Theta Corrosion Monitoring System Deployed at CNPC Oil & Gas Site

Recently, Theta successfully completed the installation and commissioning of its corrosion monitoring and thickness measurement system for an oil and gas well operated by China National Petroleum Corporation (CNPC). This deployment marks another significant milestone in Theta’s commitment to enhancing asset safety and operational efficiency in the energy sector.

The Challenge

During the production and transportation of oil and gas, corrosive substances such as sulfides, acidic/alkaline solutions, and moisture are frequently present in pipelines and processing units. These corrosive agents, under extreme working conditions like high temperature and pressure, can lead to serious problems, including local wall thinning, leakage, sulfide stress cracking, and naphthenic acid corrosion—particularly at vulnerable locations such as bends, welds, or cooler zones. Such corrosion issues pose a serious threat to equipment integrity, operational safety, and environmental compliance. However, many enterprises still rely on manual inspections or periodic thickness checks, which are labor-intensive, prone to error, and lack real-time data continuity, leaving facilities exposed to unexpected failures.

The Solution

To address these challenges, Theta deployed its DC Series Wireless Corrosion Monitoring System, a robust industrial-grade solution based on ultrasonic non-invasive thickness measurement technology. The system allows continuous monitoring of wall thickness without altering the structure or shutting down operations. Sensors are mounted directly on the external surface of the pipeline and use ultrasonic reflections to measure metal thickness in real time.

Key models installed at this site included:

• DC110 – standard temperature version
• DC110H – high-temperature version
• DC210 – ultra-high/low temperature version

All models deliver precise measurement results, with accuracy up to ±0.02 mm for DC110 and DC110H, and ±0.1 mm for DC210 in extreme temperature environments.

System Features

• Wireless Communication: Data is transmitted via Theta’s proprietary 2.4 GHz mesh network or accessed locally via Bluetooth 5.0 for mobile diagnostics.
• Remote Monitoring: Real-time corrosion status and alerts are available through a centralized cloud or local monitoring platform.
• Smart Analysis: The system provides corrosion rate tracking, remaining service life estimation, and predictive maintenance insights based on trend data.
• Rugged & Safe: The devices are intrinsically safe and designed to withstand harsh oilfield environments with features like waterproofing, dust resistance, anti-vibration, and chemical corrosion resistance.
• Low Power Design: Ultra-low power consumption enables over 10 years of battery life, reducing the need for maintenance.

Advantages

• Non-invasive Installation – No structural damage or downtime required
• High Precision Measurement – Industry-leading ultrasonic thickness accuracy
• Flexible Mounting – Adhesive, clamp, or welding installation options
• Secure Transmission – Encrypted data with device-level identity verification
• Remote Access & Alerts – Instant notifications for corrosion threshold breaches
• Mobile-Friendly – Bluetooth-enabled for local inspections via smartphone

Outcome

With the system now fully deployed and operational, the oilfield gains continuous visibility into pipeline integrity, enabling proactive maintenance planning, enhanced equipment safety, and reduced unplanned downtime. Theta remains dedicated to providing cutting-edge sensing solutions that support digital transformation in the oil and gas sector. Through intelligent monitoring and data-driven insights, Theta helps customers reduce maintenance costs, prevent failures, and extend asset life—delivering true value in high-stakes industrial environments.