Wi-Corr® CUI
Real-time moisture monitoring for corrosion under insulation.
Wireless sensors retrofit to live assets in minutes, turning continuous moisture data into a smarter inspection strategy that targets effort where risk is highest.
Wireless sensors retrofit to live assets in minutes, turning continuous moisture data into a smarter inspection strategy that targets effort where risk is highest.
- Installed on live assets in minutes
- No insulation or cladding removal required
- Minimal scaffolding requirement
- Relocatable sensors to support evolving inspection strategy
- Suitable for pipes, vessels and complex geometries
The corrosion under insulation problem
Wi-Corr® CUI explainer video
Moisture trapped within insulation causes corrosion on industrial piping and vessels. Because the insulation conceals the surface of the asset, degradation progresses unseen until failure occurs. It is one of the most persistent and costly integrity threats in refining and petrochemical operations.
The limitations of traditional inspection
Managing CUI without visibility into where it is actually occurring relies on intrusive insulation removal, assumption-based inspection intervals, and reactive repair. The process is slow, costly, and disruptive — inspections often find nothing while missing critical threats that cause leaks and unplanned outages.The modern risk-based approach
Wi-Corr® CUI replaces assumption-based inspection with continuous condition monitoring. Sensors measure moisture presence within insulation and feed this data into a risk-based inspection framework, where it is used to prioritise inspection, adjust inspection intervals, and support probability-of-failure assessments. The result is a shift from calendar-based inspection to condition-driven maintenance, with a fully auditable record of asset condition over time.The sensors
Wi-Corr® CUI Quanta
Quanta monitors long sections of pipe for water ingress that causes corrosion. Unlike other sensors, it needs only a small drill hole in the cladding for installation without needing to remove the insulation or disrupt operation, enabling rapid coverage of large assets.How it works
Quanta sensors work in pairs. The first sensor transmits radio waves that travel along the pipe, using the pipe itself to carry the signal. The second sensor further down the pipe receives the signal and analyses how it has changed, which reveals the presence of moisture anywhere between the two sensors.
If water ingress is detected, this catches the cause of CUI before the damage sets in. If the Quanta sensor detects no water, then there can be no corrosion.
Wi-Corr® CUI Proximity
Proximity is a local monitoring sensor designed for high-risk features such as supports, valves, flanges, and penetrations, where moisture ingress is most likely.How it works
Each Proximity contains humidity and temperature sensors. Once installed in the insulation, the Proximity sensor will continuously monitor local moisture levels for abnormal levels, which could lead to Corrosion Under Insulation.
Installation and operation
Wi-Corr® CUI is designed to be fitted rapidly to live assets without interrupting them. A sensor can be installed in minutes by a single technician, using standard tools and without removing cladding or insulation.The installation process
1.
A small hole (17mm) is drilled in the outer cladding.
2.
The sensor head is inserted into the cladding.
3.
The sensor is tightened into place, creating an IP66-rated seal against the cladding.
4.
The sensor is commissioned and begins transmitting to the TREND Software Platform.
Operational advantages
- Retrofit to existing assets. Sensors are fitted externally to the cladding - no modification to the pipe or vessel is required.
- Install anywhere. Zone 1 explosive atmosphere certification and reliable wireless networking allow deployment in hazardous and hard-to-reach locations.
- No cladding removal. The sensor does not require the insulation system to be removed, which is typically the most disruptive and expensive part of any CUI inspection activity.
- No downtime. Assets remain in service throughout. There is no requirement to depressurise, drain, or isolate.
- Repositionable. Sensors can be relocated as risk assessments evolve.
Ongoing operation
Once installed, sensors run autonomously on their primary battery — 7+ years for Quanta, 10+ for Proximity. Batteries are field-replaceable on a live plant under the same conditions as the original install. Data is transmitted continuously over WirelessHART or LoRaWAN to the TREND Software Platform where it feeds the Risk-Based Inspection workflow. Continuous data builds a time history of moisture exposure, enabling time-of-wetness and corrosion rate calculations and supporting long-term integrity decisions.The TREND Software Platform
From moisture data to site-wide integrity strategy
Level 1 — Where to inspect
Live moisture readings from every sensor, with early-warning alerts the moment ingress behaviour shifts at a location. Inspection effort is directed to the identified locations, rather than being evenly spread across assumption-based intervals. This results in fewer unnecessary insulation strip backs and increased asset reliability.Level 2 — When to inspect
TREND analytics convert moisture history into corrosion-rate estimates and probability-of-failure curves for each monitored location. Inspection and repair windows can now be scheduled against real asset condition, not calendar dates.Level 3 — Asset assurance services & sensor redeployment
Inspection and maintenance plans are generated for the monitored locations. Sensor data is then used to retrain the site-wide asset analysis on currently unmonitored locations. Sensors are then redeployed to new locations which pose the greatest uncertainty and CUI risk. Monitoring coverage expands in step with the risk picture, so CAPEX and OPEX follow evidence rather than habit.Specifications
| Operating temperature | Up to 300°C |
|---|---|
| Ex certification | Zone 1 explosive atmosphere certified |
| IP certification | IP66 leak-proof seals |
| Wireless protocols | WirelessHART, LoRaWAN |
Quanta
| Structure type | Insulated pipes |
|---|---|
| Detection range | 40 metres |
| Measurement resolution | 10ppm moisture sensitivity |
| Insulation compatibility | Mineral wool, fibreglass, calcium silicate, PIR, PUR, phenolic foam. Others available on request. |
| Battery life | 7+ years |
Proximity
| Structure type | Insulated pipes, vessels, tanks, etc. |
|---|---|
| Detection range | 2 metres approx. |
| Measurement resolution | Humidity: 0.1% rel. humidity Temperature: 0.1°C |
| Insulation compatibility | All insulation types |
| Battery life | 10+ years |