ABB Instrumentation
Expertise in technology A comprehensive portfolio of innovative instrumentation solutions
World class instrumentation solutions Expertise built on over 100 years of experience Unrivalled in its scope and application expertise, ABB Instrumentation provides solutions for maximizing productivity, energy efficiency, and plant safety. ABB’s worldwide presence, a history of innovation based on proven measuring principles, and over a century of experience, means that ABB is the best choice for your instrumentation needs. ABB is recognized globally for expertise in designing, manufacturing and supplying a wide range of high quality, accurate and reliable measurement, analytical and control solutions that are certified to international standards. These are all supported by a comprehensive worldwide network of manufacturing plants, calibration laboratories and service centers where hundreds of engineers provide the application support and service you need. The result is that ABB is far more than an instrumentation supplier. ABB is a partner to help your business grow and be more competitive.
ABB – your partner of choice for plant instrumentation.
2 ABB | Instrumentation – Overview
For more than 100 years, ABB and its heritage companies have been leaders in innovation and technology. ABB is dedicated to helping customers safely increase productivity and profits while saving energy and resources. ABB’s business is built on a rich heritage that incorporates the pioneers in instrumentation: Aztec, Bailey, Bush Beach Engineering, Fischer & Porter, Hartmann & Braun, Kent, Schoppe & Faeser, Sensycon, Taylor, TBI-Bailey, and Torbar Flowmeters.
Aztec
Bush Beach Engineering Limited
ABB offers a worldwide network of production facilities and service centers in order to supply the right instrument or solution at the right time. To make sure you get all the information needed during an ordering process, the web-based ABB online tool ‘Common Business OnLine’, also called ‘C-BOL’ has been developed. It serves as a personalized direct line enabling transparent order processes. The secure and user-friendly tool gives you direct real-time access to a wide variety of functions. All relevant account information with functionalities such as order tracking can be retrieved on-line with just a click at any time, 24 hours a day.
C-BOL is available at http://online.abb.com/bol.
These brands have been incorporated into ABB, while the technology that these brands were known for is fully supported, and continuously evolves. The spirit of innovation inherited from these leading companies, remains at the core of ABB. Through independent research and collaboration with customers and leading universities around the world, ABB is continuously building on the foundation of existing technologies for new applications and developing the breakthrough technologies and services needed to meet the challenges of the future. ABB Instrumentation provides world-class instrumentation solutions for any industry, utility or municipality.
Instrumentation – Overview | ABB 3
Technology leadership in automation Research and development is a vital source of ABB’s technology leadership. Over the years, ABB has not only pioneered many of today’s automation technologies, but maintains a technology advantage in these areas through sustained investment in research and development. ABB continues to build on the foundation of existing technologies for new applications, and continues to develop the breakthrough technologies needed to meet the challenges of the future. Through independent research and collaborations with customers and leading universities around the world, ABB instruments help lower your costs and energy consumption, increase productivity and flexibility, and improve the safety and reliability of your operations. ABB’s product and process innovations aim to enhance industrial productivity and energy efficiency while helping you improve competitiveness and reduce environmental impact. One of the primary goals of ABB’s technology strategy is to provide you with operational flexibility coupled with assurance that your products and systems will operate reliably for many years. Our fundamental R&D priorities never change – innovative products, systems, and services for increased productivity, reliable energy, and sustained customer partnerships.
4 ABB | Instrumentation – Overview
HMI – The display, its menus, architecture and switches share a common method of operation and look and feel.
Software framework – The software for all new products is based on a common software framework that ensures usability, consistency, and reliability.
Connectivity – Where Fieldbus connectivity is required, all instruments have HART, Profibus and Foundation Fieldbus on the same hardware and software platforms.
Look and feel – All ABB instruments share a common look and feel.
ABB’s high quality instrument solutions help to enhance your business.
Over the years, ABB has built a rich history of instrumentation innovations that have helped to shape industry and enable customers get more from their plant. ABB was first to develop the following innovations: − Mass-produced glass rotameter providing flow measurement at a much lower cost − Direct reading pH meter − Metal tube rotameter enabling measurement of high pressure, temperature and hazardous fluids − An on line dissolved oxygen electrode − An on line gas sensing ammonia probe − Two-wire intrinsically safe pH/ORP transmitter with LCD display − Electrodeless electromagnetic flowmeter for low conductivity or coating fluids − “Wafer Style” electromagnetic flowmeter with no flanges saving money on installation costs − Electromagnetic flowmeter for partially full pipes. − Electromagnetic flowmeter system specifically designed for high speed batching and packaging operations − Fully functional two-wire electromagnetic flowmeter for industrial applications − Mass flowmeter with three sensors for superior auto zeroing capability − In-situ electromagnetic flowmeter calibration verification − Single pressure transmitter with TUV SIL2 certification − Pressure transmitter with boltless gasket-free one piece design − A field-mountable videographic recorder − And many more firsts!!
ABB’s latest innovations deliver technological solutions to make it easier for you to run your plant. All new ABB instrumentation products are based on common technology, providing a common look and feel and method of operation. This results in products that are easy to configure, easy to integrate and easy to maintain.
ABB Instrumentation: easy to configure, + easy to integrate + easy to maintain = lower costs.
Instrumentation – Overview | ABB 5
Enabling energy efficient operation
Due to the sophisticated technology resulting in extremely precise measuring values, ABB instrumentation products enable a sensible and sustainable way to handle natural resources and energy consumption. This helps you to reduce wasted energy and to thereby increase the productivity of the energy value chain in your operation. Improving energy efficiency, through tighter measurement and control, remains the most cost-effective way to lower emissions. ABB Instrumentation products and services are designed to help customers make the most of their resources by improving performance while lowering environmental impacts. By reducing power consumption and losses, improving productivity and managing equipment more effectively, ABB technologies can reduce the waste of energy and more than double the current productivity of the energy value chain. Meeting energy demand while lowering environmental impact.
