Internal Corrosion Monitoring: Improving Reliability and Data-Driven Decisions
The challenges and solutions to reliable internal corrosion monitoring.
Reliable internal corrosion monitoring plays a vital role in asset integrity management across sectors such as oil and gas, nuclear, mining, and chemical. Many inspection programmes, however, still rely on infrequent and non-repeatable measurements, limiting confidence in long-term asset degradation.
Consistent wall thickness data is essential for Risk-Based Inspection (RBI), maintenance planning, and safe operation. Traditional inspection methods often fail to provide the required frequency and repeatability, leading operators to adopt fixed monitoring technologies that deliver reliable, high-frequency data from fixed locations.
Challenges with Conventional Internal Corrosion and Erosion Monitoring
Conventional Non-Destructive Testing (NDT), including Manual Ultrasonic Testing (MUT), remains widely used for internal corrosion and erosion monitoring, and while accurate in isolation, it often fails to achieve continuous or highly repeatable long-term measurement. Common limitations include:
- Limited access to Critical Monitoring Locations (CMLs)
Hazardous, elevated, or insulated assets can be difficult and costly to inspect regularly.
- Infrequent data collection
Irregular inspection intervals create gaps, making it harder to identify trends.
- Inconsistent positioning
Readings are not always taken from the same point, reducing confidence in the corrosion rate.
- High cost and safety exposure
Inspection activities often require scaffolding, rope access, or additional personnel, increasing both cost and risk.
ÃÛÌÒ´«Ã½
The ÃÛÌÒ´«Ã½ WAND Solution is a cost-effective, scalable system that uses permanently installed sensors to deliver accurate, repeatable ultrasonic thickness measurements. By taking readings from a fixed location, measurement variability is reduced, and long-term trends become more reliable. Key benefits include:
- Repeatable measurements
Permanently installed WAND Thickness Monitoring Sensors (WAND TM Sensors) enable accurate tracking of corrosion and erosion from the same location.
- Flexible data collection
- The WAND Handheld Data Collector (WAND-HDC) is an easy-to-use handheld tool that wirelessly activates a WAND TM Sensor and then collects a thickness reading in less than a second.
- The WAND Remote Data Collector (WAND-RDC) is a compact, ATEX Zone 0, battery-powered unit that can activate up to eight WAND TM Sensors and transmit data via long-range Bluetooth 5.0 (up to 200 metres / 656 feet line of sight).
- Wireless and non-intrusive
WAND TM Sensors operate wirelessly and require no intrusive modification to the asset.
- Access to hard-to-reach locations
The REACH accessory extends WAND-HDC use up to 4.3 metres / 14.1 feet, enabling safer data collection from elevated or restricted areas.
- Corrosion Under Insulation (CUI)
The ECHO extension enables wall thickness monitoring under insulation or coatings without removal.
Enhancing Data-Driven Decisions
WAND transforms wall thickness measurements into reliable, data-driven decisions, resulting in:
- Reduced Personnel on Board (POB).
- Accurate short- and long-term monitoring trends.
- Predictive maintenance.
- Confident production adjustments while maintaining asset integrity.
Without repeatable measurements from the same location, monitoring trends are uncertain, complicating maintenance planning and production decisions
Application: Online Wall Thickness Monitoring of Remote Well PadsÂ
A shale gas operator in Ohio required continuous monitoring on a remote well pad, where sand erosion threatened production equipment.
Challenges
Challenges
- Conventional methods could not provide frequent, repeatable measurements.
- Remote site lacked local wireless infrastructure.
- Repeatable monitoring required without increasing POB.
Implementation
Implementation
- 54 WAND TMS installed on pipes, sand traps, and production units.
- 9 WAND RDCs configured to collect daily readings with temperature compensation.
- Data transmitted via Bluetooth to a gateway and then via 4G to iDART software.
- Monitoring performed without routine on-site intervention.
Results
Results
- 99% reliable, repeatable measurements from fixed locations.
- Short-term erosion rates of up to 3.1 mm/year identified within two months.
- Production safely increased by 50% while erosion was closely monitored.
- Variations in erosion rates across three similar lines allowed targeted maintenance.
- Using WAND-Online, the customer avoided an unplanned shutdown, saving $130,000 and achieving ROI in 30 days
±õ²Ô»å³Ü³¦³Ù´Ç²õ±ð²Ô²õ±ð’sÌýWAND Solution provides repeatable data for internal corrosion and erosion monitoring, enhancing reliability and data-driven decisions. Â
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
