Wi-Corr® Bond

Easy-fit wireless internal corrosion and erosion NDT solution suitable for retro-fit in Zone 1 explosive atmospheres.

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Wi-Corr® Bond

Adhesively-bonded ultrasonic sensors.

Key Features


Internal Corrosion


Operating temperatures
up to 200°C


Retrofit to


Retrofit to
storage vessels


Field proven resolution
of 0.01mm


Wall thickness


Surface temperature


for Zone 1

What level of corrosion are you experiencing?

Real time high resolution measurements. Metal loss detected immediately with no need for averaging over long time periods. Autonomous battery powered system offers years of trouble free asset monitoring.

Plant with high levels of corrosion
Plant with low levels of corrosion

Data reporting system up and running from first installation using intuitive software.  Expandable system.  When new sensors are added to an existing Wi-Corr® installation they are automatically recognised.

Accurate, Easy to Install, Corrosion and Erosion Monitoring

Wi-Corr® Bond is a revolutionary wireless monitoring system suitable for use in explosive atmospheres.

Through a self-organising network of permanently-installed, wireless-enabled sensors, accurate metal wall thickness and temperature can be obtained cost-effectively, enabling corrosion and erosion to be precisely monitored. The system can be applied to many environments. For refineries and petrochemical plant, the information provided allows an analysis of the impact of feedstock selection or chemical process and a proactive approach in planning of turnarounds and preventative action.  For any other applications where there are concerns over metal-wall thinning, Wi-Corr® provides ‘fit-and-forget’ and immediate reporting capability to allow continuous, long-term monitoring of those structures of concern.

How does Wi-Corr® Bond work?

Wi-Corr® Bond uses ultrasonic sensors adhered directly by the user onto metal surfaces.  Measurements of the wall thickness at each specific location are sent back to a central controller over the Radio Frequency (RF) mesh network.  Automatically-processed data revealing wall thickness can be viewed, or alternatively, full ultrasonic waveforms (A-scans) can be requested from each sensor if desired.  Corrosion and erosion trends and safety margins can then be deduced. Alarms can be set to warn the user of excessive metal loss.  All this capability allows better process control and proactive planning of maintenance by the asset manager.

Additional Information

Wi-Corr® installed sensors offer a safe and non-intrusive method of thickness measurement with reduced exposure of staff and contractors to hazardous environments.  Ultrasound monitoring of inspection anomalies allows for continued safe operation of critical infrastructure.

Installed sensors offer reduced operating and maintenance costs by enabling intelligent repair and intervention programs.

The Wi-Corr® Bond systems are certified for operation in explosive atmospheres IECEx and ATEX Zone 1. The sensors are approved to be permanently-installed on metal surfaces running at up to 200oC

Wi-Corr® Bond sensors are state-of-the-art devices, demonstrating thickness measurement resolution of better than 0.01mm (0.0004″), applied to flat or curved metal surfaces and a wide range of pipe diameters. This is approximately 10 times more sensitive than competing solutions. Metal surface temperatures are reported as a standard feature.

The Wi-Corr® Bond sensors and network can be installed during normal operations, so no shutdown is required. Hand-held surface preparation units and simple, pre-packaged adhesive installation mean most sensors can be installed in just a few minutes.

Installing a Wi-Corr® system avoids the need to gain hot work permits. Once installed, the need is avoided to repeatedly deploy scaffolding and remove insulation to achieve wall thickness measurements.

Wi-Corr® Bond sensors can be installed under insulation and weather proofing without welding or heating ensuring the integrity of the asset is not altered and does not increase CUI risk.

Separate wireless and sensing modules provide flexibility in locating wireless transmitter to maximise RF range and minimise repeaters.

To cover large assets or large surface areas, dozens, hundreds or even thousands of Wi-Corr® sensors can be deployed. Alternatively, single sensors or small numbers of sensors can be deployed to report on any areas of special concern.

Wi-Corr® units are autonomously powered and designed for 5+ year battery life under normal operating conditions. Batteries can be replaced easily at any time on live plant.

Data reporting system up and running from first installation using intuitive software.  Expandable system.  When new sensors are added to an existing Wi-Corr® installation they are automatically recognised.

The user can configure the system to suit any particular reporting or viewing preferences, such as frequency of reporting from any sensor, the comparison of results from multiple sensors or regions, or through the setting of desired alarm levels to warn of undesirable metal loss.

The user data display allows examination of data immediately if required, by manual intervention. Short and long-term trends in metal wall thickness are stored and can be recalled for assessment to allow the user to identify any troublesome areas or historical trends in process conditions.

The Wi-Corr® units use a wireless self-organising radio frequency mesh network which has been proven in cluttered environments.  Data from 1000s of corrosion sensors can be sent back to the central control hub for user viewing and advanced control.  No lengthy cabling required.  Wi-Corr® systems can be configured to either be stand-alone or integrated into any existing WirelessHART systems. Cellular networking can be provided, if desired by the user.

Wi-Corr® Bond Product Downloads