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”.

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 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’.

Legislative pressure

Last time we explored the importance of accurate monitoring and control regime in turbulent economic times. As well as contending with financial pressures, companies are also under growing pressure for more measurement accuracy emerging from the legislative arena too.

Environmental monitoring under the Environmental Permitting Regulations (EPR) is a great example, with companies in the process and water industries now required to establish and maintain effective monitoring of their emissions of air and water within extremely tight margins of error. Slip up here and companies could face prosecution, fines or even lose their license to operate.

Technological progress

On a more positive note, improving technology is also playing a role in driving calibration standards, because more accurate calibration is called for as the measurement accuracy of the instruments being tested improves. The existing IEC 61298 standard states that the measuring equipment for process measurement and control devices should display a measurement uncertainty that is four times better than that of the device being calibrated.

Back to the bottom line

Calibration can be a difficult and expensive challenge as the cost for supporting some plant-based instrumentation can be 10% of the original purchase price on a yearly basis. Nevertheless, calibration is essential, so the key thing is to get the right regime in place to ensure that the investment in testing is not wasted.

When should you calibrate?

The right time to calibrate a specific piece of equipment will depend on the type of instrument and the criticality of the job it’s doing. There are some common situations that typically call for calibration, such as:

• With a new instrument
• At time intervals specified by the manufacturer or regulator
• After a specified number of operating hours or usage cycles
• When an instrument has had a physical shock or vibration that might potentially put it out of calibration
• Following sudden changes in the weather
• Whenever the output appears doubtful.

Who can help?

Suppliers and laboratories offering calibration services in Britain are accredited by The United Kingdom Accreditation Service (UKAS).

At a time when companies across all industries are under financial pressure, everyone is looking to squeeze the maximum value they can out of their assets. We all know that you can’t manage what you can’t measure, so maintaining an accurate monitoring and control regime is essential. That’s just one reason why it’s the right time to think about how well your calibration regime is supporting your business.

Properly scheduled and effective calibration ensures that the readings emerging from instrumentation are accurate. Without it, measurements are essentially meaningless. The trouble is that maintaining an effective monitoring regime is not a “fit it and forget it” job. Periodic calibration is essential to maintain accuracy over the lifetime of almost every type of instrument.

This may be self-evident in some types of instrument, such as pH meters that rely on the sort of wet chemistry that can easily be disturbed. But even seemingly robust, solid state sensor elements such as thermocouples rely on electronics to relay their readings to plant control systems and electronic components are subject to aging from any number of factors, such as mechanical stresses or temperature fluctuations. It’s also worth noting that the same applies to the electronics of input cards, which provide the signals to controllers, so these should also be calibrated regularly.

The bottom line

Of course, some process measurements are more critical than others. So while flow meters carrying out fiscal measurements on petroleum products may need to be accurate to ±0.025%, a meter controlling the level in a water tank used for washing down machinery may only need to achieve ±5%.

Essentially it’s about optimising the process to generate the most income from the available assets, whatever the business. The ultimate goal might be increased production yields, reduced product give-away and over-charges, more consistent product quality and/or reduced product liability.

When should you calibrate?

The right time to calibrate a specific piece of equipment will depend on the type of instrument and the criticality of the job it’s doing. There are some common situations that typically call for calibration, such as:

• With a new instrument
• At time intervals specified by the manufacturer or regulator
• After a specified number of operating hours or usage cycles
• When an instrument has had a physical shock or vibration that might potentially put it out of calibration
• Following sudden changes in the weather
• Whenever the output appears doubtful

Who can help?

Suppliers and laboratories offering calibration services in Britain are accredited by The United Kingdom Accreditation Service (UKAS).

Almost anyone working in industry will be familiar with the IP ratings of instruments that are built to withstand the ingress of certain levels of dust and moisture. But some environments present special challenges that require a bit more thought. When it comes to temperature measurement, there is a growing demand for devices that can offer high accuracy and availability under the harshest operating conditions in some of the most inhospitable regions of the world.

The big chill

For example, oil and gas companies are increasingly looking to very northerly latitudes, from Canada to Russia, in their exploration and recovery operations. The frigid conditions that these facilities have to work in can cause a major headache for electronics, which must be specially rated to operate reliably down to -50oC.

Daily cycles

Another potential problem is presented in dry, desert conditions, where temperatures can easily reach 45oC in the day and plunge to OoC at night. In such environments, temperature cycling can pose a problem for electronics, allowing components to work loose, strain connections and crack as they repeatedly expand and contract. The solution in this case is to opt for potted equipment, which holds everything steady by embedding it in a solid resin.

Hot and steamy Potted equipment is also the preferred solution in tropical operating environments, where high humidity and condensation is the big challenge. An appropriate IP enclosure is the obvious first line of defence, provided it remains firmly sealed.

