Real-Time UT Wall Thickness Monitoring
OVERVIEW
Real-time UT Wall Thickness Monitoring Systems (RTUT) continuously monitor wall loss from corrosion or erosion by measuring absolute wall thickness in mm. This online NDT “installed ultrasound” technique facilitates continuous inspection of process pipework and vessels without the need for regular inspection manpower. The systems are EEx rated and non-intrusive, so they can be hooked up and maintained without any interruption to operations. The hardware is designed for both temporary and permanent applications, with both wired and wireless options available.
BENEFITS OF RTUT MONITORING
By identifying wall thinning areas before they become critical, RTUT solutions support the prevention of equipment failure and Loss of Primary Containment (LOPC). Data can be fully integrated with client control systems for HiHi alarming at Minimal Allowable Wall Thickness (MAWT). By preventing reactive repairs, RTUT can lower maintenance costs whilst enhancing reliability and operational efficiency.
APPLICATIONS OF RTUT MONITORING
- Pipeline corrosion and erosion monitoring – Detect wall thinning in critical flowlines without disrupting operations.
- Pressure vessels and separators – Monitor erosion-prone zones caused by turbulent flow and chemical exposure.
- Onshore plants and refineries – Continuously track corrosion in elbows, tees, and high-risk pipework sections.
- Remote and unmanned sites – Long-life wireless systems allow for hands-free data collection in inaccessible and isolated locations.
TECHNICAL DETAILS
- Measurement Range: 3-25mm (standard thickness range), 6.35-50.8mm (extended thickness range)
- Battery Life (Wireless): 7 years at 2 readings/day
- Hazardous Area Classification:
- EEx ia (Zone 0) – Wireless
- EEx ec (Zone 2) – Wired
- No of Sensors: 200 per Gateway (Wireless), 32 per Transmitter (Wired)
Key Features
Enhance Structural Integrity with Accurate Wall Thickness Measurement
Measure Wall Thickness and Assess Structural Integrity
By identifying thinning areas before they become critical, it helps prevent equipment failures, reduces the risk of leaks, and ensures compliance with regulatory standards.
Calculate The Remaining Wall Thickness of Flowlines
By preventing reactive repairs, it lowers maintenance costs while enhancing reliability and operational efficiency.
FAQ
Frequently Asked Questions
What is real-time erosion and corrosion monitoring?
Real-time erosion and corrosion monitoring uses installed sensors, such as ultrasonic probes, to continuously measure wall thickness and detect material loss due to corrosion or erosion. This approach enables proactive maintenance before failures occur.
What’s the difference between erosion and corrosion monitoring?
Corrosion refers to chemical degradation of metal surfaces, while erosion is caused by mechanical wear from particles or fluid impact. Our monitoring systems detect both by measuring cumulative wall loss.
What industries use erosion and corrosion monitoring systems?
These systems are widely used in oil and gas, petrochemicals, power generation, water treatment, and marine industries—anywhere metal degradation poses operational risks or safety concerns.
How does SMS Integrity’s UT Wall Thickness Monitoring system work?
SMS Integrity’s RTUT system uses non-intrusive ultrasonic sensors to monitor wall thickness in pipelines and vessels. Data is collected continuously and can trigger alerts when material loss exceeds safe thresholds.
Is the system suitable for hazardous environments?
Yes. The system is EEx rated, with wireless versions certified for Zone 0 and wired systems certified for Zone 2 environments.
What types of assets can be monitored?
The system is ideal for pipelines, process vessels, risers, separators, heat exchangers, and other flowlines where corrosion and erosion risks are high.
What is the battery life of the wireless sensor units?
The wireless units offer a battery life of up to 7 years with two readings per day, ensuring long-term deployment in remote locations.
How accurate is real-time ultrasonic wall thickness monitoring?
Our systems offer high-resolution measurements in millimetres, with consistent accuracy over time, even in harsh and remote operating conditions.
Can the system trigger alarms for critical wall thickness?
Yes. The system can be configured to integrate with control systems to send Hi-Hi alarms when the wall thickness falls below the Minimum Allowable Wall Thickness (MAWT).
How many sensors can be connected to one system?
Our wireless gateway supports up to 200 sensors, while wired transmitters support up to 32 sensors per unit—scalable for both small and large asset coverage.
Do you offer temporary monitoring solutions for shutdowns or testing?
Yes. Our RTUT systems can be deployed for both short-term monitoring campaigns and permanent installations, depending on your operational needs.
What certifications do these systems hold for hazardous zones?
Wireless systems are EEx ia rated for Zone 0, and wired systems are EEx ec rated for Zone 2, suitable for deployment in explosive prone atmospheres.
Is remote access to monitoring data available?
Yes. Data can be accessed remotely and integrated into existing corrosion monitoring dashboards or client SCADA systems.
How often does the system take readings?
This can be configured. The default for wireless units is two readings per day, which balances data frequency with extended battery life (up to 7 years).
What maintenance is required for the sensors?
The system is low maintenance due to its non-intrusive nature. Sensor health can be monitored through the interface, and calibration checks are performed during scheduled reviews.
Can the data help with compliance reporting?
Absolutely. Continuous data supports traceable integrity logs, audit trails, and regulatory compliance with industry standards such as API 570 and ISO 55000.
Can I integrate this system with existing corrosion monitoring software?
Yes. The data can be integrated with client control systems or third-party corrosion monitoring software for centralised dashboarding and alarming.
What are the benefits of using a non-intrusive monitoring system?
Non-intrusive systems allow for real-time data without shutdowns, reduce inspection manpower needs, and eliminate safety risks associated with intrusive inspection methods.
Does SMS Integrity offer consultancy or support for erosion monitoring strategy?
Yes. SMS provides engineering support and consultancy to help operators develop a robust erosion and corrosion management strategy tailored to their asset risk profile.