ABB Instrumentation. Automation products, ProcessMaster
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1
© ABB Group 23 October 2012 | Slide 1
ABB InstrumentationAutomation Products ProcessMaster
ABB Instrumentation 2012 Gert van Bergen Measurement Products Business Development Manager
Criteria: Hoe selecteer ik een debietmeter?
Meet technieken
Nauwkeurigheid,
reproduceerbaarheid vande gemeten waarde
meetgebied
Werk condities
aggregatie toestand (gas,vloeistof)
geleidbaarheid
viscositeit
temperatuurlimieten
agressiviteit van het medium
Afzetting - vervuiling
© ABB Group 23 October 2012 | Slide 2
Wettelijke richtlijnen
ATEX zones
IJkwaardige metingen etc..
Meetgebied
diameter van de leiding
snelheid van doorstroming
drukverlies
flow profielen, verstoringen
Invloeden
mechanische belasting
chemische belasting etc...
Betrouwbaarheid en service gevoeligheid
Prijs
2
Basis werkingspricipe: de Wet van Faraday
© ABB Group 23 October 2012 | Slide 3
U= B*D*v*K
U= Geïnduceerde spanning
B= Magnetische flux
D= Meetbuis diameter
v= Gemiddelde medium snelheid
K= Opnemer constante
U ~ v
B = Gecompenseerd
D = Vaste waarde
Qv= v . 1/4 D²
Qv= Volume debiet
U ~ Qv
Proportioneel en lineair metde volumetrische doorstroming
Voor- en nadelen:
Voordelen van dit meetprincipeDe meting is onafhankelijk van:
dichtheid
temperatuur
viscositeit
druk
geleidbaarheid (mits boven minimum)
Grotendeels onafhankelijk van:
afzetting en vervuiling
flow profielen
Nadeel:Enkel geschikt voor geleidende vloeistoffen
min. 5µS/cm © ABB Group 23 October 2012 | Slide 4
3
De belangrijkste voordelen:
Gladde meetbuis zonder obstructies -> Geen drukval
Geen bewegende delen in de meetbuis
Korte in en uitroom pijpstukken benodigd 3 x DN upstream
en 2 x DN downstream
Diameters van DN 1 tot en met DN 2400 (0,0018 tot 160.000 m3/h)
Hoge nauwkeurigheid 0,15 % van de gemeten waarde.
Zeer grote “turn down” 1 : 100
Ijkwaardig voor handelsdoeleinden (DKD-NMi ijking)
Atex-uitvoering voor zone 1 en zone 2
Speciale uitvoering voor lage geleidbaarheden, vanaf 0,05 S/cm
Meetsysteem met een korte responsie van 10 ms voor vullen en doseren, totale batch tijd vanaf 0,5 seconde
Geschikt voor vloeistoffen met een hoog droge-stof gehalte© ABB Group 23 October 2012 | Slide 5
© ABB Group 23 October 2012 | Slide 6
Intuitive operationEasy Set-up guides even an inexperienceduser quickly and easily through the menu, step by step
Capacitive keysConfigure without opening the housing
High accuracy High excitation frequency combined withadvanced filtering assures accuracies upto 0.2% of rate
Practice oriented diagnosticsMonitors the operability of the instrumentas well as the customer processes. Diagnostic dependent help texts are displayed,simplifying error corrections
ProcessMaster at a glance
4
© ABB Group 23 October 2012 | Slide 7
Modern flowmeter sensorHigh excitation frequency, optimizedelectrode design, high temperature design
Advanced data storage inside the sensor (SensorMemory)Eliminates errors and assures a fast andsafe start-up
Universal Converter Fully configurable display20mA active / passive (selectable on site)Pulse active / passive (selectable on site )HART Protocol is standardOperation without opening the housingAn identical converter module forATEX, FM, CSA, IEC Reduces replacement part stock and storeroom costs
Ex-Protection Zone 2 is standard (available from July)
ProcessMaster at a glance
© ABB Group 23 October 2012 | Slide 8
Specifications ProcessMaster
ProcessMaster covers all operating conditions Integral mount design applicable for fluid temperature up to 130°C at 45°C ambient temperature
High temperature design without any limitations applicable up to 180°C at 60°C ambient temperature
This extends the field of applications
High temperature up to 180 °C is available !!
