ABB has announced that its SensyMaster FMT400 thermal mass flowmeter has achieved Safety Integrity Level (SIL) 2 certification, enabling its use in safety-critical process applications across industries including chemicals, oil and gas, power and utilities, and industrial gases. The certification, awarded by TÜV SÜD in accordance with the international functional safety standard IEC 61508-2, allows the SensyMaster FMT400 to be directly integrated into automated Safety Instrumented Systems (SIS). These systems are essential components of modern process plants, designed to monitor operating conditions and initiate protective actions when required.
Until now, thermal mass flow measurement solutions were often excluded from safety instrumented applications due to the absence of functional safety certification. The SIL 2 approval enables process engineers to incorporate reliable thermal mass flow measurement into critical safety loops while meeting stringent regulatory and operational requirements.
The SensyMaster FMT400 uses thermal dispersion technology to measure gas mass flow directly. Rather than calculating flow based on gas volume, the device determines the cooling effect created when gas passes over a heated sensor. This proven measurement principle enables accurate monitoring of natural gases and industrial gases while providing continuous self-diagnostics and fault detection capabilities.
For operators managing complex industrial processes, the ability to identify potential measurement failures before they affect plant operations is critical. The SensyMaster’s integrated diagnostic functions support improved plant safety, operational reliability and maintenance planning by providing continuous insight into device condition.
“Tightening regulatory requirements are pushing process plants to require SIL-rated instrumentation across all critical loops,” said Gerrit Weppner, Global Product Manager at ABB’s Measurement & Analytics division. “Achieving SIL 2 certification for SensyMaster reinforces our commitment to delivering safe and reliable instrumentation for industries where functional safety compliance is mandatory. Process engineers can now include thermal mass flow measurement directly into their safety loops, supported by third-party verified failure data.”
The certified flowmeter also supports digital plant strategies through continuous device health monitoring and predictive maintenance capabilities. These features help reduce dependence on manual inspections, improve asset availability and support more efficient plant operations.
ABB is a global technology company specialising in electrification and automation solutions. Operating in more than 100 countries with a workforce of approximately 110,000 employees, the company develops technologies that improve the efficiency, safety and reliability of electrical systems while supporting sustainable industrial and infrastructure development worldwide.
