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A smart and safe way to monitor rotating machines in hazardous areas
03 September 2020
Operators can now carry out remote real-time health checks on rotating machines operating in hazardous areas following the introduction of a new type of ABB Ability Smart Sensor.
Ensuring the new sensor would comfortably survive in such environments placed extreme design demands on the device, which needed to:
• Measure high-frequency vibrations
• Demonstrate physical resilience against harsh and hazardous ambient conditions
• Have a lifetime that matches that of most monitored equipment, with one non-replaceable and non-rechargeable battery
• Use a flexible firmware architecture to accommodate different product needs in the future
The new smart sensor for rotating machines extends the existing scope, particularly supporting the condition monitoring of applications in chemicals, oil and gas, mining and food and beverage.
The wireless smart sensor monitors key parameters to provide detailed insights into the performance and health of assets such as motors and pumps. Equipment installed in difficult or dangerous to access locations can be safely monitored from a distance. Combining connectivity and data analytics means operators can plan their maintenance activities in advance, reduce downtime and extend equipment lifetime.
The new generation of smart sensors provide highly accurate data to enable ABB’s advanced analytics to be used in hazardous areas. These smart sensors are more sensitive which allows customers to see problems earlier. They also offer more monitoring capabilities, a broader communication range and exceptional battery life.
The sensor benefits from a design effort that introduces some features that significantly improve the operator’s experience: easy-to-use sensor commissioning through NFC (near-field communication) activation, extended battery lifetime and improved antenna design for optimal wireless communication.
Extended battery life
The sensor offers a battery life of up to three times longer than most competing designs. It is sealed for life, with an IP66/67 rating, and can be mounted directly to the equipment in a matter of minutes using a simple mounting bracket.
Improved antenna design
The sensor communicates with smartphones, tablets, PCs and plant gateways using low energy Bluetooth or WirelessHART. A new antenna design extends its range by a factor of three to four, meaning that reliable communication over distances of a few hundred meters (line of sight) is now achievable.
Wider data range
Another crucial upgrade is that the sensors have greater sensitivity to small changes in the condition of the equipment, including advanced warning of bearing damage. This capability to generate a much wider range of data is matched with state-of-the-art integrated electronics that incorporate advanced algorithms based on ABB’s vast experience in electric motors. This helps operators and maintenance teams produce insightful information to predict potential failure, enabling remedial action to be taken before a breakdown occurs.
Hazardous-area certification
The new smart sensor is a technological success that measures vibrations with an accuracy higher than that of all previous smart sensors. Hazardous-area certification (ATEX and IECEx: Zone 0, Zone 20, Class I Division I and Class 2 Division I) for this extremely sturdy sensor has been granted. Other certificates will follow over the coming year.
In summary, the latest sensor offers comprehensive cybersecurity features, flexible firmware platform, optimised performance, and real-world control and evaluation of power consumption. These enhancements bring even more value to customers and make the new ABB Ability Smart Sensor for hazardous environments the de facto standard for condition monitoring of rotating equipment.
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