60 °C
45 °C
25 °C
50 90 130 180°C Fluid
Ambient °C
FXE4000
ProcessMasterstandard
ProcessMasterHigh-Temp.Design
5
© ABB Group 23 October 2012 | Slide 9
Specifications ProcessMasterThe perfect fit for high temperature
installations
High Temperature Design (180°C)
Integral Mount
Remote Mount
In combination with non hazardous and hazardous area design
PFA for high temperature up to 180°C
Range of PFA Liner extended up to DN200
Vacuum resistant, metallic grid
Covers 90% of all applicationsPFA 3….100…200
© ABB Group 23 October 2012 | Slide 10
Specifications ProcessMasterExtend the Field of Applications
New Liner Material:
ETFE liner for temperature up to 130°C Size: DN25 … DN1000
Vacuum tight and corrosion resistant
Can also be used for high pressures
Smooth surface, minimizes deposits
Easier to install than PTFE lined flowmeters
S iz e
v acu
um s
t abl
em
a x. T
e mp e
rat u
rP r
ice
LinerThick PTFE 25………...300 180
ETFE 25……………..…1000 130
PFA 3…..100...200 180
6
© ABB Group 23 October 2012 | Slide 11
Specifications ProcessMasterTake Advantage of Latest TechnologyExtended Reliability
Self cleaning, round shaped electrodeDouble sealed electrode headElectro-polished surface (Ra < 0.8)
© ABB Group 23 October 2012 | Slide 12
Hazardous Area
Zone 2 Div 2Zone 1 Div 1
7
© ABB Group 23 October 2012 | Slide 13
ProcessMaster – ATEXSensor inside
Ex-Area Transmitter outside
Integral mount
inside Ex-Area
Sensor andTransmitter
inside Ex-Area
10 m 50 m
FEP325DN 3… DN2000
(1/10…80”)
FEP325DN 3… DN2000
(1/10…80”)
FEP315DN 3… DN2000
(1/10…80”)
Note: cFM limited to DN300 (12”)
© ABB Group 23 October 2012 | Slide 14
ProcessMaster – ATEX
50 m
Remote Transmitter inside Ex-Area
Remote Sensor inside Ex-Area
Integral mount inside Ex-Area
8
© ABB Group 23 October 2012 | Slide 15
ProcessMaster
One identical converter module for all:
Integral design and the design with remote transmitter
FM, ATEX,CSA makes no difference -> the same identical electronic / cartridge
Capacitive keys, configuration without opening the housing
Rotatable display – no tools (screw driver) required
Kit Built Design
Single identical converter cartridge
Single identical mechanical connections
© ABB Group 23 October 2012 | Slide 30
- ProcessMaster –
Diagnostics
New
9
© ABB Group 23 October 2012 | Slide 33
ProcessMaster – Diagnostic FunctionsStandard Diagnostic functions:
Electrode coating / short circuit
Empty pipe / partially full
Extended Diagnostic functions:
Gas bubbles in the liquid, noise signal
Enhanced Coating detection
Electrode corrosion galvanic voltages
Conductivity measurement
Damage to liner electrode balance
Partially full TFE electrode and empty pipe detection
© ABB Group 23 October 2012 | Slide 34
Diagnostic functions
to keep the process up and running
to increase production volume, increase revenues
to reduce operating expenditures
to prevent Cost-intensive Plant Outages
Recognize critical factors early (Warning)
Take corrective actions prior the meter fails
to have a better planning of maintenance
Improve operational resources by utilizing maintenance-friendly instruments
Enhance the human operation asset through the use of smarter instruments to do more in less time
Benefits from Diagnostic functions
10
© ABB Group 23 October 2012 | Slide 35
Prevent Cost-intensive Plant OutagesModern Diagnostic Functions Increase
the Availability of Your System:ProcessMaster monitors
