ABB has received SIL 2 certification for its SensyMaster FMT400 thermal mass flowmeter, enabling the device to be deployed in safety-critical applications where thermal mass flow measurement has historically been excluded from Safety Instrumented Systems (SIS).

The certification, issued by TÜV SÜD in accordance with the IEC 61508-2 functional safety standard, allows the flowmeter to be integrated directly into automated SIS architectures used across the chemical, oil and gas, power generation, utilities and industrial gas sectors.

Thermal mass flowmeters measure gas flow by monitoring the cooling effect of a flowing gas across a heated sensor rather than calculating volumetric flow. The technology provides direct mass flow measurement for natural gas and industrial gases while continuously monitoring sensor health through built-in diagnostics.

Functional safety certification has traditionally been a limiting factor for incorporating thermal mass flow measurement into safety loops. With SIL 2 certification, process engineers can now specify thermal mass flow instrumentation in applications requiring independently verified safety performance.

"Tightening regulatory requirements are pushing process plants to require SIL-rated instrumentation across all critical loops," said Gerrit Weppner, global product manager for ABB's Measurement & Analytics division. "Achieving SIL 2 certification for SensyMaster reinforces our commitment to delivering safe and reliable instrumentation to industries where functional safety compliance is mandatory. Process engineers can now include thermal mass flow measurement directly into their safety loops, with third-party verified failure data."

In addition to supporting functional safety requirements, the SensyMaster FMT400 incorporates continuous self-diagnostics that enable predictive maintenance and real-time device health monitoring. ABB says these capabilities help reduce manual inspections, improve equipment availability and support digital plant initiatives focused on operational reliability.

As manufacturers continue expanding digitalization and automation strategies while meeting increasingly stringent safety and regulatory requirements, certified instrumentation capable of delivering both process measurement and diagnostic capabilities is becoming an increasingly important component of modern process control systems.