If the external atmosphere gets inside, however, the night time drop in temperature will be enough for moisture to form and cause condensation. Not only will water cause the obvious problems of corrosion or shorting out circuits, but the warm, damp conditions also provide a perfect environment for the growth of fungus.

Unless an instrument is to remain permanently sealed, potted or epoxy-coated components are thus the only realistic solutions.

Deep water

Offshore operators are increasingly choosing to position production heads on the sea bed, rather than in topside facilities, because it’s more cost-effective and helps to keep more of their equipment in relatively calm waters, rather than having to face storms on the surface. The downside is that the flow, pressure and temperature instrumentation in the production head must be protected against corrosion and pressure at depths of up to 4,000 metres.

Unlike the instruments designed for arctic environments, the electronics of the equipment used in underwater applications can be the same as in standard, good-quality instruments. Where the deep-sea installations differ is in the level of containment and protection required.

Nuclear know-how

The issues in the nuclear industry are different again, with the main challenge being the ability to cope with ionising radiation that can actually alter the chemistry of semiconductors and play havoc with the electronics.

ABB has developed a platinum resistance temperature (PRT) probe that can achieve a 90% response in the measuring element within seven seconds of a step change in temperature. This is wired up to a transmitter using a four-wire circuit that is designed to cancel out the effect of resistance in long cables. This enables operators to position the electronics tens of metres away from the source of radiation.

Growing demand

While attitudes to the expansion of nuclear power have shifted following events at the Fukushima Daiichi plant in Japan, nuclear may yet have a continuing role to play in strategies to tackle global warming. Meanwhile the days of “easy wins” are over for oil and gas companies. Whatever happens, it seems certain that the demand for temperature instrumentation that can operate in challenging conditions will continue to grow.

William Blythe, a manufacturer of inorganic chemicals, is saving thousands of pounds and several days of production time after making the switch to ABB pressure transmitters.

The company employs a number of pressure transmitters on a plant used to manufacture a halide compound which is extremely corrosive, causing chemical damage to the seals.

Andy Fort, Control and Instrumentation Engineer at the plant, says: “The problem was particularly acute if a small amount of moisture was present because this caused the chemical made on the plant to aggressively attack the metal contact parts of the pressure transmitters – particularly the seals”.

These corrosion problems meant frequent replacements were needed, with two or three transmitters out of the eight installed on the Plant needing to be replaced every 12 months – sometimes more frequently. Because the transmitters are mounted on the seal, the whole unit needed replacing. Costing around £1,000 each, it was becoming expensive to continue to use these products.

“Each transmitter took between six and eight hours to replace,” says Fort. “The maintenance staff also needed to wait for the vessels to cool before they could be worked on. After the replacement, there was a warming time as well to get the vessel to the correct working temperature, so each replacement could mean a full working day of 24 hours was lost.”

Fort contacted WH Good Automation, an ABB Instrumentation Alliance member and a company that Blythes had worked with before to specify the correct seal arrangements and materials to suit the plant’s needs.

The identified solution was to use ABB 264HD pressure transmitters. These have a Hastelloy 2000 seal, which is impervious to the type of damage caused by the chemicals.

The first one was installed nearly two years ago and during inspection, the seals have proved to have maintained their integrity. The ABB products have also proved more stable than the previous transmitters.

ABB offers an extensive range of temperature and pressure equipment for use across multiple industries and applications. For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. “Temperature and pressure‟.

For more information: Les Slocombe
Email: moreinstrumentation@gb.abb.com
Tel: 0870 600 6122

A new white paper is now available from ABB, explaining the key issues underlying water leakage and how it can be managed using the latest flowmetering technology.

The white paper first defines water leakage and details its various causes, before establishing the consequences facing water companies for failing to meet set leakage targets, such as profitability; damaged reputation; and reduced resources.

It then explains the concept of District Metering Areas (DMAs) and how these are being effectively used in leak management programmes to drive down leakage in networks that had received little or no previous detection work.

The white paper shows the benefits of electromagnetic over mechanical flowmeters for increased flow accuracy, long-term reliability and in-situ verification. It then details the key features of ABB’s AquaMaster3 and how it can be successfully deployed into a DMA system.

Available in pdf format, the white paper provides a case study where a consortium of Severn Trent Services and Costain used ABB electromagnetic flowmeters to meet strict government sustainability targets 11 years ahead of schedule.

Written by ABB’s engineers, the white paper is aimed at anyone involved in leakage management. For a copy please call 0870 600 6122 ref: ‘Leakage White Paper’.

Alternatively, please see the below link:
http://www05.abb.com/global/scot/scot203.nsf/veritydisplay/e0cc9b7d337e577dc125790d0027c37b/$file/ag_leakage-en.pdf

The role of new technology in tackling water leakage was one of the key topics explored at the recent Global Water Leakage Summit event sponsored by ABB. Held in London, the two-day event brought together 180 representatives from water operators, decision-makers and influencers around the world to discuss new developments and strategies for monitoring and tackling water leakage.