6 ABB | Instrumentation – Overview
ABB’s vast base of globally installed products and systems is coupled with technical and process expertise. ABB’s broad scope of services lays the foundation for end-to-end support for your enterprise. ABB’s automated monitoring and reporting products are simple and accurate, so critical information is always available – even when skilled technicians are not. ABB Instrumentation Services delivers the knowledge and global experience required to keep your assets operating at maximum reliability and accuracy with a full scope of services from start-up and commissioning through lifecycle support. In addition, the global strength of ABB means service support wherever and whenever help is needed.
ABB instruments deliver extremely precise and reliable measuring values. Furthermore, integrated into a control system environment, the devices play a key role in maximizing asset optimization.
A wide range of industries are served by ABB instrumentation technology, including: − Chemical and petrochemical − Food and beverage − Metals and mining − Oil and gas − Pharmaceuticals − Power / steam generation − Pulp and paper − Water and waste water − Plus many more.....
Table of contents Flow measurement ................................................ page Pressure measurement .......................................... page Temperature measurement ..................................... page Analytical instruments ............................................ page Recorders and controllers ...................................... page Actuators and positioners ...................................... page Device management / fieldbus & wireless ................ page Control systems .................................................... page Instrumentation services ........................................ page
Remote diagnosis and device status data provide maintenance management systems that bring many advantages: plant efficiency, plant security, plant availability, plant reliability, and process optimization. A complete range of measurement technologies designed for the specific needs of the markets served by ABB. Benefit from an entire portfolio of instrumentation products.
8 12 16 20 26 30 34 36 38
Giving you the best of ABB’s expertise.
Instrumentation – Overview | ABB 7
Flow measurement Power, performance, flexibility and control ABB’s knowledge about flow measurement and management is unmatched. Over the decades, ABB has developed an unrivalled understanding of customers’ needs and requirements. ABB’s innovative products continue to set the benchmark for meeting your need for better performance, power, flexibility and control. ABB flowmeters deliver previously unattainable levels of operational and financial benefits. ABB’s flowmeter portfolio contains numerous breakthrough product innovations, which provide further tangible benefits to your plant and bottom line. ABB offers one of the world’s largest ranges of flow measurement products. It is unsurpassed in the number of proven measurement techniques and provides one of the most innovative product ranges on the market. Unrivalled in its models and scope of applications, ABB flowmeters provide high-quality measurements for almost any application. For over a hundred years, the innovative designs have delivered reliable and accurate results in countless applications.
ABB’s flow portfolio includes: − Electromagnetic flowmeters − Vortex and swirl flowmeters − Differential pressure flowmeters − Variable area flowmeters − Coriolis mass flowmeters − Thermal mass flowmeters
ABB flowmeters – intuitive measurement from the masters of flow.
8 ABB | Instrumentation – Overview
Electromagnetic flow measurement in a water industry application
Swirl flowmeter FS4000-ST in an oxygen line in a steel plant
Electromagnetic flowmeters Electromagnetic flowmeters from ABB are in their element whenever the flowrate of conductive liquids, slurries or sludges is to be measured. A comprehensive range of product lines and models cover just about every application. The modular designs offer the industry’s widest range of liners, electrodes, and sizes to meet the needs of the most demanding applications. Whether an integral, remote or pipe mounted installation is required, a common electronics platform provides the best tailor-made solution. Proven to be tough, reliable and incredibly easy to work with, ABB’s electromagnetic flowmeters help to save resources – at every stage of the lifecycle. − Advanced signal processing provides outstanding measurement performance with long-term stability. − Advanced sensor design enables tighter process control. − Insitu verification of calibration and device health without system shutdown.
Vortex and swirl flowmeters The robust design of ABB’s vortex and swirl flowmeters provide high performance and reliability in liquids, gases and steam measurements. Equipped with digital signal processing (DSP) and advanced filtering techniques, these innovative flowmeters from ABB allow improved flow signal detection and provide measurement immunity from the effects of hydraulic noise and pipeline vibration. Ultimately, these flowmeters provide precise measurement without sacrificing low flow capability. − Quick and easy transmitter exchange as all calibration data and parameter values are stored in a FRAM in the transmitter housing. − Very low installation cost due to short straight sections. − Direct mass flow output through compensation due to integrated temperature measurement.
Instrumentation – Overview | ABB 9
Wedge flowmeter in wellhead natural gas application
Differential pressure flowmeters Differential pressure (DP) flowmeters are the most common type of flow measurement products in use today. ABB offers a wide range of flowmeters and primary elements to suit almost all applications. Meters available include compact and integral orifice flowmeters, averaging pitot tubes, venturi tubes, wedge meters, sub-sea meters, orifice plates, orifice carrier assemblies and flow nozzles. All available with full certification of materials, welding and NDE. ABB also supplies complex DP flow solutions, including wet gas metering and engineered venturis for XTL technology. ABB’s compact DP flowmeters are built to optimize and sustain overall performance and reliability by the integration of multiple components into a single easy-to-install flowmeter package. ABB offers the most comprehensive DP flowmeter portfolio in the market, including improved measurement performance that can be easily customized for any application. − Unrivalled range of DP flow elements. − 120 years of DP experience – design, engineering, manufacturing and documentation. − Extensive compact flowmeter family.
Variable area flowmeters Variable area (VA) flowmeters provide a cost effective solution for measuring moderate to very low flow rates in a wide variety of liquids and gases. ABB’s flowmeter portfolio includes a comprehensive line of metal, glass and purge flowmeters suitable for any application. The smallest flow ranges required in laboratory applications and high flow rates in industrial applications can be met with ABB’s variable area instruments. − Simple and reliable flow measurement and sustained repeatability for years of service. − More than 70 years of excellence from ABB based on the Fischer & Porter heritage. − Broad range of flowmeters, from simple indicators requiring no electrical power to meters with alarm sensors and 4 … 20 mA transmission with HART communication.
10 ABB | Instrumentation – Overview
Variable area flowmeter FAM541 in a metal foundry application
CoriolisMaster MC2 Hygienic in process industry
Sensyflow FMT500-IG in an industry application
Coriolis mass flowmeters CoriolisMaster is the universal solution to measure flow, density and temperature, even for non-conductive fluids. The unique S-shape tube design and modular design make CoriolisMaster the ideal instrument for your high performance measurement requirements. CoriolisMaster is easy to install in any orientation and insensitive to vibrations or gas inclusions. Flexible connection sizes enable optimal adaptation to all processes. ABB’s CoriolisMaster represents the most advanced flow measuring principle offering unrivalled accuracy in direct mass flow measurement. − Four accuracy classes in one device reduce product variability and warehousing costs. − Electronic module exchange without recalibration or reconfiguration. − Excellent density measurement with integrated concentration computation.
