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| www.abb.com/instrumentation © ABB 27 May, 2014 | Slide 1

Electro-Magnetic Flowmeter (EMF) Measuring Principle

Werner Marchewka, Export Sales / Product management

http://www.abb.com/instrumentation

U = B D v K

U = Signal voltage

B = Magnetic induction

D =Electrode spacing

v = Average flow velocity

U = v

B = Compensated

D = Constant value

qv = Volume flowrate

U = qv

proportional and linear to volume flowrate

EMF principle of operation

Measurement time ¼ T DC Signal measurement AC

Measurement time 1 T vDqv ⋅⋅

=4

2 π

Magnet coil

Meter pipe in electrode plane

Signal- electrode

Signal voltage

Based on Faraday´s Laws of Induction

fline fnew

The innovation….

The noise effects are dramatically reduced by combining DSP (Digital Signal Processing) and narrow band pass filters.

Line

N

oise

Typi

cal D

C

met

er

Ope

ratin

g R

ange

... the correct frequency !

“Waldbeer” (Fruit with grains)

ABB: COPA-XM “DC Highpower”

E+H: Promag 53 (DC)

ABB: New FSM4000: SE 21 + S4

ABB: MAG-SM: 50SM1000 +DS3112

DN25 v ~ 0,2 –0,3m/s

High power DC Mag from competition

Electromagnetic Flowmeter ProcessMaster FEP300/500 HygienicMaster FEH300/500

Uwe Mecke, Product Management, 2010

Specifications ProcessMaster

Specifications: Meter size: DN3…2400 [1/10“…80“]

Accuracy: 0,4% / 0,2% of Rate

Conductivity: > 5 µS/cm

Connections: Flanges DIN, ASME, JIS

Liner: Hard-, soft rubber, PTFE PFA, ETFE, Ceramic Carbide

Electrodes 1.4571[316Ti], Hast. B, Hast. C, Titanium, Tantalum, Platinum-Iridium

Temperature 180 °C

Protection Class IP 67, IP 68

Installation length ISO 13359

Supply power: 85 - 253 V AC 16.8 – 31.2 V DC

ProcessMaster 500 All Versions At A Glance

ProcessMaster FEP515



Cartridge FET501 ProcessMaster FEP521 FET521

Sta

ndar

d

Zone

2

Div

2

Zone

1

Div

1

ProcessMaster FEP525 FET525

ProcessMaster FEP525 FET525

HygienicMaster 300 / 500 Standard flow solution for hygienic applications

Technical Characteristics

Size DN3 .. 100

Variable process connection

PFA Liner, Vacuum resistant

Choice of electrode materials and shapes

According to ALL Hygienic-Certificates

Value Message

Excellent measurement performance

CIP/SIP cleanable

Worldwide hygienic & food approvals

Target Applications

Food & Beverage, Pharmacy

Juice, Milk, Yoghurt, Shampoo

© ABB Group May 27, 2014 | Slide 9

Speed, Ease and Security in the Field

'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

Operating the meter / Start-Up Sensor Memory Simplifies Installation


Available Liner with: - max. medium temperature (Flanged-Design) - max. pressure ratings Summary max. Pressure

Hard rubber 90 °C PN 400 / Cl. 2500

Soft rubber 60 °C PN 40 / Cl. 300

PTFE 130 °C PN 64 / Cl. 300

High temp. PTFE 180 °C PN 64 / Cl. 300

PFA 130 °C PN 40 / Cl. 300

PFA 180 °C PN 40 / Cl. 300

ETFE 130 °C PN 40 / Cl. 300

Specials PEEK / Torlon (DN1 –DN2) 20 °C PN 40 / Cl. 300

130 °C PN 10

Ceramic Carbide 80 °C PN 40 / Cl. 300

Polyurethan 70 °C PN 40 / Cl. 300


Process Connections – Stand. Pressure Rating per Size Process Connection Size (DN) Pressure Rating

Flange DN 3 – DN 80 PN 40 DN 100 – DN 400 PN 16 DN 500 – DN 2000 PN 10

Multi Connection Weld Stubs DN 3 – DN 40 PN 40

DN 50 / DN 80 PN 16 DN 65 / DN 100 PN 10

Food Fitting DIN 11851 DN 3 – DN 40 PN 40 DN 50 / DN 80 PN 16 DN 65 / DN 100 PN 10