As a key supporter of the event since its creation in 2001, ABB joined other organisations in explaining and exploring new ways to find and fix leaks more quickly. A key aim of the event was to encourage the exchange of best practice examples between representatives to try to identify a common approach to tackling water leakage.

The first day of the event focused on leakage strategies. Discussions during the day long sessions included lessons learned by Dwr Cymru Welsh Water and Northern Ireland Water following the 2010/2011 cold winter, both in terms of dealing with frequent bursts and water shortages and dealing with the media. This was followed up with a presentation by Canada’s Halifax Regional Water Commission, sharing the company’s own experiences of dealing with such conditions.

This contrasting approach was continued on the Regulator Panel, which compared the challenges and driving factors facing water utilities in the UK with those of utilities operating in Abu Dhabi and Portugal, which was particularly useful for those countries that are relatively new to leakage management.

This first day was topped off with the first Global Water Leakage Evening Gala Dinner, the idea of ABB’s Global Product Marketing Manager, Tim Door. As well as providing an excellent forum for informal networking, the Gala Dinner also helped to raise £2,105 for the Water Aid charity, with various prizes being auctioned off, including an engraved iPad donated by ABB.

The second day saw a shift in theme towards technology, covering three main areas, namely smart network management, pipeline inspection and monitoring and leakage management. All three sessions explained how new technology is being used not only to help identify existing leaks but also to help spot potential leaks before they even occur.

The whole event was closed with a wrap-up technology panel discussion session chaired by Tim Door. During which, various companies explained how their technologies could be used to help shape the future of leakage detection and management, with Tony Hoyle, ABB’s General Sales Manager for UK and Ireland, presenting ABB’s own AquaMaster 3 electromagnetic flowmeter, together with case study application examples explaining how the product has been deployed.

“As the lead sponsor for the event, we’re delighted with the success of the Global Water Leakage Summit,” says Tim Door, Global Product Marketing Manager for ABB. “The in-depth sessions certainly gave everyone a lot of food for thought about how to reduce leakage by both monitoring leakage more effectively and using the latest technology. The next step now is for the delegates to go forward and find ways to put their new knowledge into practice to help ensure that the world’s increasingly scarce water resources are managed in the best way possible.”

During the test, devices are connected to Emerson‟s DeltaV automation system to assess their performance under a full range of conditions likely to be experienced in real-life applications.

“DeltaV users now have more freedom in their choice of pressure transmitters,” says Trevor Dunger, ABB Product Specialist, Pressure & Level, “and can make use of the wide range of capable, highly accurate 2600T series of ABB pressure transmitters.”

The range of ABB 2600T pressure transmitters includes absolute, gauge and differential transmitters, allowing users to standardize transmitter installations across a whole plant.

A key part of the 2600T‟s simplicity lies in its use of ABB‟s new universal HMI. A menu-based clear text enables 2600T transmitters to be configured in just seconds, compared to the several minutes required for competitor devices using handheld configurators. This menu can also be used to quickly select and display different variables, providing operators with fast access to additional data.

Operators can also quickly repair or upgrade the transmitter in the field simply by changing the electronics module, rather than the whole transmitter. The transmitter performs an auto configure function so no additional configuration is required, avoiding the time and cost of removing a sensor from a pipeline or network.

The 2600T range also includes a standard model for pressures up to 600 bar, which is fully compliant with the hardware and software requirements of IEC61508 for SIL2 and TUV Nord applications. It also comes with IEC hazardous area certifications IEC Ex ia, IEC Ex d and IEC Ex nL, plus all of the major international certification standards including GOST, FM and CSA.

Another key feature of the 2600T range is the inclusion of 20 standard critical and non-critical diagnostic functions. Where an alarm condition occurs, messages are displayed in clear text on the indicator and can be relayed to a control system via HART, Profibus or Foundation Fieldbus. The transmitter is also programmed with the necessary software to integrate with both ABB‟s 800xA and third-party control systems.

A major development is the availability of a vertically flanged mounting variant, offered as an alternative to the Co-planar flange design. With this feature, ABB 2600T transmitters can be fitted to existing co-planar manifolds from different suppliers, eliminating the work associated with repositioning pipes.

Other new features include preset linearisation functions for level measurement applications in cylindrical and spherical tanks, enabling tank levels to be accurately measured based on volume. Also included is a square root extractor function, enabling the 2600T to be used for differential pressure flow applications.

The high performance of the 2600T range is further supported by ABB‟s extensive choice of remote seal options. Available in a wide choice of materials and process connections, ABB‟s remote seals are proven to operate leak-free even under high vacuum.