Internal Corrosion and Erosion Ultrasonic Monitoring
Wi-Corr® UT is a revolutionary solution for monitoring corrosion and erosion on pipes and structures, based on decades of ultrasonic UT experience. Our state-of-the-art sensors provide accurate and highly sensitive wall-thickness measurements for use in explosive atmospheres.
The unrivalled, field-proven 0.01mm resolution and repeatability of the Wi-Corr® UT system enables the earliest possible detection of corrosion. Metal loss is detected immediately with no need for averaging over long periods.
The game-changing improvement in measurement precision yields value beyond simple asset health inspection. With high resolution, Wi-Corr® UT enables the impact of process decisions such as feedstock selection or corrosion inhibitors on asset life cycle cost to be assessed.
Internal corrosion detection
Operating temperature up to 380°C
Retrofit to pipes
Retrofit to storage vessels
Wall thickness measurements
Field proven resolution of 0.01mm
Surface temperature measurements
Certified for Zone 1
Flexible and affordable solution
The Wi-Corr® UT system is available in various form factors to suit all needs. Single UT or four sensor UT (Quad) wireless transmitters are available, offering scalable solutions. The Wi-Corr® UT Quad unit is particularly cost-effective where multiple corrosion monitoring locations are in close proximity to each other.
The equipment for a repositionable and permanent ultrasonic sensor solution is catered for by Wi-Corr® UT Clamp as well as a low-cost adhesively bonded solution, Wi-Corr® UT Bond.
A practical solution that minimises risk
All Wi-Corr® UT ultrasonic sensors are low profile and can therefore be installed under insulation and cladding. The electrical cables that connect the sensor and wireless transmitter can exit the cladding at a convenient location, without adversely penetrating the cladding and producing a water ingress risk. This minimally disruptive form factor substantially reduces the risk of causing a new CUI (Corrosion Under Insulation) hotspot on the pipe network.
The sensors and wireless network can be installed during normal operation, so no shutdown or hot-work permits are required. The separation of the wireless transmitter module and ultrasonic sensors provides flexibility in locating the wireless transmitter to enable maximum wireless range and minimise the requirement for repeaters. The Wi-Corr® UT system is DCS ready to integrate. Networking compatible with your existing WirelessHART network.
Wi-Corr® units are autonomously powered and designed for 7+ year battery life under normal operating conditions. Batteries can be replaced easily at any time on a live plant.
Descriptive and actionable information
When Wi-Corr® UT sensors and transmitters get added to a system they are automatically recognised by the Trend Software and Data Platform.
Corrosion and erosion rates are then automatically calculated by Trend, alongside future predictions for wall thickness and time to retirement. Pre-emptive alarms can be set to alert the user to excessive metal loss. These capabilities allow for better process control and proactive maintenance planning by the asset manager.
Wi-Corr® installed sensors offer a safe and non-intrusive method of thickness measurement with reduced exposure of staff and contractors to hazardous environments. Ultrasound monitoring of inspection anomalies allows for continued safe operation of critical infrastructure.
Installed sensors offer reduced operating and maintenance costs by supporting intelligent repair and intervention programs.
Wi-Corr® UT sensors are state-of-the-art devices, demonstrating long-term thickness measurement resolution of better than 0.01mm (0.0004″), applied to a wide range of pipe diameters and thicknesses. This is approximately 10 times more sensitive than competing solutions. Metal surface temperatures are reported as a standard feature.
The Wi-Corr® UT sensors and network can be installed during normal operations, so no shutdown is required. Hand-held surface preparation units and the simple, clamp installation system mean most sensors can be installed in just a few minutes.
Installing a Wi-Corr® system avoids the need to gain hot work permits. Once installed, the need is avoided to repeatedly deploy scaffolding and remove insulation to achieve wall thickness measurements.
Wi-Corr® UT sensors can be installed under insulation and weather proofing without welding or heating ensuring the integrity of the asset is not altered and does not increase CUI risk.
Separate wireless and sensing modules provide flexibility in locating wireless transmitter to maximise RF range and minimise repeater numbers.
To cover large assets or large surface areas, dozens, hundreds or even thousands of Wi-Corr® sensors can be deployed. Alternatively, single sensors or small numbers of sensors can be deployed to report on any areas of special concern.
Wi-Corr® units are autonomously powered and designed for 7+ year battery life under normal operating conditions. Batteries can be replaced easily at any time on live plant.
Data reporting system up and running from first installation using intuitive software. Expandable system. When new sensors are added to an existing Wi-Corr® installation they are automatically recognised.
Analytics and reporting preferences are easily tailored for frequency of reporting from specific sensors, comparison of results from multiple sensors, or by asset regions, with localised alarms settings.
The user data display allows examination of data immediately if required, by manual intervention. Short and long-term trends in metal wall thickness are stored and can be recalled for assessment to allow the user to identify any troublesome areas or historical trends in process conditions.
The Wi-Corr® units use a wireless self-organising radio frequency mesh network which has been proven in cluttered environments. Data from 1000s of corrosion sensors can be sent back to the central control hub for user viewing and advanced control. No lengthy cabling required. Wi-Corr® systems can be configured to either be stand-alone or integrated into any existing WirelessHART systems. Cellular networking can be provided, if desired by the user.