Thermal mass flowmeters ABB’s Sensyflow series of thermal mass flowmeters is suitable for all industrial and test rig applications that demand quick and precise gas measurement. Sensyflow flowmeters directly indicate the mass flow or normalized volume flow of gases without any additional pressure and temperature compensation. The flowmeters have an impressively high accuracy, short response time and a very wide flow range with virtually no loss of accuracy even at the lowest flow rates. − Modular design optimizes accuracy and reduces installation, commissioning, and maintenance costs. − Up to four characteristic gas flow curves with only one single meter. − Best in class response time and accuracy.
Instrumentation – Overview | ABB 11
Pressure measurement Reliability, performance and safety With its 2600T pressure transmitter portfolio, ABB offers outstanding reliability, performance, safety and versatility in the measurement of flow, liquid level, differential, and absolute or gauge pressure to accommodate plants’ most challenging applications. Every transmitter has been designed to dramatically reduce the associated cost of ownership and increase plant productivity. The ‘through the glass’ (TTG) display, a world first for pressure transmitters, represents a new approach in commissioning cost saving even in hazardous areas. When a measurement requires a diaphragm seal, ABB all-welded technology delivers the longest reliable performance you can get on the market. Uniquely easy to operate with – the innovative plug & play graphic display, and the user friendly HMI allows simple and intuitive transmitter operation. The ‘Easy Set-up’ procedure allows the user to easily commission the instrument without the need for a hand-held terminal. ABB‘s unique Gemini-Config feature stores configuraton data in the device, so that if the electronics need to be replaced the exiting configuration data can be uploaded quickly, reducing downtime.
The communication you need The 2600T series allows you to preserve your investment allowing an upgrade from HART to any other available communication protocol in minutes with no need to remove the device from its installation or to reconfigure it. The modular construction of the 2600T series enables field repairs to be carried out so that the instrument is back in operation within five minutes of failure detection. The perfect solution for your application The 2600T family offers products specifically designed to meet the widest range of applications ranging from harsh conditions in offshore oil and gas to the laboratory environment of the pharmaceutical industry.
ABB pressure transmitters – modular design assures the most suitable transmitter for any application.
12 ABB | Instrumentation – Overview
Pressure transmitter 364 in a chemical industry application
Pressure transmitter 261: Cost effective The 261 series provides a high quality, cost effective transmitter that can be used in a wide range of pressure applications. With a robust housing made completely from 316 stainless steel, the 261 series is designed to withstand even the harshest environment. With a base accuracy of 0.1%, the 261 series provides outstanding performance for gauge and absolute measurement in all applications, including: draft range and high pressure. A wide range of process connections allows you flexibility in meeting your application requirements. The userfriendly display allows simple and intuitive transmitter operation and interfaced with any asset management software solution enabling configuration and diagnostic support. − Full 316 stainless steel body construction for harsh environments. − Wide choice of process connections enables high flexibility for demanding processes. − Diversity of approvals and certificates meets national requirements.
Pressure transmitter 364: Tough and reliable The 364 series represents the best solution for hazardous areas and highly demanding flow, level and pressure measurements where the environmental conditions are very aggressive or corrosive. The combination of compact size, low weight and standard 316 stainless steel housing are especially suited for offshore and marine applications. The intrinsic leak-proof robust design of its all welded bolt-less process chamber allows the user maximum safety and minimum maintenance. Commissioning the 364 is quick and easy. Multilanguage LCD menus, integrated totalizer, in field replaceable electronics and the all welded diaphragm seals make the product a perfect long-lasting pressure measurement investment. − Long term stability of 0.15% for approximately 10 years. − Bi-directional flow and totalization capability. − Integrated surge protection.
Instrumentation – Overview | ABB 13
Pressure measurement with pressure transmitter 266 in a refinery process
Pressure transmitter 266: Performance with intelligence The 266 represents the latest evolutionary step in the wide ABB pressure products portfolio. Users can easily find the right application solution and accuracy available up to 0.025% to boost plant productivity. ABB is the first company to offer TTG Technology (through the glass) for two-wire transmitters. This enables users to interact directly with the instrument, without removing the cover, which offers additional safety and time savings, especially in hazardous areas. Using the four button HMI (human machine interface) driven navigation, all the essential parameters can be set with just one touch. Expensive hand-held configurators are no longer necessary. External non-intrusive zero and span push buttons allow safe and quick reranging. External write protection provides additional protection for the process. − Plug-in communication board and terminal block for easy and quick commissioning. − Advanced plugged impulse line diagnostic function (PILD) prevents unforeseen control-loop shutdown. − IEC 61508 TÜV certified version to satisfy the needs of critical applications.
Pressure transmitter 268: Safety first Model 268 is the IEC 61508 TÜV certified safety 2600T transmitter for SIS and critical applications where safety and performances are the main requirement. With internal software and hardware redundancy, the 268 models allow installation in conformance with SIL2 (1oo1) and also to SIL3 in a 1oo2 architecture. The 268 safety transmitter exceeds the IEC 61508 requirements for SIL2 with a hardware fault tolerance of 1 (HFT = 1) and a safe failure fraction of 98.6%; the diagnostic coverage is 97.7%. HFT = 1 ensures that even in the case of 1 hardware failure, the transmitter can enact the safety function. In addition the following requirements have been assessed as part of the certification process: − Functional safety (hardware/software) testing. − Electrical safety testing. − EMC testing.
