Hard-to-Reach & Remote Internal Corrosion Monitoring: Increasing Accessibility Using the WAND SolutionÌý
The challenges and solutions to accessible internal corrosion monitoring.
Assessable corrosion monitoring is essential for maintaining asset integrity in sectors such as oil and gas, nuclear, mining, and chemical. In practice, however, many Corrosion Monitoring Locations (CMLs) are positioned in areas that are difficult to access, whether elevated, remote, hazardous, or insulated, making traditional inspection methods challenging.
These access limitations often reduce inspection frequency, introduce variation in measurement location, and create gaps in long-term data. As a result, operators may lack the consistency needed to confidently assess asset condition, plan maintenance, and manage risk.
Accurate, repeatable wall thickness measurement remains fundamental to Risk-Based Inspection (RBI) and safe operation. To overcome access and data reliability challenges, many asset managers are adopting fixed monitoring technologies.
Challenges with Conventional Wall Thickness Monitoring
Conventional Non-Destructive Testing (NDT), including Manual Ultrasonic Testing (MUT), remains widely used for internal corrosion and erosion monitoring; however, these methods are not always best suited to environments where access is restricted or conditions are hazardous. Common limitations include:
- Restricted access
Elevated CMLs, congested piping, confined spaces, and remote facilities often require scaffolding and rope access, increasing cost and reducing inspection frequency.
- Asset insulation and protection
Inspecting insulated assets typically requires removing insulation, which adds time, cost, and operational disruption.
- Inconsistent measurement
Although accurate, traditional NDT methods do not guarantee readings are taken from exactly the same point each time, reducing confidence in trend analysis.
- Safety and cost
Extended time in hazardous environments increases both operational risk and inspection expense.
ÃÛÌÒ´«Ã½
The ÃÛÌÒ´«Ã½ WAND Solution is a cost-effective, scalable system that uses permanently installed sensors to provide accurate and repeatable ultrasonic wall thickness monitoring. By taking readings from a fixed location, measurement variability is reduced, and long-term trends become more reliable. The technology is designed to support hard-to-reach, remote, hazardous, or insulated points monitoring using a combination of its solutions. Key benefits include:
- WAND Thickness Monitoring Sensors (WAND TM Sensors)
WAND TM Sensors are permanently installed, embeddable, wireless, and ATEX Zone 0 rated. These corrosion and erosion monitoring sensors provide accurate, repeatable wall thickness measurements with RFID-enabled data traceability.
- WAND Remote Data Collector (WAND-RDC)
WAND-RDC is a compact, battery-powered device that automatically collects thickness data from installed WAND TM Sensors. It enables remote, scheduled measurements in hard-to-access or hazardous areas, streamlining corrosion and erosion monitoring.
- WAND-Online
WAND Online enables fully digitalised, remote wall thickness monitoring. Accurate, real-time wall thickness measurements accessible from your desk via the iDART software.
- REACH
REACH is an accessory for the WAND Handheld Data Collector (WAND-HDC) that can extend up to 4.3 m / 14.1 ft. By attaching the REACH to the WAND-HDC, data can be collected from the WAND TM Sensors installed in difficult-access locations to support hard-to-reach corrosion monitoring.
- ECHO
ECHO extension is an ultra-thin, flexible cable that provides access to WAND TM Sensors for through-coat monitoring. The cable can collect wall thickness data from under coatings, cladding, or in confined spaces, without the need for removal or direct access.
Improving Access Without Compromising Data Quality
ÃÛÌÒ´«Ã½ enables improved accessibility and efficiency of wall thickness data, with key application benefits including:
- More consistent measurements from fixed locations.
- Reduced need for manual inspection in hazardous areas.
- Improved access to insulated, elevated, and remote assets.
- Lower reliance on scaffolding and insulation removal.
- Scalable deployment across large or complex facilities.
Application: Transforming Risk-Based Inspection Through Widescale Deployment of WAND
A major oil and gas operator required a more reliable way to support RBI across a facility with thousands of CMLs, manyÌýlocatedÌýin elevated, insulated, or hazardous areas.
Challenges
Challenges
- Substantial number of difficult-to-access monitoring points.Ìý
- Heavy reliance on scaffolding, rope access, and insulation removal.
- Limited inspection frequency due to access constraints.
- Inconsistent measurements from MUT.
- Poor visibility of short-term corrosion trends.
Implementation
Implementation
- WAND TM Sensors installed across Tier 1–3 CMLs to create fixed measurement points.
- Remote data collectors deployed for automated, scheduled readings.
- ECHO used to capture data through insulation without removal.
- Manual data collection supported by REACH for elevated location.
- Measurement intervals set based on risk and accessibility.
- Data accessed remotely via a digital platform.
Results
Results
- Consistent wall thickness data from previously hard-to-access areas.
- Short-term erosion rates of up to 3.1 mm/yearÌýidentifiedÌýwithin two months.
- Reduced need for scaffolding, insulation removal, and manual inspection.
- Improved safety through reduced exposure in hazardous environments.
- Expanded monitoring coverage across remote and inaccessible locations.
- Stronger RBI supported by higher-frequency, reliable data
The WAND Solution provides a practical way to extend monitoring into areas that are typically difficult or costly to inspect. By improving both accessibility and data consistency, it allows operators to reduce reliance on periodic manual inspection and move toward a more continuous, data-driven approach to integrity management.
Enquire today
Speak with a member of the team today to learn how WAND can upgrade your manual UT inspection to fully digitalised wall thickness monitoring.
Enter your details below
"*" indicates required fields
