HELIX

HELIX Sensor Wrap

Continuous condition monitoring
for critical piping.

Sensors for erosion and corrosion monitoring that enable predictive maintenance, and reporting that delivers end-of-life (EOL) estimates and increased plant throughput.

See the live demoDiscuss a pilot

With Helix

Our sensors enable predictive maintenance.

Months of readings at every point, run forward to a date.

See it in the live demo

Coverage

Cover surface area, not points.

Our flexible Sensor Wrap measures wall thickness everywhere the wrap covers, so thinning is found where it actually is.

See the live demo

HELIX Horizon with wall thickness mapped across the whole surface of a scanned pipe run, the colour range being swept so different bands of thinning come forward

History

A history for every point on the pipe.

Each scan lands on the same model as the last one. What you get is not a number for today but a rate of change per location, with the evidence behind it.

A scanned pipe elbow in HELIX Horizon, with a date slider dragged back and forth so the wall-thickness colouring changes scan by scan

Forecast

Forecast and quantify asset risk.

Run the trend forward against your minimum allowable wall. The answer is a date and a confidence band, which is what a shutdown gets planned around.

Discuss a pilot

The predicted wall thickness fan in HELIX Horizon, with the time cursor dragged forward and a 3D model of the elbow updating alongside it

Why predictive

A survey shows where the wall was. Monitoring shows where it is going.

Wall loss develops between inspections, when nobody is measuring it. A sensor that stays on the asset closes that gap where you monitor, and turns a record of the past into a forecast.

  • See wall loss while there is still time to act
  • Send inspections where and when they are needed
  • Plan the repair into the next maintenance window
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Capability

Periodic
inspection

HELIX
monitoring

Access the asset once

Continuous readings

Area coverage, not spot readings

Visibility between inspections

Same sensor, same spot, every reading

A forecast that stays current

Planning on measured condition

Time between readings

Months to years

Minutes

Time between readings from the live Sensor Wrap pilot: 4,800 readings in 8 hours. HELIX monitoring is screening, not certification. It does not replace a code-required inspection; it tells you where and when to send one.

30–40%

Reduction in maintenance cost compared to running to failure

US Department of Energy, on facilities moving off reactive maintenance.

DOE / PNNL, O&M Best Practices ↗

8–12%

Maintenance cost saved again over scheduled preventive maintenance

The gap between maintaining on a calendar and maintaining on measured condition.

DOE / PNNL, O&M Best Practices ↗

2×

The margin the code can make you carry

In some cases API 570 sets thickness-measurement intervals at half the calculated remaining life, subject to the maximum interval for the piping class. Half, because between inspections nobody can see the wall.

API 570, piping inspection code ↗

Proven in the field

Running on critical assets now.

3,200+

ft² of scanned area

2,000h

Continuous monitoring hours · live

360M+

industrial data points collected

The Helix asset viewer showing two rusted riser pipes with live wall-thickness heat maps, histogram and trend panel.
Live asset viewer · twin risers, wall-thickness field
The Helix asset viewer showing a propane tank scan coloured by wall thickness, with eddy-current and pulsed-eddy-current layers.
Propane tank · pulsed eddy current scan
The Helix asset viewer with every reading above 94% wall hidden, leaving an orange band of thinned metal running the length of a scanned spool between two flanges, against a scan range of 88 to 104% wall.
Monitored pipeline · wall loss below 94% of scan
The Helix asset viewer showing a monitored line coloured by pulsed-eddy-current wall thickness over a 8.0 to 10.3 millisecond window, beside the histogram and the wall-thickness trend plotted in capture order.
Monitored pipeline · wall-thickness trend in capture order

Deployed with, and supported by

  • Fisheries and Oceans Canada
  • National Research Council Canada

Proof of value

Proven Impact

Results from measuring wall thickness continuously, instead of waiting to find out at the next inspection.

$250K

Saved

Estimated new pipeline construction avoided.

12×

Return

Value back against what the assessment cost.

4 days

On site

Screened in place, with the line still in service. Nothing cut, drained or shut down.

How HELIX
Works

Step 1

We wrap once.

One install, no shutdown, no access work to book again. The wrap goes on and stays on.

Start a pilot

Start with one critical asset.

Put a Sensor Wrap on one location you already inspect, keep inspecting it the way you do now, and compare.

01

Pick one location

An elbow, a spool, or wherever your last inspections found the most wall loss.

02

We install and baseline

The wrap goes on externally. The first full-surface reading becomes your baseline.

03

Run both methods

Keep your normal inspection cycle. When it next runs you have two numbers for the same steel.

04

Decide with data

A measured degradation rate for that location, and a basis for expanding. Or not.

A typical pilot

Locations
1 to 3
Validation period
Defined up front
Install and support
HELIX
Horizon access
Included

Scoped against the asset you have in mind and what its current inspection cycle costs you.

Discuss a pilotSend us a photo or drawing

Documents

Case studies, white papers and data sheets.

All documents

Trusted technology

See the research papers.

47 papers, reviews and reports on pulsed eddy current, ultrasonic and EMAT thickness monitoring, acoustic, temperature, vibration and strain sensing, linked to their sources.

All 47 papers

Springer · 2017

Pulsed Eddy Current NDT and Evaluation: A Review

The standard survey of pulsed eddy current: the physics, probe design, signal features and where the method is used. The first paper to read.

Sophian, Tian, Fan

PubMed Central · 2017

Eddy Current Testing with GMR Sensors and a Pipe-Encircling Excitation for CUI

An encircling excitation coil with an array of magnetic sensors, reading corrosion under insulation without removing the insulation.

Bailey, Long, Hunze

PubMed Central · 2019

On-Line Monitoring of Pipe Wall Thinning by a High Temperature Ultrasonic Waveguide System

A high-temperature ultrasonic waveguide monitoring pipe wall thinning on-line, run for 3,300 hours.

Oh et al.

Journal of Electroanalytical Chemistry · 2018

On Quantitative Corrosion Rate Monitoring with Ultrasound

A fixed ultrasonic sensor resolving a corrosion rate of 0.1 mm per year within hours.

Zou, Cegla