Since the launch of the Cygnus 1 Ex three years ago, Cygnus Instruments Ltd.’s intrinsically safe ultrasonic thickness gauge (UTG) has maintained its reputation as one of its most reliable and recognized solutions for hazardous environments.
Launched in 1983 by George Edes, Cygnus Instruments Ltd pioneered the use of ultrasonic thickness measurement for non-destructive testing (NDT) of ship hulls. From its headquarters in Dorchester, South West England, the company has grown into a global leader in multiple-echo ultrasonic thickness gauges. These gauges are used to assess metal thickness across a wide range of industries, including marine, oil and gas, civil engineering, and plant maintenance.
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What Distinguishes the Cygnus 1 Ex Among Ultrasonic Thickness Gauges?
The Cygnus 1 Ex stands out from other UTGs with its full intrinsic safety certification, which enables it to operate in all hazardous gas environments – including ATEX/IECEx/UKEX Zones 0, 1, and 2 – as well as in coal mines and combustible dust zones (21 and 22).
When many UTGs require shutdowns or hot-work permits, the Cygnus 1 Ex enables safe, frequent in-service thickness measurements in explosive atmospheres. It integrates rugged functionality with Cygnus’ top-of-the-range multiple-echo technology, which enables precise through-coating measurements while ignoring coatings up to 20 mm thick.
When combined with the Cygnus High-Temperature Ex Probe, the device can conduct on-stream corrosion inspections of hot assets without shutdowns or system depressurization. It is also the only ultrasonic thickness gauge approved for ATEX Zone 0, the highest safety classification.
What Does Live Measurement in Hazardous Zones Mean for Operators?
For operators, being able to carry out ultrasonic thickness measurements live in hazardous or prohibited zones is advantageous for multiple reasons:
- Reduced inspection costs: Coating removal, depressurization, and system isolation are not needed
- Improved asset integrity management: Operators can more reliably track corrosion trends
- Less downtime: Inspections can be conducted without shutting down plants or equipment
- Enhanced safety: No need for hot-work permits or extra risk mitigation procedures
- Higher efficiency: Allows for more inspections for preventative maintenance
The Cygnus 1 Ex is certified for use anytime, anywhere within hazardous zones. It supports continuous, proactive maintenance that prolongs asset life and reduces long-term operational risk.
How Important Is the Multiple-Echo Technique for Through-Coating Accuracy?
The Multiple Echo technique is a product of Cygnus Instruments, now widely known and specified by Classification Societies for Ultrasonic Thickness Measurement (UTM) across the marine industry.
Unlike traditional UTGs, which rely on the first echo returned, the Cygnus multiple-echo approach accounts for several back-wall echoes from the metal substrate. This automatically overrides the coating layer, guaranteeing:
- Precise readings of remaining metal thickness
- Protective coatings don’t need to be removed
- Corrosion protection systems are preserved
- Lower cost and higher efficiency
With the Deep Coat function, the Cygnus 1 Ex can penetrate coatings up to 20 mm thick, making it ideal for assets that are heavily coated or insulated.
This information has been sourced, reviewed, and adapted from materials provided by Cygnus Instruments Limited.
For more information on this source, please visit Cygnus Instruments Limited.