Keeping plant assets in top condition
29/07/2024
Numerous operations are running concurrently in process plants. The condition of operation equipment must be maintained regularly to prevent the risk of unplanned downtime and costly repairs. This is particularly true for structures susceptible to corrosion and erosion. However, the conundrum for plant managers and operators is that maintenance inspection could disrupt operation and productivity.
With a focus on addressing these challenges, Cygnus has developed an effective solution of easy-to-use ultrasonic thickness gauges, offering a reliable method of measuring wall thickness or corrosion without the need to remove protective coatings. Using the Cygnus-pioneered multiple-echo technique, Cygnus thickness gauges can ignore thick coatings and only provide accurate thickness measurements of the substrate material, saving precious time and costs from removing coatings while avoiding exposing the substrate material to further corrosion.
When it comes to safety, regular maintenance is a top priority for industries processing hazardous materials or operating in explosive atmospheres, such as the oil & gas, petrochemical and chemical industries. The Cygnus 1 Ex ultrasonic thickness gauge, designed for use in all hazardous Zones (0, 1 and 2), is not only safe to use but also certified Intrinsically Safe to Zone 0 (the most dangerous area) for ATEX, IECEx and UKEX. This Ex-certified ultrasonic thickness measurement (UTM) gauge eliminates the need for hot work permits or plant shutdowns.
Industrial plants have diverse infrastructure, including storage tanks, pipes and production equipment, which may be prone to corrosion and erosion. Internal corrosion often takes place without notice. What makes it worse is that many structures do not allow access from both sides for inspection. This is where the ultrasonic thickness gauges come into play. The clever Cygnus 6+ ultrasonic thickness meter can measure the wall thickness from one side and ignore protective coatings up to 20 mm thick. This rugged and compact device, with its small ultrasonic probe, enables access to awkward, confined spaces. Its intuitive menu on a large LCD coloured display makes it extremely simple to use; any staff member can pick it up and use it with minimal training, making it a valuable tool for any plant.
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| Structures susceptible to corrosion and erosion must be maintained regularly |
In the energy and process sectors, plant equipment such as reactors, pressure vessels, boilers and pipes could operate at high temperatures. High temperatures exacerbate the corrosion process and pose additional difficulty for maintenance and inspection. With the Cygnus High-Temperature probes, the Cygnus 1 Ex and Cygnus 6+ thickness gauges can continuously carry out high-temperature thickness measurements of on-stream hot assets without a cooling period. This practical solution reduces inspection time and minimises disruption, providing operators with more time to focus on other important tasks.
It is not uncommon to find structures heavily corroded, prompting inspectors to investigate further. When this is the case, the Cygnus 1 Ex and Cygnus 6+ offer an array of advanced functions to tackle extreme corrosion. Thickness measurements can be shown live via an A-scan display to assist with visual verification. Surveyors can also use the B-scan function to take a series of continuous thickness measurements and display the results graphically to represent a cross-section through the material. If a user wants to hone in on a particular area of interest or heavily corroded spot, the advanced data logging offers Radial Points, allowing up to 12 thickness measurements to be added around the principal measurement in a ‘clock-face’ pattern.
The Cygnus 1 Ex and Cygnus 6+ gauges boast comprehensive data logging capability to streamline the inspection and prevent human errors. Inspectors can record measurement data on the gauge, which can be easily transferred via Bluetooth or cable to a Windows computer for post-inspection reporting and analysis.
Cygnus Instruments celebrated its 40th anniversary last year and has been a leading manufacturer, providing reliable ultrasonic testing equipment for asset integrity management (AIM) above and below water across various industry sectors. All Cygnus ultrasonic testing equipment is simple to use, robust and has a three-year warranty.