Tri – Clamp DN 3 – DN 50 PN 16 DN 65 - DN 100 PN 10

Male threads DN 3 – DN 25 PN 16

Flange DN 3 – DN 80 PN 40 DN 100 PN 16

Wafer DN 3 – DN 50 PN 40 DN 65 - DN 100 PN 16


ScanMaster The Diagnostic Tool



ProcessMaster/HygienicMaster 500 Diagnostic Functions At A Glance

Diagnosis 300 500

Empty Pipe • • Full Pipe Electrode • • Gas Bubbles * • Electrode Coating * • Conductivity * • Electrode Impedance * • Grounding Check * • Fingerprint & Trending • Sensor Temperature • * Zone 1 / Div 1 in preparation


ProcessMaster/HygienicMaster 500 Automatic & Continuous Checks / Diagnostics

Output Monitoring (20mA) for

20mA Line break

Signal Processing Monitoring for

Signal Quality, Noise (SNR)

Transmitter Monitoring for

µP Function

Memory in Transmitter + Sensor

Signal Pick-up, A/D Converter

Drift, Automatic Compensation

Process Monitoring for

Full Pipe or Empty Pipe

Gas Bubbles

Temperature

Conductivity (min./max. Alarm)

Electrode Corrosion

Flowrate (min./max. Alarm)

Coil And Magnetic Field Monitoring for

Constant coil current, constant magnetic field driven by the transmitter

Coil Monitoring for

Coil-Resistance, Coil-Current, Coil-Voltage

Line Break / Short-Circuit

Temperature

Electrode Monitoring for

Line Break / Short-Circuit

Electrode Coating

Electrode Impedance

Leakage


ProcessMaster/HygienicMaster 500 Manual Function-Tests / Diagnostics

Grounding Check for Grounding Line Noise

Frequency / Amplitude of the Noise

Quality of the Grounding (Power Spectrum)

Fingerprint Check Sensor and Transmitter Signature

Comparison to Sensor and Transmitter Reference Data

Verification (ScanMaster) Provides Current Meter-Status

Trending (e.g. Electrode Coating)

Indicates Deviations

Prints a Verification Report

Stores Results in a Database

Function-Test Signal In-and Outputs

Digital Communication (HART,PA, FF)

Flowrate Simulation Signal Processing Linearity

External Signal Processing (i.e. to PLC)


Gas Bubble Detection Customer Benefit - Applications

Reduce Maintenance Costs

Dry run protection of pumps

Air intake recognition of the pump due to gas bubbles

Ensure Exact Measurement

Gas bubbles have effect on measurement accuracy


Coating Detection An Example

Field test in treatment plant

Activated sludge containing Fe3Cl forms conductive layer within the meter tube in a 3 weeks time

Size DN100 (4“)

Conductivity 750µS/cm

Coating Value

170 prior cleaning

115 after cleaning with a high-pressure cleaner

103 after intensive cleaning, meter tube removed from pipe work


Partial Filling Detection Avoid Incorrect Readings

Without Full Pipe Electrode

No Alarm

Incorrect Readings

With Full Pipe Electrode

Prevention of Incorrect Readings

Fluid Fluid


Grounding Check Make Sure The Grounding Is Correct

Frequency Spectrum on the grounding line

0

1020

3040

50

6070

80

0 100 200 300 400 500

Frequency

Am

plitu

de

w ithground

w ithoutground

Incorrect or faulty grounding belongs to the most frequent reasons for incorrect flowrate readings

Grounding Check analyses the quality of the grounding (Frequency Spectrum)

Grounding Check indicates the 4 highest Noise-amplitudes within the frequency spectrum

Grounding Check helps to start-up the meter

Grounding Check – for a most accurate flow measurement from day one


ScanMaster Finger Print Technology



Fingerprint Indication Of Deviations

Fingerprint is a baseline signature, a set of sensor and transmitter data - a reference

Verifying the meter, the current meter status is compared to this reference Deviations are indicated

Factory-Fingerprint Done in the feeder factory with water

Start-up Fingerprint Done on site with the fluid

to be measured

Fingerprint on demand Done at the moment of the verification (check)


Fingerprint Indication Of Deviations

Fingerprint Consist of Sensor Data

Coil-Current, Coil-Voltage and Coil-Resistance

Electrode-Coating Value

Electrode-Impedance Value E1 - GND

Electrode-Impedance Value E2 - GND

Transmitter Data

Common Mode Rejection

Transmitter – Check @ 5 m/s

Transmitter – Check @ 10 m/s


ScanMaster The Verification Tool



ScanMaster The Add-On That Makes Sense

Diagnostic capabilities combined with Fingerprint technology to create a baseline signature that describes the meter status at the time of factory calibration or start-up

Verifying the meter through ScanMaster, the current meter status is compared to this baseline signature. Deviations are indicated

Fingerprint Diagnosis ScanMaster


ScanMaster Verification-Report - Print Out Version

This page of the verification report is created for 300 and 500 series flowmeter

Verification report with individual and overall test results

ScanMaster stores the test results in a database on the hard disk drive of the PC


Steel Industry


Applications in Steel Industry Cooling water in rolling mill

Application Details:

Water is being sprayed onto the steel going to the rolling mills for finishing. Control of the spray rate is essential to the quality of the steel.

