Tapping data pipelines: Ethernet-APL-enabled flowmeters

New possibilities for digital collection and analysis of data in the chemical, oil & gas and hydrogen processing industries are now on the horizon thanks to the introduction of Ethernet-APL to ABB’s industry-leading SwirlMaster and VortexMaster flowmeters. An innovative communications technology, Ethernet-APL not only eliminates the risk of sparking in hazardous conditions but offers a readily scalable solution for connecting vast numbers of devices in the field to a control system.

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_{Tilo Merlin, BL Instrumentation / Measurement & Analytics, Frankfurt, Germany, tilo.merlin@de.abb.com}

Ethernet cables are familiar to just about everyone who uses a computer. They provide high-speed wired connectivity to local area networks, metropolitan area networks and wide area networks. However, until recently, such cables could not be used at the field level in factories that have potentially hazardous conditions. To overcome this obstacle, ABB, in cooperation with a group of leading process industry suppliers and international standards organizations, has developed a solution in which intrinsic safety is fully integrated, including a profile that limits supply voltage and current, thus eliminating the risk of sparking.

Improving operational efficiency

Known as Ethernet Advanced Physical Layer (APL), the solution offers enhanced data rates of up to 10 Mbps, a shielded two-wire connection for carrying power and data safely over the same cable, and cable lengths of up to 1,000 meters. The technology thus opens new possibilities for digital collection and analysis of data in chemical, oil & gas and hydrogen industry processes →01.

Ethernet-APL’s innovative communication technology can help manufacturing companies improve their operational efficiency by providing a high-speed channel for process data as well as configuration and diagnostic information. It furthermore offers a readily scalable solution for connecting devices in the field to a control system and enables simplified networking with all instruments in a plant, as well as opening new opportunities for process optimization by utilizing valuable data that was previously locked away. 

With these advantages in mind, ABB has added this innovation to its well-known FSS450 SwirlMaster and FSV450 VortexMaster flowmeters →02, giving them Ethernet-APL connectivity and allowing all the benefits of high-speed field data transmission with none of the safety drawbacks. The technology also saves on costs and complexity since it removes previous limitations on cable length, which made it difficult to establish communication networks across large industrial facilities. ABB’s swirl and vortex flowmeters are the first instruments to have received Ethernet-APL certification from the FieldComm Group. This certification assures superior product quality for process instrumentation, and reliable interoperability throughout industrial communication networks.

Swirl and vortex flowmeters, which are among the industry’s most widely used flowmeters, measure both volume flow and temperature, as well as mass flow and energy flow by tracking key inputs such as pressure. In addition, the devices make it possible for industrial companies to easily and remotely access device health status and maintenance data, thus obtaining valuable diagnostic information.

New possibilities for predictive maintenance

ABB’s unique swirl technology also offers the benefits of minimal installation requirements and superior measurement precision. In addition to supporting the widely adopted FDI standard for configuration, the devices are easily configurable with the integrated web interface – no tools, drivers, or specialized software are required. The screen layout is responsive, adapting automatically to computer screens, tablets, and smart phones.

With the ability to measure volumetric, mass and energy flow, as well as process temperature, the swirl and vortex flowmeters with Ethernet-APL open new possibilities for operators to make operational decisions and carry out predictive maintenance based on real-time data, thus significantly reducing potential errors and downtime. 

By enabling fast access to an expanded array of process and device data, Ethernet-APL also offers benefits for plant operators facing the challenge of gathering data from potentially hundreds or even thousands of devices when combined with ABB’s Ability™ SmartMaster suite. SmartMaster is an asset performance management platform that enables fast troubleshooting, remote diagnostics, non-invasive process analytics, and many other possibilities by combining operational data, engineering data, and IT services. ABB plans to integrate Ethernet-APL technology into all its instruments and is already in the process of doing so.

References
[1] ABB. Merlin, Tilo. How the Ethernet is going to change operations in the field. Available: https://new.abb.com/products/measurement-products/measurement-products-blog/how-the-ethernet-is-going-to-change-operations-in-the-field [Accessed June 7, 2024]
[2] ABB. ABB transforms flow measurement in the field with Ethernet-APL connectivity. Available: https://new.abb.com/news/detail/116352/abb-transforms-flow-measurement-in-the-field-with-ethernet-apl-connectivity [Accessed June 7, 2024]

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