ABB Instrumentation. Automation products, ProcessMaster

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© 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


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


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


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

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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)



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

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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


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

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Specifications ProcessMasterTake Advantage of Latest TechnologyExtended Reliability

Self cleaning, round shaped electrodeDouble sealed electrode headElectro-polished surface (Ra < 0.8)


Hazardous Area

Zone 2 Div 2Zone 1 Div 1

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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”)


ProcessMaster – ATEX

50 m

Remote Transmitter inside Ex-Area

Remote Sensor inside Ex-Area

Integral mount inside Ex-Area

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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


- ProcessMaster –

Diagnostics

New

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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


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

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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


Enabling the Impedance Measurement

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Setting of the limiting values


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)

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HART DTM


Keep ProcessMaster Up To DateThe Modern Infrared Data Link:

Read instrument settings

Update language packages

Update Firmware

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Enhanced Diagnostics


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

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E1

GND

E2

Z1

Z2 Z2

U2U1

Rm

Coating Detection

ElectrodeE1

ElectrodeE2


Isolating Coating

Conductive Coating

Clean Electrodes

E1

GND

E2Q1, a1 R1

R2Cep

R2

Q2, a2Cep

Q1, a1

Q2, a2

Coating Detection

ElectrodeE1

ElectrodeE2

Z

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-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


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 ]

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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]


HandlingDisplay

SensorMemory

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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


ProcessMaster – Ready for operationLog-in:

Intuitive Operation

4 Log-in Level

Read Only

Standard (Password)

Advanced (Password)

Service (Password)

Additional Hardware Switchfor Write Protection

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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


ProcessMaster – Easy Setup

EASY -SETUP guides the user quickly and safe

through the configuration

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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


ProcessMaster – Menu

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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)


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

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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


'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

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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


ProcessMaster – Display-OrientationRotate Display

No additional Tools required

Pull rotation lock (1)

Rotate Display 90° Left / Right

1

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ProcessMaster – OrientationRotate Transmitter Housing

Slacken (but do not remove) the screws (No.1)

Remove screws (No.2) and rotate housing

1

1

2


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

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ProcessMaster – SealingUser Lock

Screws (No.1) to be screwed out

1


ProcessMaster – Nameplate

25





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High Excitation frequency and filter

technic

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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


More Cost-effective OperationsAdvanced Filtering Technology:

Higher metering performanceLess noiseMost stable output signalsBetter product qualityTighter Control avoids rework

Q

t

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Validation in the Field

Stock keeping


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

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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


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

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Flow Simulator with

new Adapter for

FlowMaster Electronics

Validate and Optimize the Performance


Field Tests

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Agenda

Product Positioning

Strategic Goals

Product Description

Specifications (Technology)

Customer Advantages

Field Tests

Summary


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

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Field Tests

Field Test in a Paper Mill

Recycled paper, 3% pulp stock

DN65 [2-1/2”]


Field Tests

Field Test

Glucose solution, 70°C, 3 m3/h

5 - 20µS/cm,

Piston pump with 230 strokes / minute

DN25 [1”]

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Field Tests

Field Test in a Chemical Factory

Lime water, 95°C, 40 m3/h, very abrasive

Vertical installation, DN 80 [3”]


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

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Agenda

Product Positioning

Strategic Goals

Product Description

Specifications (Technology)

Customer Advantages

Field Tests

Summary


Summary

The most important facts at a glance

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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


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

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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



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)


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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 Instrumentation. Automation products, ProcessMaster

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