Theta Deploys Wireless Thickness Monitoring for Sulfur-Containing Wastewater Tank

At a major gas purification plant under PetroChina, severe internal corrosion was discovered in a large sulfur-containing wastewater storage tank during routine operations. Due to the lack of real-time monitoring tools, the facility had long relied on manual ultrasonic thickness inspections to assess the tank’s structural integrity. However, these periodic inspections were labor-intensive, time-consuming, and carried significant safety risks—particularly because the tank stands over 6 meters tall, requiring scaffolding for each inspection.

To address these challenges and enhance corrosion monitoring capabilities, the facility deployed Theta’s DC Series online ultrasonic corrosion monitoring system. The system uses non-intrusive ultrasonic sensors mounted directly on the tank’s exterior to continuously monitor wall thickness. By measuring ultrasonic wave travel time and applying advanced temperature compensation algorithms, the sensors deliver high-accuracy thickness measurements under varying environmental conditions.

Key Benefits of the Solution:

Industrial-Grade Reliability: All sensors are explosion-proof, waterproof, dustproof, shock-resistant, and corrosion-resistant—ideal for harsh environments.

Non-intrusive & Wireless: Sensors are adhesive-mounted on the tank surface—no need to drill or interrupt operations. Data is transmitted wirelessly via a 2.4GHz network to a local gateway, then relayed to the cloud via 4G or Ethernet.

Ultra-low Power: Each sensor features ultra-low power consumption, with a battery life of over 10 years.

Real-time Monitoring & Alerts: The system supports continuous monitoring and triggers alerts when corrosion rates or thickness thresholds are exceeded.

High Accuracy: The DC110 and DC110H models deliver ±0.02mm precision in ambient and high-temperature conditions; the DC210 model supports extreme temperature applications with ±0.1mm accuracy.

The deployment of Theta’s corrosion monitoring system has allowed the customer to replace inefficient manual inspections with real-time, automated tracking of corrosion trends. This not only reduces operating costs and labor requirements but also enhances equipment safety by enabling predictive maintenance and timely interventions.

As a leader in industrial IoT sensing solutions, Theta remains committed to delivering high-reliability monitoring technologies that empower energy operators to build smarter, safer, and more efficient infrastructure.