14 ABB | Instrumentation – Overview
Pressure transmitter 266 in a power plant application
Multivariable pressure transmitter 267 / 269 The unique combination of several advanced sensor systems in a single device permits the simultaneous measurement of differential and absolute pressure, and temperature measurement to provide a mass flow output. As a result, the transmitter is capable of measuring flow gases, vapours and liquids using the differential pressure method. With dynamic flow calculations, that consider the type of primary element and the operating density of the fluid as a function of pressure and temperature, the real mass flow is directly available as an output in accordance with AGA 3 or DIN EN ISO 5167. − Single transmitter can be used for up to three measured values. − Exchangeable electronics with self-reconfiguration. − World‘s most accurate multivariable transmitter: 0.04%.
Diaphragm seals Diaphragm seals are used to isolate the pressure transmitter from process conditions that will either shorten the transmitter life or dramatically affect its performance, such as heat, vibration and noise. Equipped with the widest range of material and process connections in the industry, ABB’s proven ’all-welded’ technology is the best choice for remote seals. The innovative wetted materials open new frontiers to enhance existing measurement life without compromising performance. In addition, ABB provides remote seals with a unique diaflex coating that is designed to meet the most abrasive installations. − All welded constructions, combines an economically feasible and technically sound solution ensuring total reliability at line pressure down to full vacuum. − Fill fluids dedicated for high temperature applications. − Specific diaphragm materials to withstand these high corrosion environments. − Diaphragms with anti-stick coating for those highly viscous sticky applications. − Industry-leading abrasion resistance for your toughest application. Instrumentation – Overview | ABB 15
Temperature measurement Flexibility in sensors and transmitters Temperature is a key measuring variable for many different processes and it is the most frequently measured parameter in the process and utility industries. As an ABB customer you will benefit from ABB’s extensive knowledge in the field of temperature measurement, proven for years in many applications for a wide range of industries. You may choose from one of the most comprehensive temperature measurement portfolios available on the market. ABB offers the device or system that perfectly suits your individual, application-specific needs. Select among advanced solutions for standard, industry-specific and project-specific applications which are designed, engineered and manufactured based on ABB’s expertise in temperature measurement technology.
Your portfolio of choice includes: − Universal temperature sensors: TSP series − High-temperature sensors: TSH series − Temperature sensors for sanitary applications − Mineral isolated temperature sensors − Thermowells − Temperature transmitters: TTH series, TTR series, TTF series
ABB temperature measurement – efficient temperature measurement covering your entire control loop.
16 ABB | Instrumentation – Overview
Temperature measurement of a process gas with sensor TSP131
High-temperature calibration of a thermowell during production
Universal temperature sensors: TSP series ABB’s universal temperature sensors are available in two versions, standard and heavy-duty. The standard version is used in vessels and pipes with aggressive or explosive liquids or gases. The heavy-duty version is used in harsh environments. ABB temperature sensors are available with individually selectable insertion length and with thermowells in a welded, drilled or turned design. A wide choice of process connections and housings is available to meet your process requirements. − Obtain the most precise measuring results. − Benefit from the highest sensor stability in demanding applications. − Reach optimal plant productivity and efficiency by selecting the most appropriate and correctly dimensioned temperature sensor for your process.
High temperature sensors: TSH200 series ABB’s high temperature sensors are available for use in virtually all high temperature applications up to 1800 °C (3272 °F). The product series offers several process connections and a variety of thermowell materials. The high temperature sensor series TSH200 has proven to have outstanding functionality in applications such as industrial furnaces, garbage and hazardous waste incineration, air-circulation furnaces, glass manufacturing, smelting operations and hot gas conduits. − Successfully manage your high temperature processes with a sensor you can rely on. − Benefit from an extremely long product lifetime. − Reach optimal plant productivity and efficiency by selecting the most appropriate and correctly dimensioned sensor for your specific high temperature application.
Instrumentation – Overview | ABB 17
Sanitary temperature sensors Sanitary temperature sensors for hygienic applications from ABB are specifically designed for process requirements of the food and beverage, pharmaceutical and bio-chemical industries. ABB temperature sensors are suitable for inline or surface measuring and provide CIP / SIP capabilities. The product series is produced and certified according to 3A sanitary, EHEDG and FDA as well as directive 85.357.EEC and the milk executive order (MVO). − Rely on sensors specifically made for the food and beverage industries which offer extremely short response times. − Reach optimal plant productivity and efficiency by selecting the appropriate and correctly dimensioned temperature sensor.
Thermowells Designed to protect and allow direct replacement of temperature sensors, thermowells are produced in two basic design styles. ’The pocket’ made from high quality metal tubing, sealed at the end and supplied with a plant fitting of either a screw thread or flange. The ’solid type’, made from a solid piece of high quality metal bar. Drilled to within 9 or 6 mm of the end of the bar and again fitted with a plant connection of either a screw thread or flange. The thermowell is an important part of a process plant. Its integrity is vital to the safety of the operation and should be chosen with the same care as any other fitting. − Choose safe, tough and reliable thermowells. − Wide range of standard and custom designs. − Benefit from the right product for the right application, manufactured to ABB’s demanding quality standards. − Select from standard or specifically tailor-made solutions to meet the needs of your process.
18 ABB | Instrumentation – Overview
TTH300 temperature transmitter, 2 inputs with 3 wires each, grounded
Mineral isolated temperature sensors Mineral isolated temperature sensors made by ABB contain mineral insulated cables assembled with plastic cable and plug or housing in various lengths. The sensors are extremely flexible in shape, vibration-proof. Temperature ranges from -200 to 1000 °C (-328 to 1832 °F). − Benefit from tailor-made custom-designed solutions, which meet your specific requirements.
