ABB opens new UK Instrumentation Service Centre

Providing unparalleled access to equipment and expertise for our UK and International customers, our new state-of-the-art instrumentation, calibration, repair and training facility at our UK manufacturing site in Stonehouse, Gloucestershire is dedicated to return to base calibration and repair services.

A wide range of products ranging from gas and liquid analysers, electromagnetic and differential pressure flowmeters to temperature probes are supported from this production factory.

We currently operate six flow meter calibration rigs at the Stonehouse site, supplied by a one million litre underground water tank. The rigs can be used to test virtually every type of flow meter at flow rates from one millilitre to 2,700 litres per second. ABB is certified by UKAS (The United Kingdom Accreditation Service) and is the only company in the UK with a calibration rig accurate to within an expanded uncertainty of ±0.027 percent.

This significant investment in a dedicated service centre demonstrates ABB’s commitment to supporting the complete life cycle of our products for UK and International customers. The addition of a training suite inside the UK’s largest instrumentation manufacturing facility enables ABB to offer an unrivalled calibration, repair and training centre.

ABB provides a comprehensive portfolio of standard courses and customised training to help operations and maintenance personnel keep their skills up-to-date. The training is designed for engineers and technicians who are responsible for the day to day maintenance of ABB measurement products.

The training courses on offer include detailed product and application knowledge, and theory of device operation. The courses are supported by hands-on exercises with demonstration equipment. Delegates are also being offered a tour of ABB’s manufacturing facility. Courses cover a number of ABB’s measurement products from electromagnetic flow meters to analytical instruments and result in delegates obtaining certification on completion of a course.

Looming drought should spur investment

By Tony Hoyle, General Sales Manager for UK and Ireland, ABB

It’s not even spring but the south and east of England is already in drought, according to the Department for Environment, Food and Rural Affairs (DEFRA) this week. Many consumers can look forward to hosepipe bans from the early spring onwards, and farmers are warning about the impact on next year’s crops of restricting the amount of water they can abstract from rivers over the summer.

It’s not a happy prospect, especially since the news comes just weeks before average water bills are set to rise by 5%. But the reality is that it takes a lot of investment to keep us all in showers and cups of tea, let alone Jacuzzis and car washes. It’s also Ofwat that sets the pricing framework, not the water companies, and the regulator recognises that we have to keep investing.

After a lot of neglect throughout the 20th century, we now have some of the best water services in the world, thanks to £90bn invested between 1990 and 2010. Between April 2010 and March 2015, Ofwat wants the industry to invest another £22bn, and the looming water shortage highlights the need for this investment, rather than negating it.

So, in a week when Thames Water pleaded with customers to voluntarily reduce their water consumption in the face of a drought to rival 1976, water companies should also be looking at how to make the most of our precious resources.

Readers of my past blogs will know that leakage reduction is one of my pet topics. Leakage figures across the UK have so far remained stubbornly at between 15 and 25%, equating to some 3,300 megalitres per day, so there’s still huge scope for improvement.

Whilst it’s encouraging to spot water companies using Twitter to ask their customers to keep an eye out for leaks, it’s also slightly worrying too. The amount of water lost from a given flaw depends on the water pressure and the length of time taken to fix it, so it’s crucial to have the metering technologies in place to track down problems fast, rather than relying on the diligence of the general public.

There is technology available that can not only identify where leaks are happening, but also spot situations where they are likely to happen too. District metering schemes, a long time tool in the fight against leakage, have now been joined by smart network technology, which monitors parameters such as pressure and flow to identify potential weak spots in a water distribution system where leaks are likely to occur.

Investment in these techniques is certainly more practical than grand schemes like piping water en masse from the soggy northwest to the parched southeast – an idea most recently championed by London mayor Boris Johnson. That idea has been a dead duck since 2006, when the Environment Agency concluded that better regional water conservation measures could be as effective for a fraction of the cost.

Any increase in prices is always going to be unpopular with the public, especially at a time when household incomes are already stretched. While such rises may be a bitter pill to swallow, at least we can still wash it down with a glass of water. If we fail to make the investments needed in safeguarding today’s water stocks, then in future we may not even be able to take this basic luxury for granted.

ABB showcases the latest technologies at IWEX

At IWEX this year (stand J20, NEC Birmingham, 22nd – 24th May), we will be demonstrating to our customers our full range of products, systems, services and expertise that can be put to work to help them optimise their water and waste water treatment processes. As always, our aim is to emphasise ABB’s ability to provide complete integrated solutions for use throughout the water production and treatment cycle.