its own operability - electronics- flowmeter primary and the process- operating conditions
ProcessMaster displays the present status
© ABB Group 23 October 2012 | Slide 36
Enabling the Impedance Measurement
11
© ABB Group 23 October 2012 | Slide 37
Setting of the limiting values
© ABB Group 23 October 2012 | Slide 40
Read-out Diagnostic Data through HART
HART DTM:
Graphical Information
Recorder Functionality
Scaling (Zoom-in)
Alarm Limits can be seen
Save device configuration (Up and Download)
12
© ABB Group 23 October 2012 | Slide 45
HART DTM
© ABB Group 23 October 2012 | Slide 46
Keep ProcessMaster Up To DateThe Modern Infrared Data Link:
Read instrument settings
Update language packages
Update Firmware
13
© ABB Group 23 October 2012 | Slide 49
Enhanced Diagnostics
© ABB Group 23 October 2012 | Slide 50
ProcessMaster – Diagnostic FunctionsStandard Diagnostic functions:
Electrode coating / short circuit
Empty pipe / partially full
Extended Diagnostic functions:
Gas bubbles in the liquid, noise signal
Enhanced Coating detection
Electrode corrosion galvanic voltages
Conductivity measurement
Damage to liner electrode balance
Partially full TFE electrode and empty pipe detection
14
© ABB Group 23 October 2012 | Slide 51
E1
GND
E2
Z1
Z2 Z2
U2U1
Rm
Coating Detection
ElectrodeE1
ElectrodeE2
© ABB Group 23 October 2012 | Slide 52
Isolating Coating
Conductive Coating
Clean Electrodes
E1
GND
E2Q1, a1 R1
R2Cep
R2
Q2, a2Cep
Q1, a1
Q2, a2
Coating Detection
ElectrodeE1
ElectrodeE2
Z
15
© ABB Group 23 October 2012 | Slide 53
-10 -8 -6 -4 -2 0 2x 104
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0x 104
real [Ohm]
imag
[Ohm
]
10000 S/cm5000 S/cm2000 S/cm1000 S/cm800 S/cm600 S/cm400 S/cm200 S/cmf max
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2x 104
-10000
-9000
-8000
-7000
-6000
-5000
-4000
-3000
-2000
-1000
0
real [Ohm]
imag
[Ohm
]
10000 S/cm5000 S/cm2000 S/cm1000 S/cm800 S/cm600 S/cm400 S/cm200 S/cmf max
Z1
Z2
Constant Phase Element CPE
E1
GND
E2Q1, a1 R1
R2Cep
R2
Q2, a2Cep
Q1, a1
Q2, a2
Electrical device model
Coating Detection
© ABB Group 23 October 2012 | Slide 54
Coating Detection – Conductivity EffectEffect of Conductivity
Impedance measurement Electrode 1 vs Electrode 2 is shown here
0
20
40
60
80
100
120
140
160
180
208166,1137,8111,577,140,321,912,3
Conductivity (measured)[µS/cm]
Impe
danc
e Z1
2 [k
Ohm
]
RE12 [k ]
16
© ABB Group 23 October 2012 | Slide 55
Accuracy of Conductivity MeasurementConductivity Measurement - Comparison
Conductivity measured with Instrument compared to coductivity measured with ProcessMaster
0
50
100
150
200
250
1 2 3 4 5 6 7 8
No of measuring point
Con
duct
ivity
[µS/
cm]
gem [µS/cm]ProcessMaster [µS/cm]
© ABB Group 23 October 2012 | Slide 56
HandlingDisplay
SensorMemory
17
© ABB Group 23 October 2012 | Slide 57
ProcessMaster – Easy to Operate
Ready for operation as received
Preconfigured instruments(install, connect, start-up)
Tag with Meter Identification No. on instrument(easily identify multiple instruments)
Meter Identification No. displayed
Quickest start-up, saves costs
© ABB Group 23 October 2012 | Slide 58
ProcessMaster – Ready for operationLog-in:
Intuitive Operation
4 Log-in Level
Read Only
Standard (Password)
Advanced (Password)
Service (Password)
Additional Hardware Switchfor Write Protection
18
© ABB Group 23 October 2012 | Slide 59
ProcessMaster – Easy to Operate
