Current corrosion detection methods are often inadequate for addressing the challenges of modern industrial operations.
Traditional techniques, while useful in certain contexts, come with significant limitations that hinder their effectiveness and efficiency. For instance, ultrasonic testing, though reliable for measuring wall thickness, requires direct access to clean surfaces of the equipment, making it impractical for large-scale or continuous monitoring. Similarly, electromagnetic techniques offer the potential for non-destructive evaluation but are often constrained by the need for close proximity to the test surface, and they can struggle with complex geometries or certain material properties.
Magnetic sensors enabling rapid inspection of pipe supports or rust scabs, requiring only a dime-sized clean area.
Furthermore, many existing methods often necessitate the removal of insulation or coatings and fail to measure corrosion under supports or inside equipment without consequential disruption to operations. These challenges not only increase the labor and costs associated with testing but also limit the frequency and comprehensiveness of corrosion monitoring.
The VIR System: A revolutionary solution
To address these challenges, VIR Inspection has developed the VIR System technology, which is a proven, NDT method for inspecting any conductive material using direct current. The system uses one or more pairs of sensors to collect data on corrosion or degradation in conductive materials, even in hard-to-reach areas. Notably, corrosion under pipe supports can be assessed without the need to lift or remove wrapped pipe. Doing this offers a significant advantage in maintaining the integrity and longevity of industrial equipment. The VIR System provides repeatable, consistent results, making it an effective tool for assessing material wall loss, flaws detection, growth rates and life expectancy.
The VIR System technology employs corrosion-resistant stainless-steel sensors housed within a self-contained unit that can be magnetically attached, clamped or secured to the test object. Permanent sensors can also be installed using a stud welding technique or permanent adhesion. The system offers a durable, reliable solution for continuous corrosion monitoring. The ability to perform measurements without direct access to the test surface and to integrate these measurements into a networked monitoring system represents a significant advancement over existing techniques.
Magnetic sensors enabling rapid inspection of pipe supports or rust scabs, requiring only a dime-sized clean area.
Enhancing safety and operational efficiency
The VIR System not only addresses the technical challenges of existing corrosion detection methods but also offers a practical solution for industries seeking to enhance the safety, reliability and longevity of their infrastructure. By providing a means for continuous, accurate monitoring of corrosion, the VIR System stands to significantly impact the maintenance strategies and operational efficiencies of facilities prone to corrosion-related issues.
Check for corrosion or cracking beneath wrapped pipes to monitor any changes in growth patterns.
Seamless integration with ongoing operations
The VIR measurement data is interpreted to provide information related to the corrosion of the pipe without requiring destructive testing. This feature allows for the accumulation of VIR data from multiple points, enabling comprehensive corrosion monitoring and the ability to predict and prevent equipment failure through advanced data analysis techniques. Through continuous and accurate corrosion monitoring, the system assists in scheduling maintenance and repairs before significant degradation occurs, thus avoiding unplanned downtime and extending the usable life of the equipment. The collected data is uploaded to a VIR System analysis program tailored to the customers’ requirements with a yearly flat software rate with unlimited company users.
Above is a picture of the actual VIR System.
The VIR System can be performed while the plant is fully operational. The inspection procedure begins by preparing two dime-sized bare surface test areas for each sensor. Next, the nominal wall thickness is verified using ultrasonic thickness readings, and the ambient temperature of the vessel or pipe is recorded with a non-contact infrared thermometer. Once these preliminary measurements are complete, the VIR test is conducted.
Securing equipment integrity
Damaged or corroded equipment poses serious safety risks and can jeopardize the smooth operation of any plant or facility. With the VIR System (patent pending), users can ensure that their equipment remains in the best condition, as the technology makes detecting faults simple, effective and non-disruptive.
For more information, visit virsystems-us.com.