Temperature transmitters ABB’s temperature transmitters are available in three different designs for a wide range of applications. ABB offers a comprehensive explosion protection design as well as SIL2 / SIL3 for safety-related plants. Head-mounted temperature transmitters of ABB’s TTH series incorporate enhanced diagnostic information, such as automatic redundancy switching and sensor drift monitoring for two Pt100 three-wire connections. They are robust, easy to install and available with an alphanumerical digital display including the option of on-site configuration. Field-mounted temperature transmitters of ABB’s TTF series offer a large, easy-to-use terminal block with a convenient cable guide to ensure a secure connection. The sturdy and compact transmitter housing is rated to IP 66/67 (NEMA 4X) protection. The TTF incorporates enhanced diagnostic information and offers an alphanumerical digital display with the option of on-site configuration. Rail-mounted temperature transmitters of ABB’s TTR series are in-line mounted DIN rail transmitters providing a 4 … 20 mA output signal. They can be mounted in confined spaces. Device status is displayed by LEDs. − The TTH series enables you to use one transmitter size to cover HART, PROFIBUS PA and FOUNDATION Fieldbus communication protocols. − Benefit from high stability in demanding applications. − Reach optimal plant productivity and efficiency with advanced diagnostic functions such as automatic redundancy switching and sensor drift monitoring. Instrumentation – Overview | ABB 19
Analytical instruments For when quality and accuracy matter An innovative leader in analytical instruments, ABB offers one of the broadest ranges of products on the market today. ABB’s extensive application experience and unsurpassed range of measurement parameters – 24 and growing – allow ABB to satisfy your needs for a single source supplier of analytical instrumentation. Because accuracy matters ABB Instrumentation is able to provide measurements and expertise for a wide variety of applications. Modern process plant and utilities need accurate, reliable, cost effective analytical measurements in order to monitor product quality, meet process requirements, control chemical usage and conform to local and global environmental regulations.
ABB has developed and manufactured analyzers for a wide range of industries. Today, ABB is a global industry leader providing a wide selection of measurement, monitoring and analytical solutions to meet the exact quality and process requirements of all sectors.
ABB analytical – one of the largest analytical instruments and sensor portfolios available.
20 ABB | Instrumentation – Overview
Integrated analyzer solutions for power and water applications
Conductivity / resistivity – for water, waste water, power and process The widest range of conductivity sensor technology available. ABB’s sensor family includes two, four and toroidal electrodes in a variety of materials including stainless steel, epoxy resin and PEEK. Whether for high purity water or aggressive chemical applications, ABB has the sensor to meet your requirements. − Precision two electrode cells eliminate calibration factors. − Four electrode dirty sensor diagnostics to detect and compensate for coating by process media. − Insertion, flow-through, dip and retractable sensor styles. − Choice of cable connections – fixed, detachable, terminal head.
pH/Redox (ORP) – for water, waste water, power and process ABB has an unrivalled range of instruments and pH sensor styles for installation in any application. Patented sensor technologies for even the most challenging conditions – including high temperatures and pressures, ultra pure water and contaminated liquids. − In-line, real time sensor diagnostics for preventative maintenance. − Integral PID control, process alarms, and sensor cleaning software. − Non-incendive or intrinsically safe instruments − Self-cleaning glass electrodes and patented processresistant solid state electrodes. − In-line, dip, submersible and retractable sensors. − Longest-lasting pH sensor in the industry.
Instrumentation – Overview | ABB 21
Instruments for steam, ultrapure water, water and waste applications
Aluminium, iron, manganese, phosphate & ammonia – for water treatment The Aztec 600 range provides compact, yet reliable on-line colorimetric analyzers for the key parameters in water treatment. Each unit is designed for ease of use and maintenance simplicity. − − − − − −
Lowest cost of ownership due to less maintenance. Graphical trending analysis and diagnostic displays. Self cleaning measurement cell. Automatic two-point calibration. Analysis of up to three sample streams. Flexible communications including embedded web server.
Dissolved organics and nitrate – for water applications Designed specifically for the potable water market, providing information in a simple cost effective way to assist with optimizing the water treatment process, and ensuring compliance with operating limits, these systems use the latest UV light absorption techniques. − Automatic cleaning. − Reagentless operation. − Long-life and ultra-stable light source.
Residual chlorine, chlorine dioxide & ozone – for water applications A simple and reliable system for measuring residual chlorine (free and total), chlorine dioxide or ozone in water. Optional pH and ORP measurements are also available. − Continuous on-line operation. − Self cleaning sensor assembly prolongs sensor life and maintains accuracy. − Optional PID control. − Up to three sensor inputs.
22 ABB | Instrumentation – Overview
Hotwell condenser cubicle in power plant
Turbidity – for water treatment ABB’s rugged turbidity systems operate in the most demanding installations. Whether measuring industrial effluent or processes of near perfect clarity, ABB’s line of turbidity systems gets the job done. Simple maintenance and operator safety is ensured using a dry standard calibration method. − Ranges from 0 to 1 NTU and up to 250 NTU and 2,000 FTU. − Accurate and reliable results below 0.1 NTU. − Dry standards eliminate use of toxic formazine. − Auto-cleaning performance for reduced maintenance.
Chloride, fluoride, nitrate, ammonia – for water, waste water and power ABB provides a range of ion selective monitoring analyzers delivering reliable continuous measurement with automatic calibration and sample temperature control. − Automatic two-point calibration ensures continued accurate operation without the need for manual intervention. − Ease of operation and maintenance. − On-line diagnostics provide automatic confirmation of the integrity of performance.
Dissolved Oxygen – for water, waste water (high level DO) and power (low level DO) High-level (ppm) measurements for sewage treatment, rivers and process water – features immersion, floating ball or flow-through sensor. − − − −
Auto jet wash significantly reduces maintenance. Integrated PID controller for aeration control. Dual-input analyzer minimizes capital outlay. Low maintenance, long-life sensor.
Instrumentation – Overview | ABB 23
Hydrogen purity monitoring is important for efficient power plant operation
Silica and phosphate – for ultra pure water and steam applications in power plants Utilizing colorimetric measurement techniques and a carefully designed liquid handling section to reduce reagent usage while providing accurate and reliable measurements with minimal maintenance, the Navigator 600 range is ideal for steam raising- and generating plants. − − − −
Continuous measurement. Capable of analyzing up to 6 streams. Will operate up to six months on one set of reagents. Extensive diagnostics.
Hydrogen purity monitoring – for power applications Gas analyzers to monitor hydrogen purity in hydrogen cooled power generators. ABB can provide a complete system for monitoring hydrogen purity during normal operation and purge gas monitoring during commissioning and decommissioning of the generator. − Certified intrinsically safe. − Fail safe design. − Full redundant measurement of hydrogen purity.
