Project Overview
In a recent field application, iSensPro conducted an inspection campaign at a major chemical plant in The Netherlands. The aim was to evaluate the effectiveness of our handheld sensor technology in detecting Corrosion Under Insulation (CUI)—a critical concern for process pipelines in industrial environments.
Project Objectives
The inspection was designed with three core goals in mind:
-
Validate the iSensPro sensor technology for accurate moisture and corrosion detection.
-
Assess practical applicability for routine inspection and monitoring tasks.
-
Evaluate insulation and coating conditions on selected pipeline segments.
Pipeline Set up and Conditions
Three distinct pipelines were selected for inspection, each presenting unique characteristics:
-
PL 1: 4” Carbon Steel, 50 mm mineral wool, no tracing, 5.5 m segment — High corrosion risk.
-
PL 2: 8” Carbon Steel, 60 mm mineral wool, steam tracing, ~5 m segment with vegetation and high-risk areas.
-
PL 3: HP Steam line, Carbon Steel, mineral wool with wire mesh, 4 m segment with a bend — Low corrosion risk.
Key Findings
PL 1: High-Risk Segment
-
Corrosion detected in Segment 1 and Segment 3 (even though it was considered low risk).
-
Sections confirmed wet with coating degradation.
-
Action: Immediate intervention recommended.
PL 2: Steam-Traced Segment
-
Wet insulation and corroded steam tracing found in both segments.
-
Vegetation had no additional effect on corrosion.
-
Action: Preventive measures needed to halt degradation.
PL 3: Low-Risk Steam Line
-
No significant corrosion detected.
-
Coating intact and dry insulation.
-
Action: Recommend ongoing monitoring to maintain condition.
Conclusions
The field inspection clearly validated the reliability and efficiency of the iSensPro handheld sensor system:
-
Unexpected corrosion in a low-risk segment highlighted the importance of proactive maintenance.
-
A pre-inspection setup assessment was found critical to avoid false readings.
-
Regular periodic checks are essential to monitor high-risk zones effectively.
Key Benefits of Using iSensPro Technology
Financial Savings – Reduce maintenance costs through proactive planning and minimized downtime
Financial Savings – Reduce maintenance costs through proactive planning and minimized downtime
Improved Safety – Enable faster, data-backed response to risks, reducing exposure in hazardous areas
Enhanced Sustainability – Prevent environmental incidents and align with ESG goals
Higher Asset Reliability – Detect early signs of corrosion to extend asset lifespan
Increased Operational Efficiency – Optimize maintenance with non-intrusive, real-time monitoring.
Increased Operational Efficiency – Optimize maintenance with non-intrusive, real-time monitoring.
Final Thought
This successful project marks another step forward in transforming pipeline inspections with smart, non-invasive sensor technology. With reliable results and faster turnaround times, iSensPro is enabling safer and more cost-efficient infrastructure management.