the pipeline. When internal deposits reduce or redistribute that heat flow, SHIELD converts the change into a measurable signal," Tanju said. "SHIELD turns the natural heat loss from a producing pipeline into both the power source and the measurement signal."

Conventional tools (e.g., pressure monitoring, production surveillance, 
flow assurance modeling, offshore sampling, ROV inspection, pigging, and CT scanning) will continue to have roles in subsea operations, he explained. The technology is designed to complement those programs by adding localized, repeatable, non-intrusive thermal deposition data at the subsea edge. 

"SHIELD provides a non-intrusive, externally mounted method for detecting deposition-related changes in heat transfer through the pipe wall," he added. 

For operators, the technology could provide a way to monitor wax deposition between costly inspection campaigns and potentially identify developing problems before production is affected.

Field trial results

The technology has successfully completed offshore deployment and 10 months testing on a producing subsea asset.

Chevron conducted the field trial on a gas-dominated deepwater production system where wax deposition posed a significant flow assurance challenge. The battery-free sensor was installed externally on a subsea pipeline using a clamp-and-magnet attachment system designed for ROV deployment without modifying existing infrastructure.

Prior to installation, the sensor's temperature measurements were validated against a calibrated reference instrument, and its performance was later benchmarked against independent CT scan measurements collected along the pipeline. 

The trial demonstrated good agreement between SHIELD's wax-thickness estimates and CT scan data, confirming the viability of the technology under real-world offshore conditions.

According to Chevron, the technology's wax-thickness estimates achieved an R² correlation of 0.907 when compared with independent CT scan measurements collected during the trial.

After about nine to 10 months subsea, Chevron reported that the sensor assemblies remained in good condition, providing additional confidence in the system's durability and suitability for long-term deployment.

"The main finding was that SHIELD successfully demonstrated the core technical premise: deposition-induced changes in heat transfer can be detected from outside a subsea pipeline using a battery-free, thermoelectric, ROV-readable device," Tanju said.

Next steps

Following successful field validation, Chevron is working to scale the technology beyond pilot testing and expand deployment across additional subsea assets.

Development of the next-generation SHIELD Mark II clamp incorporates lessons learned from the initial offshore trial, while new SHIELD Spot sensors are being designed for deployment at multiple locations along a flowline to provide wider monitoring coverage.

Chevron plans to deploy more than 42 sensors across a deepwater asset by the third quarter of 2026.

Longer term, the company views the sensor as more than a wax-monitoring tool, positioning it as a platform for subsea edge sensing that could support continuous infrastructure monitoring through low-power, externally mounted sensors powered by harvested energy.

"SHIELD is being treated as a platform for subsea edge sensing rather than a single-purpose clamp," Tanju said.

The concept could help operators transition from periodic inspection campaigns to more proactive, data-driven approaches to flow assurance and integrity management.

"It demonstrates how existing energy in the production system can be converted into useful sensing and communication at the subsea edge, enabling operators to move from infrequent diagnostic snapshots toward more proactive, digitally enabled flow assurance and integrity management," Tanju concluded.