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 HotSense™ 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 HotSense 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

ADVANTAGES

Network Map Draft

OPTIMISED

  • Increase what can be monitored – HotSense transducers allow for deployment directly to hot assets for measurements from -55 to + 550˚C (-67 to 1022 ˚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

  • 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.

WIRELESS

  • 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

CASE STUDIES

P7190416
Online Wall Thickness Monitoring

Refinery wide HotSensedeployment to reduce risk, increase safety and maximise data availability.

Shell Monitoring Configuration 1
Realtime, Remote Erosion Monitoring of Shell Wellheads

Upstream HotSense
deployment with cellular data transfer to:

• Maximise production, based on known erosion rates
• Increase safety, reduced site activity & personnel exposure
to X-ray
• Reduced costs by automating data collection remotely

Example Data Flow
Direct Integration of HotSense™ UT Wall Monitoring Sensors into Plant Optimisation and Control Systems

Downstream HotSense
deployment with data delivered direct to plant control systems:

• Utilisation of established WirelessHART network backhaul

• Data direct to control systems and outside of plant fence without additional IT infrastructure

• On-stream thickness measurements from hot, hazardous and inaccessible locations.

 

 

TECHNICAL DETAILS

SURVEY, INSTALLATION, COMMISSIONING AND SUPPORT

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.

DATA & SYSTEM HEALTH CHECK

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.

 STANDARD SYSTEM SPECIFICATION

Parameter Value
MEASUREMENT
Temperature-55ºC to +550ºC
Resolution0.010 mm (0.4 mil)* to 0.025 mm (1mil)
Thickness RangeSee transducers
SYSTEM
Channel per node1* - 4
ThermocouplesIntegrated into transducer or
standalone
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)*
RatingIP65*/IP66
Battery typeLithium D
Battery lifeUp to 5+ years
* Increased resolution system.
Parameter Value
WIRELESS
Communication ProtocolWirelessHART (IEC 62591)
Security128-bit AES Security
Max units per gateway100
Max total number of devices30,000
Data collection frequency1 hour +
SOFTWARE
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

 STANDARD TRANSDUCER & DEPLOYMENT SPECIFICATION

PARAMETERVALUEVALUEVALUE
HOTSENSE
SINGLE
ELEMENT
BONDED
SINGLE
ELEMENT*
DUAL
ELEMENT
Frequency3 MHz5 MHz5 MHz
ApplicationAllLow
temperature
vessels
Low
temperature,
thin walled
Thickness Range>2.5 mm>2.5mm>1mm
Continuous
temperature
range
-55 °C to
+ 380 °C
550 °C by request
-40 °C to
+200 °C
-55 °C to
+150 °C
Deployment
options
Straps, welded
studs
EpoxyStraps + epoxy
Cable
length
0.325 - 2.5 m high temperature
+
2-15 m flex
1.5 m standard
(3 or 6 m by
request)
2-15m
PARAMETERVALUEVARIABLES
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

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