“Easy Set-up” guides even an inexperienced operator step by step through the menu to set parameters as quickly as possible
The allowable ranges for the parameter selected are displayed and invalid entries rejected. This decreases errors
The Softkey functionality supports the user friendly operation and makes configuration as simple as using a mobile phone
In up to 8 different languages
Security
4 different access levels
protected by access codes
© ABB Group 23 October 2012 | Slide 60
ProcessMaster – Easy Setup
EASY -SETUP guides the user quickly and safe
through the configuration
19
© ABB Group 23 October 2012 | Slide 61
ProcessMaster - Display
Backlit DisplayContrast adjustable Up to 3 lines4 operator pagesCharacter sizeDecimal places
Diagnostic Functions
Up to 8 Languages
Capacitive Keys
Easy Setup
Expanded Software Menu
Rotatable Display
Help Text During an Alarm Condition
© ABB Group 23 October 2012 | Slide 62
ProcessMaster – Menu
20
© ABB Group 23 October 2012 | Slide 63
ProcessMaster - DisplayThe display leaves no wishes unfulfilled :
Backlit, graphical display, adjustable contrast
Rotate without the need for any tools
The size of the characters, the number of lines and the resolution (decimal places) can be selected.
Multiplex mode with up to 4 operator pages with different sets of data can be configured
Data entry over capacitive keys(“Through-the-glass” control, non-contacting, without opening the housing)
© ABB Group 23 October 2012 | Slide 64
ProcessMaster – SensorMemory
Fast Start-up, ease and security in the field
No need to match sensor and transmitter in the field
Converter automatically recognizes the flowmeter primary
After the supply power is turned on, Self-configuration sequence automatically replicates the data from the flowmeter primary and the meter site specific parameters into the converter
Eliminates the opportunity for errors
Leads to increased speed of start-up and is more certain – even for an inexperienced operator
Start-up costs are reduced
21
© ABB Group 23 October 2012 | Slide 65
ProcessMaster – SensorMemoryQuickest start-up – fast and easy:
Starting a complete new system press „Tx“ Calibration Data and Plant Data will be uploaded from the SensorMemory.
Having exchanged the Transmitter press „Tx“ Calibration Data and Plant Data will be uploaded from the SensorMemory.
Having exchanged the Sensor press „Sensor“Calibration Data will be uploaded from the SensorMemory and Plant Data will be downloaded from Tx into the SensorMemory
Press „Tx“
Press „Tx“
Press „Sensor“
Loading System Data
Verification
INSTALLATION CHANGED
Identify Changed Item
Transmitter Sensor
© ABB Group 23 October 2012 | Slide 66
'Fit and Flow' data storage
Intelligent sensors
All data items duplicated in each memory segment
Self repairing in the event of a rare data corruption
Total security / integrity
Back potted for extra security
Speed, Ease and Security in the Field
Sensor Memory Simplifies Installations
22
© ABB Group 23 October 2012 | Slide 67
Press TX / New
Starting a complete new system press “TX Cartridge / New”
Calibration Data and Plant Data uploaded from SensorMemory.
Loading System Data
Verification
INSTALLATION CHANGEDIdentify Changed Item
Tx CartridgeNew Sensor
Press TX / New
Press Sensor
Exchanging the Transmitter press “TX Cartridge / New”
Calibration Data and Plant Data uploaded from SensorMemory.