Measuring the flow rate in the individual spray nozzles enables for tighter control, better quality and less wear


Pulp and Paper

Industry

ProcessMaster Pulp & Paper Industry Applications

Applications Stock Flows – continuous digester, high

density, mixing chest, basis weight, flow to washers, batch blow line

Chemical mixing and additives – sodium hydrosulphite addition

Latex and clay flows

Power plant, energy supply

Water preparation and treatment

Color kitchen

Pulp preparation

Deinking plants

Refiner street

Constant part

Pulp head box

Screen water


White water measurement

Deinking Plant

Reject


FSM4000 - Success Stories in Pulp & Paper Paper Mill, Varel, Germany

Process Fluid: Reject up to 10% pulp

Check for Variation of 20mA Output FSM4000 versus competitor magflowmeter

Competitor

FSM4000


FSM4000 - Success Stories in Pulp & Paper Armstrong World Industries – Marietta, PA

Worldwide leader in manufacturing and marketing acoustical ceilings and suspension systems for commercial and residential applications

Location: Basis Weight

Process Conditions

Minaboard: 1.0% Clay, 6.2% paper

Fiberboard: 1.8% Fiberglass, 4.3% Paper

Line size: 6 inch, Range: 1000 GPM

Temperature: 70°F, Pressure: 15 psi

Process Tracking within 1% of expected at 1 second damping


Food & Beverage


Only Pay for What you Need given by modular instrument design

Commissioning as quick and simple as possible given by SensorMemory technology

Through-the-Glass Control for easiest parameter change

Lower Inventory Costs by modular sensor adapter concept

Meets all Regulatory Agency Approvals

Industry application areas

Breweries, Dairies, Cosmetics, Wine and fruit juice production, Pharma, Biochemical

HygienicMaster The Clean Choice for Hygienic Applications


How to avoid Liner Damage


ProcessMaster 500 Extended Service Life In Case Of Abrasive Liquids

Ceramic Carbide liner for extremely abrasive liquids

Cost savings through reduced maintenance

Extended service life compared to standard liners

From size DN25, temperature resistant up to 80°C

For fine-grained muds, lime, pulp, concrete measurement, bentonite


How to avoid Electrode Coating


Specific electrode tip

Size: DN10...400

Applicable for

Fluids with fat (Milk, Cheese)

Fluids that form some sort of mud, grease inside the sensor (Some wastewater applications)

Fluids with some content of oil

Improved Mesurement Performance

Self cleaning effect

ProcessMaster Pointed Head Electrode – Improved Performance

Steel Industry Take advantage of latest electrode design to keep the process up and running

Problem Heavy coating in the pipes.

High pressure cleaning of piping required every 6 weeks. Once the coating gets dry it is like Stone

Solution

Electrode design is key Take Swedish design electrode made from Tantalum

After 6 weeks meter is still working perfectly See the electrodes pointing out under the coating

DN40 magmeter 6 weeks after Installation


Selection Guide Liner and Electrode Material

Hardrubber Softrubber PTFE Thick PTFE PFA ETFE Linatex Ceramic Carbide

Standard

Standard Applications


Standard Applications,

High Temperature



Tungsten Carbide

Stone-loaden slurries

Stone-loaden slurries

Double Layer

Abrasive, fine grained slurrries




Pointed Head

Mashes, Chunks of Fruits, fatty

fluids


fluids


fluids

Swedish Design

Clay, Latex, fluids with trend to coat

Focus: P&P


Filling & Dosing


ProcessMaster/HygienicMaster 500 Batch Function

Min filling time >3 sec, Start through digital input (2)

Digital output (4) to shut the valve at the end of the batch

Transmitter measures overrun quantity (tn) and calculates overrun compensation

In addition, low flow cut-off can be activated

ProcessMaster Chemical Dosing Station

Challenge

Corrosion resistant wetted parts

Fluid varies in temperature and concentration

Grounding

Hazardous Area

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