Sodium – for ultra pure water and steam applications in power plants ABB provides monitoring systems for the effective and reliable measurement and control of sodium. Users can achieve maximum efficiency, and minimize downtime from excessive boiler corrosion or scaling in the water/steam cycle or the water treatment plant of modern power stations. − − − −
Automatic sample temperature compensation. ’Pumpless’ liquid handling section. Comprehensive diagnostics facility. Simple to use and monitor results.
24 ABB | Instrumentation – Overview
Integrated water monitoring system
Hydrazine – for oxygen scavenger monitoring in power applications This analyzer enables measurement of hydrazine in boiler feed water. With full calibration available, the instrument enables monitoring of expensive hydrazine dosing so there is minimal waste of this costly product. − − − −
Auto range switching. Low volume reagent usage. Compensation for pH and temperature. Refurbishable sensor.
Combustion gas analysis – for process and industrial applications The Endura range of analyzers provides accurate and reliable monitoring of oxygen or oxygen plus combustibles, supporting efficient combustion and compliance with environmental regulations. The range includes close-coupled extractive and true in-situ options, providing a system designed to suit virtually any combustion optimization control system. − − − −
Proven, accurate and stable sensors. Advanced system diagnostics. Fully integrated automatic calibration. Wide range of certification and approvals.
Integrated monitoring solutions – for power, water and waste water ABB offers custom designed, engineered and pre-assembled water/steam monitoring solutions plus professional commissioning and installation services. Each system can be tailored to meet individual specifications, reducing the time for installation, testing and commissioning while increasing ease of operation and efficiency. − Self-contained monitoring cabins. − Rack-mounted sample preparation equipment to meet application requirements. − Rapid installation with minimal on-site costs. − Minimal maintenance and reliable operation. Instrumentation – Overview | ABB 25
Recorders and controllers Control and information at your finger tips ABB manufactures and markets a wide range of industrial recorders and controllers. From the latest high visibility, secure videographic recorders to single and dual loop controllers and indicators, the ABB range can be used across a wide spectrum of applications, even in the harshest of environments.
A clearer view of your process ABB has developed a comprehensive family of process control instrumentation including process controllers, digital indicators, videographic and paper chart recorders, all of which share the same high standards of reliability and flexibility along with the capability of withstanding the harshest of process environments. Many products in the range can be conďŹ gured in operation using software on your PC.
All ABB recorders and controllers have a high degree of dust and water protection, with most to NEMA 4X and IP66 as standard. Clear, bright displays mean that process status can be seen at a glance. Universal inputs, transmitter power supplies and extensive process outputs are available within the standard instrument. Totalizers, math functions, batch and logic equations are available on many models for advanced application functionality.
ABB recording and control – a clearer view of your process.
26 ABB | Instrumentation – Overview
ScreenMaster videographic recorder in a power generation application
ScreenMaster SM500F videographic recorders can be field, panel or wall mounted
Process controllers and indicators – ControlMaster The ControlMaster range of universal process controllers and indicators offer a comprehensive portfolio of powerful features, making them suited for use in a wide spectrum of industries. A concise line of models with flexible I/O capability makes model selection extremely simple. Each ControlMaster can be scaled to suit basic through to advanced application requirements by the addition of plug-and-play function keys. ControlMaster’s color TFT display clearly shows process information and provides unsurpassed ease of use with menus and operator prompts displayed in full text. − Fully scalable to meet basic through to advanced application requirements. − Flexible display formats including dual loop displays and historical trending. − Powerful control capability featuring dead time compensation, adaptive control and dual loop capability. − Flexible functionality including math, logic, totalization and delay timers provide problem solving capability. − Full IP66 and NEMA 4X environmental protection.
ScreenMaster videographic recorders ScreenMaster videographic recorders provide advanced solutions for electronic data recording and analysis. Features include a maintenance free solid state design, clear color LCD operator displays and an intuitive Windows style user interface. Ethernet communications allow plant wide access to process information and historical data while data security features meet even the most stringent requirements. − − − − − − − − − − −
Single to multipoint process measurements. Totalization of recorded values. Advanced computation and logic functions. Process alarming with relay outputs. Ethernet transfer of data files. Web server access to real time data. Emailing of process values and alarm status. Offline data analysis using PC software. Suitable for harsh environments to IP66 / NEMA 4X. Removable Compact Flash or SD memory card. Panel and field mounted models with display sizes from 12.5 cm (5 inch) to 31 cm (12.1 inch). − Multiple display formats. Instrumentation – Overview | ABB 27
Flexible in their application, recorders and controllers can be used across a wide range of process plants
DataManager Pro DataManager Pro advanced data analysis software provides access to data archived by ScreenMaster video-graphic recorders. Automatic collection of data via Ethernet and database management ensures secure long-term storage of valuable process data. − − − −
Security validation of data files. Automatic management of process data. Automatic collection of process data via Ethernet. Advanced analysis functions.
Paper chart recorders A comprehensive range of strip and circular chart recorders, suitable for a wide range of applications – based on many years of practical experience. − − − −
1 to 24 trace strip chart recorders. 1 to 4 trace circular chart recorders. Integrated process control. Data logging to compact flash memory cards.
Field mountable indicators and controllers A range of highly versatile panel and field mountable indicators suitable for displaying a wide range of process variables including temperature, pressure, flow and level. − Wall or pipe mounted. − Indication and totalization. − Full IP66 and NEMA 4X environmental protection.
28 ABB | Instrumentation – Overview
Recorders and controllers are ideal for use in the food and beverage industries
Instrumentation – Overview | ABB 29
Actuators and positioners First class valve automation control Valve automation products are important devices for a variety of applications in process automation. As a customer, you greatly benefit from ABB‘s extensive knowledge in the field of valve automation products, proven over many years in numerous applications for a wide range of industries. You may choose from a complete portfolio of cutting-edge valve automation products to exactly meet your application specific needs. Select among advanced solutions of actuators and positioners for the widest range of final control elements, designed, engineered and manufactured based on ABB’s technology expertise.
Your portfolio of choice includes: − Continuous electrical actuators and pneumatic actuators − Electro-pneumatic, pneumatic, and digital positioners − I/P signal converters
ABB actuators and positioners – your product of choice for efficient valve automation and monitoring in any application.