Among the products on display will be the new AquaMaster3 GSM-SMS/GPRS electromagnetic flowmeter, which gives users the option of using renewable wind and solar power sources, making it ideal for remote locations. Based on the same technology as a mobile phone, the AquaMaster3 can be contacted using a PC, or through a mobile phone via SMS messaging, providing operators with instant remote access to accurate flow and pressure data.

A key feature of this year’s stand will be a range of instrumentation specifically for applications in anaerobic digestion, including the direct mass flowmeter SensyFlow and Swirl flowmeter, which can be used for accurate biogas measurement. Both flowmeters offer high accuracy, short response time and a very wide flow range with virtually no loss of accuracy even at the lowest flow rates.

Other ABB products will include K-TEK level measurement equipment and the new Aztec 600 ISE fluoride ammonia water analyzer.

As well as products, we will also be using IWEX to share our knowledge with visitors, with ABB experts scheduled to participate in two free seminar sessions:

Tony Hoyle, ABB General Sales Manager UK & Ireland, will be taking part in a panel discussion on smart water networks, in the Water Theatre, on Wednesday 23rd May, at 1:55pm. The panel will look into the future of smart networks in tackling UK water leakage.
Julian Edwards, ABB UK Sales Specialist, will be presenting a seminar explaining ways to improve the effectiveness of the coagulation control process. This will also take place in the Water Theatre on Wed 23rd May, at 10:30am.

For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘IWEX’. Alternatively, please visit ABB’s water industry portal at www.abb.co.uk/water.

ABB expands measurement product range with BETA pressure and temperature switches

Our measurement products portfolio has expanded yet again with the addition of the ABB BETA range range of pressure and temperature switches, enabling safe and reliable control of pressure and temperature in a range of industrial applications, including chemical, oil, gas and power.

The switches, characterised by their ability to offer safe and reliable performance in extreme conditions are fully certified to leading international standards. The range includes pressure, differential pressure, vacuum and temperature switches, making them ideal for measuring fluids and gases in a wide variety of applications.

The switches incorporate a precisely engineered, self-aligning, piston sensor for precise operation. The limited travel in the piston, and its direct contact with the microswitch, allows accurate pressure transmission and full protection against the highest over range pressure.

The BETA temperature switch is a pressure switch enclosure with a built-in sealed two-phase temperature sensor for use in gas and fluid applications. As the temperature of the process increases, the vapour pressure of the liquid also increases. If the vapour pressure exceeds the setpoint of the pressure switch, then the switching element will be actuated.

Manufactured from 316 stainless steel, the temperature switch sensors can be fitted into standard thermowells of up to 10mm bore, or can be direct or capillary mounted.

BETA temperature switches are available in both weathertight and ATEX approved explosion proof models, enabling them to be used in arduous and hazardous locations.

All switches in the BETA range are available in a wide range of materials, avoiding the need for expensive chemical seals.

Certifications for the ABB BETA range include EXIDA (SIL2 Certification), CSA, FM, ATEX, IECEx, and TUV.

For more information including full safety certification and specifications, call 0870 600 6122 or email moreinstrumentation@gb.abb.com ref. ‘BETA switches’.

ABB dissolved oxygen meters help Thames Water cut energy consumption for compressed air by 10%

Our dissolved oxygen meters are now helping Thames Water to reduce energy consumption by around 10% in its compressed air blowers at the giant Beckton sewage treatment works in the London Borough of Newham.

The meters are part of a new control system designed to optimise the amount of compressed air used to treat the sewage. At Beckton, like virtually all sewage treatment works, oxygen is used in the process to break down organic matter by injecting oxygen in the form of compressed air into the sewage. But substantial sections of the site date back to the 1960s and previously included no instrumentation to match the supply of compressed air to the variable oxygen demand of the sewage.

The new installation includes 28 dissolved oxygen systems in total, made up of 16 AX480 single-input analysers and 6 AX488 dual-input analysers. All the systems are controlled from a central computer using on-board Profibus communications. The rugged, IP65 rated design of both analysers makes them suitable and safe to use in harsh environments. They are also simple to install and use and require minimum maintenance, which makes them ideal for fully automated control schemes such as the installation at Beckton.

Beckton is already one of the largest sewage treatment works in Europe, serving 3.5 million people and discharging its effluent into the River Thames. The new control system is part of a £190 million programme upgrade that will enable the site to treat up to 60% more sewage by the end of March 2014. This will enable it to handle storm water as well as a growing population, helping to safeguard the Thames.

Our AX400 Analyzers incorporate the latest technology providing highly reliable, flexible, feature-packed devices that satisfy a diverse range of process monitoring and control applications. The complete range encompasses solutions for pH/Redox (ORP), conductivity and dissolved oxygen.

For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘AX468’.

