Non-Invasive Thickness & Corrosion Monitoring

Minimise operational risk and maximise productivity with enhanced asset intelligence.

We are the extreme environment experts. We enable plant digitalisation and the realisation of Industrial IOT solutions. We combine our market leading HotSenseTM sensors with the best-fit data collection system to provide a complete monitoring solution to deliver key asset integrity data, meeting cost, HSE, and operational targets across refining, oil & gas, energy, nuclear and process sectors

Start monitoring your assets with HotSenseTM to increase plant productivity:

  • Remove variables caused by periodic inspection process.
  • Provide more frequent data, with no increase in costs to improve RBI data / deliverable.
  • Get more actuate data to feed your FFS studies.
  • Remove conservatism from your asset retirement planning.
  • Enable use of lower cost feedstock options
  • Confirm effectiveness of corrosion inhibitors.
  • Enable better data to make informed decisions around change management:
  • Production increases
  • Shutdown planning


Network Map Draft


  • Increase what can be monitored – HotSenseTM transducers allow for deployment directly to hot assets for measurements from -55˚C to + 550˚C (-67 to 1022 deg F).
  • Increase Safety – Intrinsically safe and certified for deployment across your business (FM Cl 1 Dv 1-2, ATEX & IECEx Zone 0-1)
  • Reduced maintenance – Transducers and node may be positioned independently to allow for ease of access for battery change – no need for scaffolding or rope access. Service packages available.
  • Cost efficient – Multiple transducers per measurement node to minimise batteries.
  • Improved network stability – Nodes positioned to maximise wireless signal.
  • Maximise flexibility – Flexible and robust deployment and data management options


  • Automated – thickness measurements, temperature measurements and corrosion rates transmitted directly to your control room.
  • Security – Advanced data management software on local server or data direct to you DCS and PIMS – data never leaves your site.
  • Configurable alarms – Robust and reliable measurements for determination of wall loss rates & absolute thickness.
  • Inhouse data access – Make data available to both maintenance and operations teams to better optimise plant productivity.
  • Built-in calibration – Measurements may be validated using HotSenseTM transducer integrated calibration block.


  • Fully WirelessHART certified and compliant for integration into your operations.
  • Remote measurement configuration and maintenance.
  • Battery life is transmitted allowing maintenance and data collection scheduling.
  • P7190416
  • P7160432
  • P7170424
  • P7160442
  • P8270477
  • P7180404


Online Wall Thickness Monitoring

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



Ionix, with our system and global or local service partners can provide planning and pre-installation surveys, as well as ongoing system service and data health packages tailored to your requirements.


Ionix understand that the project doesn’t finish at installation. To support the operation of your monitoring solution and continual improvement in data collection, we provide ongoing System Service packages tailored to a client’s requirements.


Parameter Value
Temperature-55ºC to +550ºC
Resolution0.010 mm (0.4 mil)* to 0.025 mm (1mil)
Thickness RangeSee transducers
Channel per node1* - 4
ThermocouplesIntegrated into transducer or
CertificationIS/Class I, Division 1, Groups A/B/C/D;
Ex ia IIC T4 for -55°C ≤ Ta ≤ +55°C;
Ex ib IIC T4 Gb (Ta = -40°C to +70 °C)*
Battery typeLithium D
Battery lifeUp to 5+ years
* Increased resolution system.

Parameter Value
Communication ProtocolWirelessHART (IEC 62591)
Security128-bit AES Security
Max units per gateway100
Max total number of devices30,000
Data collection frequency1 hour +
Data outputThickness, wall loss rate (short & long),
temperature, battery, A-scan
ExportWhole database or subset, .csv
Data storage and accessLocal server, DCS, PIMS etc
ProtocolEtherNet/IP, Modbus RTU/TCP, OCP
DiagnosticsRemote diagnostics of transducer,
node, network and measurement
CalibrationAt install and manual online
Battery remaining lifeAs a function of usage or voltage

System Renders


Frequency3 MHz5 MHz5 MHz
thin walled
Thickness Range>2.5 mm>2.5mm>1mm
-55 °C to
+ 380 °C
550 °C by request
-40 °C to
+200 °C
-55 °C to
+150 °C
Straps, welded
EpoxyStraps + epoxy
0.325 - 2.5 m high temperature
2-15 m flex
1.5 m standard
(3 or 6 m by

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


  • For the standard 25mm delay line, the nearfield is contained within the delay line close to the coupling face. The beam spread in the asset will be dependent on the material being inspected.

  • 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.

  • 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.

  • 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.

  • 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
    • 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.
    • 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.