30 ABB | Instrumentation – Overview
Contrac linear actuator after three years in an on-shore installation on a boiler‘s superheater spray water valve
Pneumatic part-turn actuator UP4 used for combustion air control on power plant boiler
Continuous electrical actuators and pneumatic actuators Contrac electrical actuators offer continuous heavy duty cycle control with virtually wear-free operation, maintenance cycle of up to 10 years and provide high accuracy and stability regardless of positioning time. The continuously operating actuators are with stall-proof motors and do not require torque switches or position-dependent protection devices, nor starting current protection devices. The portfolio includes linear actuators used for operations of final control elements, as well as part-turn actuators for operations of final control elements with rotary movement. The modular concept includes integrated and remote power electronic units. UP part-turn and LP linear pneumatic actuators by ABB are rugged in design and suitable for applications that require fast and accurate positioning of the final control element and are available with fail-safe or fail-freeze operation upon loss of the demand signal and energy source. − Benefit of hysteresis-free process control resulting from the unique continuous modulating actuation principle. − Rely on proven performance and wear-free operation even in the harshest environments due to the actuator’s robust and compact design. I/P signal converters I/P signal converters are a central element of pneumatic positioners and also used for direct control of pneumatic actuators. ABB has installed more than one million I/P converters throughout the world. The product is available in a variety of signal designs with different signal ranges and OEM solutions. A patented force balancing system for current to pneumatic signal conversion provides best-inclass performance. − Rugged design provides reliable performance and long product lifecycle with vibration and shock resistance up to 10 g. − Best in class performance due to linearity and reproducibility of the output signal in proportion to the input signal. − Easy installation due to compact design and suitability for any mounting orientation.
Instrumentation – Overview | ABB 31
Installation of digital positioner TZIDC in a food and beverage table salt application
Positioners The TZIDC series of digital positioners provides flexible and cost effective valve management and control. The product is the link between the control system and the valve. The TZIDC digital positioner incorporates automatic self-commissioning and a valve tuning program. ABB positioners are EMC-compliant and protected to IP65 (NEMA 4X) with certified explosion protection for intrinsically safe and flameproof site design. AV series of positioners provide fast, sensitive and accurate positioning of single or double acting final control elements with linear or rotary motion. The AV is available in pneumatic or electro-pneumatic versions and incorporates a pilot valve mechanism for high pressure and large volume applications. − User friendly product selection with many variants available. − Standardized installation routines with a large variety of mounting brackets available. − Highly efficient performance due to the auto-adjust functionality providing best position control. − Rely on smooth operation for years due to superior shock and vibration resistant ABB positioners.
32 ABB | Instrumentation – Overview
Instrumentation – Overview | ABB 33
Device management, fieldbus & wireless Easy integration for maximum productivity ABB’s instrumentation devices feature the latest in onboard diagnostics and intelligence to help you run your business more effectively. Just as important, ABB gives you the choice to decide which communication protocols you want to use to access this information. You may choose from a family of tools and from different ways to manage the lifecycle of the devices in order to get the most out of your investment. The dedication to providing customers with a choice, results in products with features that give you open system integration. ABB‘s transmitters feature plug-in fieldbus modules so you can stock one model of transmitter and decide onsite whether it is HART, FOUNDATION Fieldbus or PROFIBUS compatible. ABB uses FDT / DTM technology enabling independent engineering and maintenance of field devices, regardless of manufacturer or protocol, thus removing the need for multiple tools.
All new ABB instrumentation products feature the same easy to use local keypad and display interface to make configuration and commissioning as simple as possible. ABB‘s device management includes: − Fieldbus and wireless solutions − Mobility handhelds − Asset vision software − Scalable service management
ABB device management – measurement and control for all areas of your plant.
34 ABB | Instrumentation – Overview
Fieldbus and wireless solutions ABB’s intelligent instruments will be complementary to hard wired versions (4 … 20 mA and fieldbus) offering a low cost and low risk installation route for process monitoring with plug-in adapters for existing installed instruments. Mobility handhelds When configuration and calibration management and documentation of multiple instruments is needed, ABB’s mobility handhelds provide added features and the ability to download and manage data on a PC. Asset Vision software For optimal management, Asset Vision provides diagnostic alert handling, condition-based asset monitoring, calibration management, and integral work order processing with Maximo and SAP. Automatic alerts can be issued based on asset monitor conditions with PC emails or mobile phone / pager text messaging to remote personnel. The software screwdriver for your application! Asset Vision is a modern FDT Frame Application based on the latest 1.2.1 standard that provides an open interface for ABB and 3rd party DTMs to effectively configure, diagnose, and maintain intelligent HART, PROFIBUS and FOUNDATION Fieldbus field devices. Scalable service management The correct operation and availability of instrumentation in your plant can have a major impact on productivity and efficiency. When instrumentation issues are affecting your plant operations, devices that can deliver predictive diagnostics to your team for fast, accurate decisions are a competitive advantage. ABB offers a family of device management tools that improve daily work processes so this information is used most efficiently, allowing you to focus your limited resources on the right assets. ABB’s device management solutions are designed to grow with your business. All are designed to give you greater control over configuration, calibration and maintenance of your instrumentation so you maximize the return on your investment.
Instrumentation – Overview | ABB 35
Control systems Scalable systems for the entire enterprise A reliable, cost effective and easy to use process automation system is perhaps the single most important success factor for a manufacturing enterprise. As the world‘s largest supplier of process control systems, ABB’s automation systems give you the best platform to optimize your plant and safely operate your industrial processes. ABB’s extended automation systems can be used not just for process control, but also for safety, process optimization, data acquisition and information management. In addition, ABB systems can easily be integrated with business and production planning systems to truly integrate the enterprise, from the ‘boardroom’ to the ‘production floor’. ABB’s commitment to open standards facilitates the integration of activities and the interface with existing automation components and information systems, creating an additional layer of investment protection. Products and systems are designed to work standalone or as part of a completely integrated scalable solution, enabling enterprises to implement new functionalities as operations needs evolve. ABB’s control and automation systems include the latest state-of-the-art automation functions to meet all the needs within process controls. Developed from ABB’s long experience in the field, ABB’s solutions are built with industryspecific knowledge to provide high quality applications from small hybrid systems to totally integrated automation solutions for demanding processes.