Exchanging the Sensor press “Sensor” Calibration Data uploaded from the SensorMemory and Plant Data will be downloaded from TX into SensorMemory
Sensor Memory Simplifies Installations
© ABB Group 23 October 2012 | Slide 68
ProcessMaster – Display-OrientationRotate Display
No additional Tools required
Pull rotation lock (1)
Rotate Display 90° Left / Right
1
23
© ABB Group 23 October 2012 | Slide 69
ProcessMaster – OrientationRotate Transmitter Housing
Slacken (but do not remove) the screws (No.1)
Remove screws (No.2) and rotate housing
1
1
2
© ABB Group 23 October 2012 | Slide 70
Display Rotation • No additional Tools required• Pull rotation lock 1• Rotate Display 90° Left/Right
2
1
1
Housing Rotation• Loosen rotation lock 1• Remove screws 2• Rotate Display 90°/180° L/R
Display and Housing Rotation for Any Installation
Powerful and Flexible Transmitter
24
© ABB Group 23 October 2012 | Slide 71
ProcessMaster – SealingUser Lock
Screws (No.1) to be screwed out
1
© ABB Group 23 October 2012 | Slide 72
ProcessMaster – Nameplate
25
© ABB Group 23 October 2012 | Slide 73
ProcessMaster – Nameplate
© ABB Group 23 October 2012 | Slide 74
ProcessMaster – Nameplate
26
© ABB Group 23 October 2012 | Slide 75
ProcessMaster – Nameplate
© ABB Group 23 October 2012 | Slide 76
High Excitation frequency and filter
technic
27
© ABB Group 23 October 2012 | Slide 77
ProcessMaster - SensorSuperior Control Of Your Process:
Faster response time, Less noise
Optimized coil circuits with high excitation frequency
Noise reduction by 1/3
Excitationfrequency
Good !
Noise reduction Good !
6.25 Hz 12.5 Hz 25 Hz
Response time
© ABB Group 23 October 2012 | Slide 78
More Cost-effective OperationsAdvanced Filtering Technology:
Higher metering performanceLess noiseMost stable output signalsBetter product qualityTighter Control avoids rework
Q
t
28
© ABB Group 23 October 2012 | Slide 79
Validation in the Field
Stock keeping
© ABB Group 23 October 2012 | Slide 80
ProcessMaster - ElectronicA Completely Thought Out Design:
Pulling out connection cables no longer required
Simplifies disassembly
Simplifies testing
Eliminates errors
Fully encapsulated electronics
Minimizes risk of damage due to electrostatic charges
Guide rail assure exact positioning
Simplifies installation of the converter modules
29
© ABB Group 23 October 2012 | Slide 81
ProcessMaster - ElectronicEasy Stocking:
Universal electronics „in one piece“
No individual circuit boards
Problems with different hard- and software levels eliminated
This saves time
This reduces searching
This shortens down time
This saves costs
© ABB Group 23 October 2012 | Slide 82
Validate and Optimize the Performance
Verification on site, Easy and Fast
For all electromagnetic flowmeters an identical test tool is available – the Flowmeter Primary Simulator.