On the level: A guide to level measurement

By Les Slocombe, Marketing Services Manager, ABB

With ever-changing developments in technology, there have been a number of key developments in the ways in which level measurement is performed.

Being able to transmit level data via 4-20 mA, HART, Foundation Fieldbus and the other commonly used communication methods is a significant advance in level measurement. The K-TEK magnetostrictive level transmitters for instance, come ready to support communication protocols, allowing the transport of level measurement information.

So what benefits have these developments brought? As well as being far more convenient, it can also be prove much safer, as personnel are away from potentially hazardous materials.

Previous generations of level technology often required a fair amount of technical knowledge to install and configure properly, today’s software rich level measurement systems allow just about anybody to commission the device.

There has also been a significant increase in the precision of interface measurement. The latest magnetostrictive technology is capable of accuracies 0.010 per cent to 0.25 per cent in comparison to older methods like hydrostatic tank gauging, which could only offer accuracies ranging from 1 per cent to 25 per cent.

Selecting the right level measurement solution can prove a rather daunting prospect. My advice would be to avoid the temptation to go for level measurement systems that can do everything. Concentrate on the core goals of your application and keep in mind that the product itself is less important than the solution you’re trying to achieve.

To guide your selection, keep some essential questions in mind:

• What kind of accuracy does the application require?
• What is the temperature, pressure, media type?
• What is the temperature range of the application?
• What is the budget?

Look for a supplier with a broad range of level measurement solutions, as they will be able to identify the appropriate solution for your application. If you’re lucky, they may also provide online tools to make commissioning, installing and troubleshooting the level measurement system much easier and convenient. Talk to the manufacturer and give them as much application information as possible.

So what exactly does the future hold for level measurement? Well, there will be more support for protocols in level measurement systems, including 4-20 mA, HART and Foundation Fieldbus, together with more emphasis on functional safety with products certified to standards such as SIL2.

The future is sure to see level instruments incorporating more digital features, as well as using wireless in creative ways to provide application visibility and flexibility for level measurements.

For more detailed information on ABB’s level measurement offering please phone 0870 600 6122 re: ‘level measurement’ or email moreinstrumentation@gb.abb.com.

New ABB White Paper gets to grips with control theory

PID control theory is made easy with new White Paper

If you’re looking at using control theory in the production, distribution or treatment of industrial processes, our latest White Paper, crafted by ABB experts has the answers.

Explaining how controllers can be used to optimise virtually any industrial process, the new White Paper builds on recent advances in control technology to establish a host of possibilities for the way that processes can be monitored and controlled. These include the use of complex algorithms capable not only of reacting to changes in process conditions, but also increasingly predicting them as well.

The paper also provides an overview of control applications, types of control systems and PID (Proportional-Integral-Derivative) controllers, before exploring the main features of our ControlMaster range, describing how the four versions can be used in a variety of industrial control applications.

Copies of the white paper are available on request. For a copy please email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref: ‘Control White Paper’.

ABB solves level measurement problem for wastewater plant

Reliable and accurate measurement with ABB’s K-TEK LM200 level transmitter

An ABB K-TEK LM200 laser level transmitter is helping a well-known wastewater plant return to reliable level measurement, after issues with a competitor’s hydrostatic level transmitter.

The company uses level measurement to activate pumps to a pre-treatment plant when the water reaches a pre-determined volume. Previous measurement techniques failed to cope with the amount of debris and grit present in the effluent, which clogged up sensors, causing inaccurate readings and making them difficult to re-calibrate.

The ABB K-TEK LM200 laser transmitter is ideal for this application and was purposefully designed for the measurement of dry bulk solids, opaque liquids, and slurries at distances of up to 200 feet. It features an advanced timing system and sophisticated, self-correcting signal processing function that allows it to accurately and reliably measure level, distance, and position in the harshest of conditions.

A key feature of the LM200 is its ability to work in the presence of dust, vapours, or turbulence. A rugged, powder coated aluminium enclosure, rated for IP65 or NEMA 4X, with CL II and III, Div 1 and 2, Gr E, F, G dust ignition proof ratings to FM and CSA, ensures operation in a variety of challenging environments. Stainless steel dust tubes prevent dust build-up and protect the optical lens from being coated.

Non-contact measurement technologies, such as ultrasonic and open air radar, have an inherent “beam spread” nature (up to 24˚) and find it hard to deal with issues such as dust, vibration and constantly changing levels. However, the LM200 overcomes these by combining accurate, long distance laser measurements with no beam divergence (less than 0.2˚).

The system design allows the software to perform distance measurements quickly, dedicating more time for sophisticated signal processing, data analysis, and distance display. An intelligent “Last pulse‟ capability means the LM200 can select true signals from among the many that are reflected from dust clouds, agitator blades, or other obstacles.