A reliable and straightforward operator workplace facilitates the smooth, safe running of the plant and minimizes the risk of costly mistakes. ABB’s development of an integrated, object-oriented workplace enables real-time access to information across the whole enterprise. It offers a clear process overview and a user-friendly environment with seamlessly linked easy-to-use tools. Specific information, needed by the operator to take corrective action, is retrieved quickly thanks to fast and intuitive navigation. ABB’s automation solutions integrate the intelligence embedded in today’s field devices into the control system, thus making it available for plant and business processes. The result streamlines work to achieve lower deployment costs, better process and product quality, and improved availability. These industrial automation solutions provide you with the technology needed to achieve a sustainable competitive advantage in today’s challenging business environment. They lay the foundations for continuous improvement in life cycle and operations dimension of information flow, resulting in time savings, better engineering, and a real increase in productivity.
ABB control systems – extended automation solutions put you in total control.
36 ABB | Instrumentation – Overview
Instrumentation – Overview | ABB 37
Instrumentation services Life cycle services for instrumentation A broad range of services combined with a wealth of product service knowledge enables ABB to ensure that an instruments‘ optimum performance is maintained throughout its serviceable life. ABB has a global network of instrumentation specialists delivering local service and support. Dedicated to optimizing your plant productivity and performance, ABB services enable improved utilization and performance of site automation equipment, processes and people. ABB’s instrumentation service specialists are strategically located to support all products and systems globally. They provide field instrumentation and control system application expertise to implement, maintain, and optimize your process. Health and safety is of paramount importance to ABB and all ABB service personnel work strictly in accordance with national and international health and safety requirements. ABB knows that the key to providing world-class service is not only to respond quickly, but also to provide better solutions than can be found elsewhere.
ABB service – unparalleled expertise.
38 ABB | Instrumentation – Overview
ABB’s service portfolio includes: − Consulting − Installation & Commissioning − Maintenance and Field Services − Migration and Upgrades − Repairs and Calibration − Spare Parts and Consumables − Support and Remote Service − Training − Maintenance Support Agreements
Consulting ABB specialists have the expertise required to evaluate plant conditions, identify and advise clients on improvement opportunities and implement a cost effective performance enhancement program. Installation and Commissioning High maintenance costs and plant inefficiencies can be avoided using ABB’s engineering expertise to ensure correct installation and commissioning of your instrumentation and control equipment. Maintenance and Field Service Predictive, preventative and corrective maintenance services help maximize the performance of instrumentation and control equipment. ABB engineers use advanced diagnostic tools to provide in-situ maintenance and repair services. ABB uses benchmark maintenance practices to help maximize the long term reliability and accuracy of all measurement devices. ABB’s maintenance and field services reduce costly downtime and maximize the performance of your automation assets. Migration and upgrades ABB has developed cost effective upgrade programs which enable low risk, phased migration to the latest technology. After a thorough site evaluation, ABB will develop a customized implementation plan for the migration of installed equipment. Repair and calibration Through ABB’s global network of repair and calibration workshops, it provides an extensive range of return-to-base repair services. These services are carried out under controlled conditions in one of ABB’s factory based repair centers or can be carried out on site by factory trained service specialists. Additionally, ABB provides proactive test and calibration activities in accordance with instrument specification on an as required basis.
Spares & Consumable Parts Having critical spare parts and consumables when and where you need them is fundamental to achieve your business goals. ABB’s instrumentation service team can facilitate the supply of spare parts and consumables (such as pens, charts, pH electrodes, reagents, etc.) as discrete spares or packaged options. ABB also provides customized supply solutions such as remote stock holding. Support and remote services ABB provides telephone, on-line and remote (where possible) product and application support via technical specialists enabling urgent assistance and minimizing instrumentation downtime. Training The skills of operations and maintenance personnel play a key role in equipment performance as well as maximizing return on investment. ABB provides a portfolio of standard courseware and customized training to help personnel keep skills up-to-date at your site or in a factory-based classroom. Maintenance support agreements Customers can combine any of ABB’s life cycle services from above to create a customized solution to meet their needs and budget. Local service managers have the knowledge to advise customers about which are the most appropriate service options.
For additional information about instrumentation service, to order spares or schedule a service visit, please contact your local ABB service contact by visiting www.abb.com/service or www.abb.com/instrumentation
Instrumentation – Overview | ABB 39
ABB Automation Products GmbH Borsigstr. 2 63755 Alzenau, Germany Phone: +49 551 905 534 Fax: +49 551 905 555 E-Mail: vertrieb.messtechnik-produkte@de.abb.com ABB Limited Oldends Lane Stonehouse Gloucestershire GL10 3TA, UK Phone: +44 1453 826 661 Fax: +44 1453 829 671 E-Mail: instrumentation@gb.abb.com ABB S.p.A. Via Statale 113 22016 Lenno (CO), Italy Phone: +39 0344 58111 Fax: +39 0344 56278 E-Mail: abb.instrumentation@it.abb.com ABB Inc. 125 E. County Line Rd Warminster PA 18974-4995, USA Phone: +1 215 674 6000 Fax: +1 215 674 7183 E-Mail: instrumentation@us.abb.com ABB Engineering (Shanghai) Ltd. 32 Industrial Area Kangqiao Town, Nanhui District Shanghai, 201319, P.R. China Phone: +86(0) 21 61056666 Fax: +86(0) 21 61056677 E-Mail: china.instrumentation@cn.abb.com ABB Limited No.5, Lane 369, Chuangye Road 121001, Faridabad, Haryana, India Phone: +91 129 2448100 Fax: +91 129 4023006 www.abb.com/measurement
Note: Copyright© 2011 ABB All rights reserved
All copyrights and trademarks are the property of their rightful owners. ® HART is a registered trademark of HART Communication Foundation ® PROFIBUS is a registered trademark of PROFIBUS International ™ FOUNDATION Fieldbus is a trademark of Fieldbus Foundation ™ Wireless HART is a trademark of HART Communication Foundation
PB/Overview-EN Issue 6 06.2011
Contact us