Gives a reference that is not effected by conditions at the measuring location
Adaptor board is compatible to existing simulator
Less inventory, less costs
An economical test, which assures the quality of your system, is possible
30
© ABB Group 23 October 2012 | Slide 83
Flow Simulator with
new Adapter for
FlowMaster Electronics
Validate and Optimize the Performance
© ABB Group 23 October 2012 | Slide 84
Field Tests
31
© ABB Group 23 October 2012 | Slide 85
Agenda
Product Positioning
Strategic Goals
Product Description
Specifications (Technology)
Customer Advantages
Field Tests
Summary
© ABB Group 23 October 2012 | Slide 86
Field Tests
First Field Tests Confirm
ProcessMaster provides a most stable 20mA signal
Higher excitation frequency of the sensor is effective and gives superior control
ProcessMaster exceeds the metering performance of the FXE4000
32
© ABB Group 23 October 2012 | Slide 87
Field Tests
Field Test in a Paper Mill
Recycled paper, 3% pulp stock
DN65 [2-1/2”]
© ABB Group 23 October 2012 | Slide 88
Field Tests
Field Test
Glucose solution, 70°C, 3 m3/h
5 - 20µS/cm,
Piston pump with 230 strokes / minute
DN25 [1”]
33
© ABB Group 23 October 2012 | Slide 89
Field Tests
Field Test in a Chemical Factory
Lime water, 95°C, 40 m3/h, very abrasive
Vertical installation, DN 80 [3”]
© ABB Group 23 October 2012 | Slide 90
Field Tests
Lime water
Comparison of 20mA outputs
ProcessMaster to FXE4000
Parameters for FXE4000Excitation current 100mAExcitation frequency 12.5 HzDamping 10 sec.Filter = ON
Parameters for ProcessMasterExcitation current 200mAExcitation frequency 25 HzDamping 10 sec.All Filters ON (mean + notch filter)
--- FXE4000 --- ProcessMaster
GOOD0.4 mA noise
BETTER0.15 mA noise
20 mA Output
34
© ABB Group 23 October 2012 | Slide 91
Agenda
Product Positioning
Strategic Goals
Product Description
Specifications (Technology)
Customer Advantages
Field Tests
Summary
© ABB Group 23 October 2012 | Slide 92
Summary
The most important facts at a glance
35
© ABB Group 23 October 2012 | Slide 93
ProcessMaster - SummaryFlowmeter Sensor:
Better measurement performance due to higher excitation frequency
Larger selection of liner materials expand the applicability spectrum
Improved electrode design increases reliability
High temperature for integral and for remote converter design
SensorMemory Technology stores all data – start saving money from day one
© ABB Group 23 October 2012 | Slide 94
ProcessMaster - SummaryConverter:
Intuitive operation
Capacitive keys, configuration without opening the housing
Practice oriented diagnosticsMonitors the functionality of the instrument as well as the customer processes
High measurement accuracy using modern filter technology achieves an accuracy up to 0.2% of rate
Universal ConverterReduces replacement parts stock and storeroom costs
Most modern memory technology (SensorMemory) in flowmeter primary prevents errors and allows a fast and certain start-up
36
© ABB Group 23 October 2012 | Slide 95
Quickest start-up, safe and easy SensorMemory, intuitive operation and EasySetup guides even an inexperienceduser quickly and easily through the menu, step
by stepRobustConfigure without opening the housing even inharsh environmental conditions
Most Cost-effective Operations High excitation frequency combined withadvanced filtering assures accuracies upto 0.2% of rate
Recognize critical conditions early andinitiate corrective measuresPractice oriented diagnostic functions monitors the operability of the instrumentand the customers process. Diagnostic dependent help texts are displayed,simplifying error corrections
ProcessMaster at a glance
© ABB Group 23 October 2012 | Slide 96
Reduce Lifecycle Costs An identical converter module forATEX, FM, CSA, IEC Reduces replacement part stock and storeroom costs
Extended Reliability, less mainenanceDouble sealed electrode headSelf cleaning, round shaped, electro-polished electrodes
Extended Field of ApplicationsStandard temperature design130°C fluid / up to 45°C ambientHigh temperature design180°C fluid / up to 60°C ambientChoice of liners (ETFE, PFA up to DN200)
Ex-Protection Zone 2 is a standard (available from July)
ProcessMaster at a glance
37
© ABB Group 23 October 2012 | Slide 97
The First Choice for Industrial Applications
. Enhanced ReliabilityRevolutionary self-cleaning and double sealed electrodes enhanced reliability and performance
Superior Control through Advanced Sensor DesignAdvanced filter improves measurement accuracy
by reducing fluid and electrode noise
Detailed Diagnostics for Rapid Decision MakingDiagnostics in accordance with NAMUR NE107
provide the right information to keep the process up and running
Speed, Ease & Security in the Field“Sensor-Memory” data storage
eliminates the need to match sensor and transmitter
Powerful & Flexible Transmitter
All product versions utilize a common electronics to lower
inventory costs and spare parts
Intuitive Navigation & ControlUser friendly interface allows quick and simple data entry for all process parameters
© ABB Group 23 October 2012 | Slide 98