Non-Intrusive Corrosion Monitoring – Pyramid Technical Services

Non-Intrusive Corrosion Monitoring System

Ultrasonic Wall-Thickness Monitoring

Pyramid’s Non-Intrusive Corrosion Monitoring suite delivers continuous, high-resolution wall-thickness measurement for pipelines and vessels without penetrating the pipe wall. Designed for topside, onshore and subsea applications, these clamp-on ultrasonic systems detect micrometre-level metal loss in real time, enabling proactive integrity management, rapid inhibitor tuning and reduced reliance on invasive inspection (pigging / NDT).

Key Benefits :

Zero penetration — no holes, no shutdown.
Real-time alerts and trending (minutes → days response).
High repeatability down to single-digit micrometres where specified.
Works through common exteriors and coatings (FBE, 3LPP, PE).
Suitable for topside process units, pipelines, subsea flowlines and retrofit installations.

Technology foundation — High-Resolution Pulse-Echo Ultrasonics

Systems use arrays of pulse-echo ultrasonic transducers mounted externally to provide wide coverage and repeatable wall-thickness data.
Advanced signal processing and thermal compensation convert echo returns into reliable thickness / metal-loss measurements with excellent repeatability and stability.
Array deployment delivers spatial corrosion/erosion mapping (not a single point) and allows discrimination of pipe wall, weld and heat-affected zones (HAZ) for targeted integrity assessments.

Topside monitoring
Swarm S2®

Subsea monitoring
UltraMonit®

Topside & Onshore Systems

Swarm-class (Continuous & Portable Options)

Non-intrusive, quick to install and maintenance-free, the topside family provides continuous wall-thickness monitoring for process piping and vessels. Deployment can be wireless (battery) or wired (autonomous/real-time), depending on site needs.

Continuous wireless sensors (Swarm-class) :

Multiple thermal ratings to suit process environments: Low (≈150°C), High (≈350°C), Ultra-High (≈550°C).
Wireless options use industrial standards (ISA100 or other LPWAN options) or can be fitted with wired outputs for higher bandwidth.
Typical repeatability: sub-10 µm to single-digit µm (product dependent).
Use cases: corrosion-sensitive bends, bottom-of-line areas, process vessels, heater outlets.

Short-Term Monitoring (STM) :

Portable, battery powered kit: sensors + data logger + software for campaign monitoring (weeks → months).
Fast deployment for hotspot verification or pre-/post-inhibitor trials.
Typical repeatability: ≈ ±10 µm for short-term campaigns.
Data capture: CSV output (raw echo, thickness, temperature, timestamp).

Wired / Autonomous Field Data Loggers :

Field Data Logger (Ex and non-Ex variants) for continuous wired installations.
Protocols supported: Modbus, 4-20 mA, Ethernet, GSM, optional RS-485/HART integration.
Local Bluetooth / portable reader support for onsite downloads and configuration.

Subsea Systems

UltraMonit-class (Permanent & Retrofit)

Subsea deployment capability :

Non-intrusive, externally mounted subsea ultrasonic systems engineered for long-term reliability (design lives: permanent ~30 years, retrofit ~15 years).
Can measure directly through standard subsea coatings (PE, 3LPP, FBE) — avoids costly coating removal.
Pressure-compensated electronics and canisters rated to extreme depths (up to multi-hundreds of bar).

Permanent PL (Pipe-Lay) installations :

Integrated during pipe lay for Greenfield projects.
Real-time monitoring for weld/HAZ and pipe wall; used to validate inhibitor performance and reduce pigging frequency.

Retrofit Solutions :

ROV / diver installable units for brownfield and late-life assets.
Removable loggers and modular sensors enable long operational life with periodic data recovery if needed.

Specialized subsea erosion monitoring (XT-class) :

High measurement frequency and continuous recording focused on high-kinetic sand-erosion zones (chokes, bends).
Designed to support real-time sand-control optimization and fast corrective action.

Subsea communications & data modes :

Options for online integration to subsea control systems (Modbus TCP/IP, RTU, CAN, SIIS) or autonomous battery operation with periodic logger recovery.
Autonomous battery life can be multi-year depending on measurement frequency and power profile. Future LPWAN/wireless subsea options are emerging for select use cases.

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