HotSense™ Measurement Hub

HotSense™ Measurement
Hub for low cost, manual
data collection from
installed ultrasonic probes

Improve measurement precision through reduced operator variability and enable data trending to facilitate predictive and preventative maintenance of critical assets

Complete fixed-point HotSense™ ultrasonic thickness
measurement solution for use with standard UT gauges and
flaw detectors. The lowest cost entry point for non-invasive
corrosion and erosion in-service monitoring. For applications
including thickness, corrosion, erosion / wear and gas
void / entrainment in refining, oil and gas, nuclear and
energy industries

OUR TECHNOLOGY

Full fixed point non-invasive corrosion and erosion monitoring solution utilising the HotSense^™ extreme environment UT probes for -55 to +550 °C [-67 to 1,022 °F] applications.
No electronics, batteries or wireless – make measurements by connecting an industry standard UT thickness gauge or flaw detector.
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 to enable upgrade to a full automated wireless system.

Webpage: Measurement-Hub-Measurement-Taking

Web Page: Measurement-Hub-Data-Collection

ADVANTAGES

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.
Save operational costs with replacement of manual inspections, reducing scaffolding and insulation removal requirements.
Increase safety with reduced exposure to hazards and man-hours at asset.

For More Information Contact Us

APPLICATION INSIGHTS

TECHNICAL DETAILS

HotSense^™ Measurement Hub

Houses intrinsically safe sensor connections to enable quick and easy measurements to be collected from HotSense™ from an accessible location using your existing NDT equipment and procedures.
Compatible & configurable to Ex location installations to meet site requirements and enable simple data collection under hot work permits.
Probes installed on live plant in minutes for in-service measurements, designed to survive the harshest of environments.
The widest range of sensor deployment options for pipes and vessels.

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, without shutdown or isolation.
Integrated delay line provides near surface resolution and simple calibration at any temperature.

CASE STUDIES

MEASUREMENT HUB APPLICATION SPECIFICATION

PARAMETER	VALUE
Compatible UT Probes	HotSense™ DE, HotSense™ 380, HotSense™ UHT
Number of probes per Hub	1 to 4
Thermocouple type	K-type with IEC miniature connector
Number of thermocouples per Hub	0 to 4
Maximum distance from measurement location	3 m or 16 m total cable length options
Sensor connector*	Lemo 00 (adapter available by request)
UT hardware compatibility	Any meeting or ASTM E1065 with A-scan representation. Contact Ionix for compatibility enquiries. Optimised gauges available from Ionix.
Measurement standard	Solution compatible with ISO 16809 and conventional in-service UT procedures

*Variations available via special request.
For other specification requirements or to purchase measurement hardware please contact our sales team.

MEASUREMENT HUB™ ENCLOSURE SPECIFICATION

PARAMETER	VALUE
IP Rating	IP66
Ex compatibility	Suitable for installation in ATEX / IECEx Zone 0 & 20 to IEC 60079-14
Material of construction	Stainless Steel
Dimensions	See diagram
Hub access	Lockable, swing door
Mounting	Wall, pipe, pole or rail mounted with straps

Measurement Hub™ can be upgraded to a fully automated and wireless monitoring solution at any time.

For More information contact us

HAZARDOUS LOCATION INFORMATION

HotSense™ probes and supplied thermocouples are certified to intrinsically safe standards.

The Measurement Hub™, when installed within the requirements of IEC 60079-14, is compatible with Zones 0 (gas/vapour) 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 safe method when installed in an explosive environment.

HOTSENSE FAQ

What is the near field length of the transducer?
Can I order different delay line lengths, diameters and transducer frequencies?

The standard format is a 25mm long, 30mm wide delay line, 10mm diameter spot contact with a 3MHz transducer. These parameters have been optimised to for thickness measurement in steels up to 23mm in depth at temperatures up to 380°C.
Different delay lengths are available on special request, but consideration of the transducer nearfield and total transducer length and Ex requirements should be taken prior to ordering.
Ionix are available to offer advice and guidance when selecting the delay line for your application.
Different diameters and frequencies are not currently available, but please register your interest with Ionix Advanced Technologies from the contact page.
My hardware isn’t listed, can I use it with HotSense™ transducers?

HotSense™ transducers are compatible with all flaw detectors, UT thickness gauges, and proprietary hardware that we have tested to date. Ionix do not recommend the use of thickness gauges without A-Scan capability, and should only be used once measurements on calibration pieces have been made to validate readings.
Ensure that the pulser max/minimum voltages are compatible with the HotSense™ transducer specification.
Ideally the transducer should be pulsed at 3MHz with a 100 – 170ns wide pulse, although hardware with 2MHz, 2.25MHz or 5MHz settings can also be used.
Adapters are available for connectivity of the transducer to your hardware. Contact Ionix Advanced Technologies for further information.
Can I use high temperature coupling liquids, gels or pastes for installed monitoring?

Ionix does not recommend a high temperature dispensable coupling liquid, gel or paste that is suitable for continuous use at high temperature. Available high temperature coupling gels may be used for positioning of the sensor during installation, but transducer face and asset surface should be thoroughly cleaned with a nonflammable solution prior to coupling with a foil.
Why don’t I see an A-scan or delay line reflection?
The transducer is of single element type and for pulse-echo measurement should be connected to the TX/RX port, not the RX port.
- Ensure the pulser-receiver is set to operate in pulse-echo mode
- On multi-channel instruments ensure that the correct channel is selected
- Turn the gain up on the pulser-receiver or flaw detector
- Ensure pulser output is enabled and pulser voltage is adequate.
- Set the A-Scan delay to 0 and the range to 100mm in steel (approx. 40us)
- Inspect the cable and connections for damage
- Connect a spare HotSense™ Transducer to the instrument, without coupling. Check that the instrument can be set to receive an A-scan with a delay line reflection present
Why don’t I see a backwall reflection from my pipe/asset?
- Is the A-scan window/range wide enough? Ensure adequate time is given to receive the backwall signal.
- Is the backwall reflection overlapping with the delay line repeat echo? This will occur if the time of flight through the asset being inspected is the same as the time of flight through the delay line.
- Ensure that the delay line length is greater than the asset wall thickness.
- Do you observe a reflection from the delay line? If so then it may be that coupling between the transducer and asset has not been successful.
- In circumstances of extreme pitting or where the back wall is angled, a usable signal may not be returned, try coupling the transducer in a different location.
- If an extension cable or adaptor is fitted, remove this and check connections. Replace if necessary.
Why is my received echo very low?
- Ensure the filters on your pulser receiver are off, or configured for a 3MHz signal. If 3MHz is not available then either 2MHz, 2.25MHz or 5MHz should be used depending on which provides the optimum signal for your application.
- Ensure the pulser receiver gain has been turned up.
- Ensure that the pulser output is enabled and the pulse voltage is adequate.
- Is the reflector non-parallel? This would result in minimal signal being reflected to the transducer and low amplitude backwall reflection.
- If the delay line reflection is significantly higher amplitude than backwall reflection, then coupling may not have been optimised.
- Has the foil couplant been correctly inserted and has the transducer been tightened adequately to deform the foil and achieve coupling.
- If coupling is not being achieved using a foil couplant then attempt coupling using a gel couplant that is rated to the asset surface temperature.

DOWNLOADS

HotSense™ Measurement Hub Datasheet (PDF)