Case Study: Structural Integrity achieves continuous high-temperature thickness monitoring and early wall-loss detection with StructInt ultrasonic thick-film sensors

Structural Integrity monitors 0.005 inches of wall loss in 8 months with StructInt

The customer, Structural Integrity, sought to move from schedule-based to condition-based inspection and maintenance for high-temperature components susceptible to wall thinning. To address this challenge, they partnered with vendor StructInt (Structural Integrity Associates) to utilize their SIIQ™ intelligent monitoring system featuring robust thick-film ultrasonic sensors.

The solution implemented by StructInt involved installing low-profile, high-temperature ultrasonic sensors directly onto piping components. These sensors provided continuous, real-time thickness monitoring, accurately quantifying even minimal wall loss. The results demonstrated the technology's longevity and effectiveness, with one sensor operating continuously for over two years at 800°F and data from a power plant application showing the precise measurement of 0.005 inches of wall loss over an eight-month period. This enabled predictive maintenance, early issue identification, and optimized plant operations for the customer.

Structural Integrity