In process industries – where uptime, safety compliance and long-term asset integrity directly determine productivity – reliable inspection tools are essential. Across oil and gas, chemicals, energy, marine, water treatment and general manufacturing, engineering teams rely on accurate thickness measurement and tightness verification to reduce failure risk, control maintenance costs and meet regulatory demands.
Cygnus Instruments, a long-established leader in digital ultrasonic testing, offers a suite of solutions designed for these challenges. Its latest product – the Cygnus 1 Ex, plus the Cygnus 6+ Pro and Hatch Sure – provides operators with robust, data-driven inspection tools for harsh and safety-critical environments.
Cygnus 1 Ex: Intrinsically Safe UTM for Hazardous Areas
In hazardous zones such as refineries, offshore platforms, petrochemical facilities, gas processing sites and storage terminals, inspections must be performed without creating ignition risks, interrupting operations or triggering extra permit-to-work requirements. The Cygnus 1 Ex meets these demands as the world’s only fully certified intrinsically safe ultrasonic thickness gauge approved for ATEX Zone 0, ensuring safe operation in Zones 0, 1 and 2, as well as combustible dust environments (Zones 21 and 22) and coal mining applications.
This makes it a highly versatile tool for the most challenging industrial settings. Certified to IECEx, ATEX and UKEX, the gauge allows in-service thickness measurement in explosive atmospheres without shutdowns or hot work permits. This capability is particularly valuable for continuous operation facilities where isolations, gas-free or cooling periods create significant disruption. When paired with the Cygnus High Temperature Ex Probe, engineers can inspect live steam systems, hot vessels and elevated temperature pipework without interrupting production.
Engineered for Intrinsic Safety
To achieve the highest level of intrinsic safety, the Cygnus 1 Ex incorporates:
- Low-energy circuitry to eliminate spark potential
- Antistatic housing to prevent charge accumulation
- Voltage clamping technologies for controlled electrical output
- Redundant safety electronics
- Fail-safe battery and thermal protection systems.
These features support compliance with stringent hazardous area safety frameworks.
Accurate Through Coating Measurement
Corrosion monitoring often requires measuring thickness through protective coatings. Cygnus’ Multiple-Echo technique ignores the coating layer and analyses multiple back wall echoes, producing reliable readings of remaining metal thickness without coating removal. This minimises preparation time, preserves protective systems and improves efficiency of hazardous area inspections.
Why Operators Choose the Cygnus 1 Ex
- Safety: Fully certified for Zone 0.
- Efficiency: No shutdowns or hot work permits needed.
- Cost Savings: No coating removal or production delays.
- Integrity: High accuracy data for predictive maintenance.
Cygnus 6+ PRO: High Performance Corrosion Monitoring
Corrosion remains one of the most persistent threats to industrial infrastructure, affecting pipework, tanks, vessels and structural supports – especially where chemicals, temperature cycling and moisture accelerate material degradation. The Cygnus 6+ PRO, the most advanced surface range thickness meter from Cygnus, offers a rugged and highly capable solution for detailed corrosion assessment.
With a lightweight, compact, IP67 rated and shatter resistant design, it performs reliably in demanding environments, including confined spaces, elevated work areas and outdoor installations. Its ability to take readings from one side of the material is particularly beneficial where access is limited.
Built for Professional Inspectors
Key features include:
- Intuitive interface with large colour LCD
- Three measurement modes for varied corrosion conditions
- Measurement Stability Indicator (MSI) for real-time accuracy validation
- Live A-scan and B-scan displays for signal verification
- Manual gain and range controls for difficult materials
- Comprehensive data logging with auto-log
- Radial Points for corrosion mapping
- Bluetooth and cable connectivity for streamlined reporting.
The ability to measure through coatings up to 20 mm eliminates unnecessary coating removal, making the instrument suitable for chemical plants, power stations, food processing operations and water infrastructure.
Cygnus Hatch Sure: Ultrasonic Leak and Tightness Testing
Many process environments require routine seal integrity verification—whether in storage compartments, transport vessels, watertight spaces, pharmaceutical facilities or food-grade environments. The Cygnus Hatch Sure ultrasonic tightness tester offers a clean, quick and effective alternative to hose testing and visual inspection.
With 19 ultrasound emitters and six adjustable power levels, Hatch Sure adapts to numerous compartment sizes, including confined spaces. Its lightweight, ergonomic design enables single operator testing, allowing maintenance teams to complete inspections efficiently without clearing compartments. This promotes frequent, proactive testing and early detection of seal fatigue, helping reduce contamination, leakage or environmental risks.
A Unified Approach to Asset Integrity
Together, the Cygnus 1 Ex, Cygnus 6+ Pro and Hatch Sure deliver a comprehensive ultrasonic inspection suite that supports key operational goals across the process industries:
- Maximising uptime
- Reducing inspection and maintenance costs
- Supporting regulatory compliance
- Extending long-term asset performance.
Cygnus Instruments remains a trusted partner for engineers seeking robust, field proven inspection technologies designed for safety, durability and accuracy.
