HotSense Measurement Hub

HotSense Measurement Hub

Low cost entry to thickness monitoring

Low cost entry to thickness monitoring

Complete fixed-point ultrasonic thickness measurement solution for use with standard UT devices (thickness gauges and flaw detectors). The lowest cost entry point for non-invasive corrosion and erosion on-demand monitoring. Ideal for reducing Capex in applications across the refining, oil & gas, energy, nuclear and process sectors.

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  • Full fixed point non-invasive corrosion and erosion monitoring solution utilising the HotSense extreme environment ultrasonic sensors for -55 to +550 °C [-67 to 1,022 °F] applications.
  • ATEX & IECEx Zone 0 ready to enable quick and safe measurements to be made from sensors installed in your most hazardous and inaccessible environments
  • Better data. Fixed sensors provide increased precision, accuracy, repeatability and measurement frequency
  • Low cost entry into non-invasive corrosion and erosion monitoring utilising standard NDT ultrasonic hardware and procedures
  • Flexibility enables Upgrade to full automated wireless system


  • Your first step towards in-service automated integrity monitoring which uses your current NDT equipment and personnel
  • Increase your accuracy and precision by monitoring using installed transducers – up to x5 increase in precision compared to standard inspection methods.
  • Facilitate measurements in hot and inaccessible locations and increase data collection frequency for improved trending to support RBI, FFS and FEA.
  • Reduce costs with replacement of intrusive manual methods and reduced scaffolding / insulation removal
  • Increase safety with reduced exposure to hazards and man-hours at asset


HotSense Measurement Hub
  • Houses up to 4 sensor connections to enable quick and easy measurements to be collected from HotSensesensors from an accessible location using standard NDT equipment and procedures.
  • Optional thermocouple integration for temperature measurement and compensation
  • Compatible with various Ex installation configurations to enable simple data collection.

HotSense Sensors
  • Wide continuous operating temperature range from -55 to +550 °C (-67 to + 1,022 °F) for an extensive variety of online monitoring requirements
  • High temperature capable piezoelectric element and transducer components designed for permanent installation in extreme environments and under insulation.
  • Suitable for intrinsically safe ATEX & IECEx Zone 0 equipment installations
  • Single element, compression wave, pulse-echo operation.
  • Accurate and precise thickness measurements with resolution from 0.01-0.1 mm.
  • Stable and secure fixation methods available via clamping or stud welding to a structure for permanent installation even at extreme temperatures.
  • Installation during plant operation
  • Integrated delay line provides near surface resolution and simple calibration at any temperature.


Online Wall Thickness Monitoring

Refinery wide HotSenseTM
deployment to reduce risk, increase safety and maximise data availability


Parameter Value
Compatible SensorsHotSense 380 & HotSense UHT (550 C)
No. of sensors per Hub1-4
ThermocoupleOptional K-type
No. of thermocouple per Hub0-4
Maximum distance from sensor3 m total cable length base option Up to 16 m total cable length advanced option
Cable routing optionsCompatible with cable trays, sealed or open conduit
UT hardware compatibilityAny meeting EN 12668-1 or ASTM E1065 with A-scan
Contact Ionix for more information or to screen
Measurement standardSolution compatible with ISO 16809 and
conventional in-service UT procedures


Parameter ValueUnit
Operating Temperature-55 to +380 (550 by request)ºC
Delay Line Material304 Stainless Steel-
Delay Line Length25 (longer by request)mm
Delay Line FormCylindrical, 10mm spot contact-
RuggedisationCertified to IP66 and IP68. Stainless steel construction-
Connector Type 00 Lemo receptacle as standard-
Certified to Intrinsically Safe Certification MarkingII 1 GD Ex ia IIC T* Ga
"X" Special conditions T* = Ts, Ta + 15 K
Active Element Diameter10mm
Transducer Centre Frequency 3.25MHz
+ compatible with both 2.25 MHz and 5 MHz flaw detectors / UT hardware
-6 dB Bandwidth80%
Signal to Noise Ratio> 20dB
Material Mounts/Clamps316 Stainless Steel-
Standard Clamp Sizes for PipesNPS 2” to NPS 16”Other sizes available via special request
Standard Stud for VesselsM8 x (40 - 60 mm)Other sizes available via special request
Standard Stud Spacing52.5 +/- 5mmOther sizes available via special request
Stud Torque Resistance>20 N.m-
Total Mass (Transducer + deployment)1.0 - 1.4 kgDependent on deployment method
Ionix Employment Options-01


HotSense™ transducers and supplied thermocouples are certified to intrinsically safe standards:

II 1 GD  Ex ia IIC T* Ga / Ex ia IIIC T* Da

The Measurement Hub™ when installed within the requirements of IEC 60079-14 is compatible with Zones 0 (gas/vapor) and 20 (dust) hazardous locations.

Certificates and Descriptive System Documents available on request.

Measurements must be taken under a hot work permit or other recognised method without intrinsically safe UT hardware.