⚙️ A technical summary of thermal flow measurement with safety functions
ABB announced that its SensyMaster FMT400 thermal flow meter has obtained SIL 2 certification, enabling its use in critical applications that rely on functional safety standards, especially in the chemicals, oil and gas, energy, and industrial gases sectors.
This step is important because it allows thermal flow measurement to be integrated into Safety Instrumented Systems (SIS), which was not previously possible due to the lack of functional safety certifications.
SensyMaster is distinguished by highly accurate mass flow measurement for gases, along with continuous self-diagnostic features, which support predictive maintenance and enhance operational reliability in industrial facilities.
🔥 The importance of SIL 2 certification in critical industrial applications
The SIL 2 certification is an internationally recognized standard under IEC 61508-2 that ensures equipment and systems are capable of operating safely in environments that require safety-critical functions. The SensyMaster FMT400 device receives this certification from the independent assessment body TÜV SÜD, which raises confidence in reliability and safety during process control applications in plants.
This meter is typically used in fields that require extremely precise gas monitoring, such as:
- Chemical plants.
- Oil and gas sectors.
- Power plants and utilities.
- Industrial gas manufacturing.
The certification allows the device to be directly introduced into SIS systems, which are one of the fundamental pillars of automation engineering for industrial processes to ensure safety.
🔧 How SensyMaster works for thermal mass flow measurement
SensyMaster is based on a technical principle that measures the mass flow of gases in a different way from traditional volumetric flow meters. Instead of measuring the volume of flowing gas, the thermal sensor measures the amount of cooling that occurs to a small heating element through which the gas passes.
This principle means that:
- Flow is measured directly on a mass basis rather than by volume, which is more accurate when dealing with gases.
- The change in sensor temperature is the primary indicator of the gas flow rate.
- The device is capable of operating accurately with multiple types of industrial and natural gases.
The major advantage here is the presence of a continuous self-diagnostic system that monitors the device’s condition and detects any early faults. This feature is essential to prevent incidents that could threaten worker safety or the work environment.
🏭 Integration with automation control systems and safety systems
Integrating flow meters into Safety Instrumented Systems (SIS) is considered a cornerstone in automating sensitive industrial processes. These systems monitor and control thermal and mechanical processes, and automatically take safety actions when a malfunction occurs.
Previously, when thermal flow measurement was used, it was not included in SIS because strict safety certifications for the device were unavailable. Now, the SIL 2-certified SensyMaster enables process engineers to integrate thermal flow measurement directly into safety loops, providing reliable data and continuous monitoring.
- Supports safe control and operation in thermal plants and factories.
- Flow data can be linked with digital maintenance systems to enhance predictive maintenance.
- Helps improve energy efficiency and reduce risks.
🚗 Supporting predictive maintenance and improving operational reliability
SensyMaster includes advanced self-diagnostic systems that support modern industry trends in digital maintenance. This makes the following possible:
- Detecting faults early before they develop into critical failures.
- Reducing reliance on routine manual inspection.
- Extending equipment life through precise and targeted maintenance.
- Increasing available uptime and reducing downtime.
These capabilities are especially important in gas plants and distribution facilities, where accuracy and continuity are decisive factors in operations and efficiency.
🏭 ABB’s role in developing mechanical and thermal systems in factories
ABB is considered one of the global leaders in automation and industrial electrification, combining digital engineering and process automation to deliver effective and sustainable solutions that increase factory performance and reduce resource consumption.
With more than 140 years of experience and around 110,000 employees, ABB provides a diverse range of solutions covering sectors such as:
- Power generation.
- Manufacturing.
- HVAC systems.
- Industrial control and process automation.
The SensyMaster device receiving SIL 2 certification reflects ABB’s commitment to meeting high engineering requirements for functional safety in critical process environments.
🔍 Conclusion
The SIL 2 certification obtained by the SensyMaster FMT400 thermal flow meter represents a qualitative leap in the ability of process engineers to integrate thermal mass flow measurement directly into SIS safety loops. This enables precise and safe application in critical industrial environments, with continuous support for modern maintenance strategies based on intelligent self-diagnostics.
These developments position thermal flow measurements as a key element in advanced and reliable control of thermal and mechanical systems in the chemical, energy, and gas industries.
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