For more information please email moreinstrumentation@gb.abb.com or phone 0870 600 6122, ref. “level measurement”.

Keeping ammonia levels in check

Control and measurement equipment help to regulate effluent flows at sewage treatment works

Previously, achieving the required flow rate of discharged treated effluent and ammonia limit could be difficult, depending on the types of waste received on a particular day. Testing and monitoring was done manually and there was no easy way to electronically record results for future reference.

Now instantaneous, live data can be sent from the site and recorded on PCs for easy interrogation. This improvement has been extremely valuable for environmental management services by allowing works to demonstrate compliance to regulators to optimise site operations and plan for future improvements.

Alpheus Environmental has recently installed ABB control and measurement equipment to regulate effluent flows into receiving sewage treatment works at Basildon – improving operations on reduced future costs on site.

Tankered liquid waste is brought to the site by road tankers, treated and then discharged to the sewage treatment operated by Anglian Water Services.

Two key parameters which Alpheus is required to regulate and monitor are the flow rate of the discharged treated effluent and its ammonia level.

Following discussions with ABB, a solution was devised that uses an ABB ControlMaster universal process controller together with an ABB MagMaster flow meter transmitter unit. This arrangement controls the speed of the outlet flow using an actuator valve.

The ABB ControlMaster also receives input from an ammonia analyser. If the level of ammonia leaving site is close to reaching the consented limit then the analyser signals the controller to shut down the site and close any outlet valves. It can also send e-mails to Alpheus and Anglian Water when levels are nearing the consented limit.

An ABB SM500 data recorder was fitted to oversee, record and report the data from this new control system. Daily reports are produced giving statistics on the volume and ammonia loading, which are sent straight to the Alpheus server. Data can be exported to produce Excel spread sheets and graphs.

For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. “Alpheus‟.

ABB expands potable water quality analyzer range with new ISE monitors

ABB’s Aztec 600 range now includes ISE as well as colormetric analyzers – allowing cost savings of up to 25% on reagent usage

ABB has expanded its Aztec 600 range of potable water quality analyzers to include Ion-Selective Electrode (ISE) monitors for ammonia and fluoride – joining the Aztec 600 colorimetric range of analyzers for Aluminium, Iron, Manganese, Colour, Phosphate and Ammonia.

The Aztec 600 ISE Ammonia uses gas sensing electrodes to monitor ammonia concentrations in water between 0.05 and 1000mg/l. A pump draws in the sample and passes it through two solenoid valves used for calibration. The sample is then mixed with reagents in the peristaltic pump, with the resulting solution sent to the sensor flowcell, under temperature controlled and constant flow conditions. Available in both the colorimetric and ISE models – the latter provides a wider range of measurement.

The Aztec 600 ISE Fluoride monitor uses a different ion-selective electrode and reagent for the measurement process. The reagent stabilizes the pH in the sample and suppresses any chemical interference from metallic compounds, providing a more stable and accurate measurement.

The range also provides an additional safeguard in potable water applications. The Aztec 600 Ammonia’s wide measuring range, for example, makes it ideal for potable water intake protection, whilst the Aztec 600 Fluoride helps ensure that doses of fluoride added to water are maintained within the regulatory limits set by the Drinking Water Inspectorate.

Furthermore, both these monitors offer cost savings of up 25% on reagent usage, with additional savings achievable using the monitors’ new ‘Eco’ mode feature – enabling users to reduce pump speed in applications where a fast response time is not required. By slowing down the pump speed, less reagent is consumed, reducing the frequency of reagent changes to up to three months.

The ISE analyzers are available in single stream configuration, whilst the colorimetric range comes in either single or multi-stream configurations, enabling operators to use just one device to monitor up to three streams sequentially all with current loop, Ethernet or Profibus outputs.

A key benefit of the Aztec 600 range is its ease of operation. Front-mounted pushbuttons allow easy device interaction in a familiar Windows™ environment. Operation and commissioning is straightforward, with menus presenting options for setting and fine-tuning parameters. Added support is provided by an extensive context-sensitive on-line help feature.

Based on ABB’s common operator interface, the Aztec 600 colorimetric analyzers feature a full colour graphical display, allowing process trends to be easily viewed and analyzed locally. Historical logs provide operators with access to alarm and audit trail data. Process data and historical logs are securely archived to a removable SD card with capacity of up to 2 GB.

A built-in Ethernet communications link with onboard web and ftp servers enables remote monitoring, configuration selection, data and log file access to the analyzer from a web browser.

ABB Aztec 600 analyzers are backed up by a comprehensive local service and support network, offering everything from commissioning through to upgrades throughout the life of the product.

For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘Aztec 600’.