2News

ProcessPerspectives in Liquid Process Analytics

INGOLDLeading Process Analytics

THORNTONLeading Pure Water Analytics

OpticaltechnologymeetsISMDissolved oxygen sensors based on an optical measurement technique are over-taking other designs as the preferred choice for DO measurement in the pharma industry. Low drift, fast response and less maintenance make optical sensors highly suited to monitoring batch fermentations. The new InPro 6860 i DO sensor adds to this by incorporating the easy handling and predictive diagnostics benefits of METTLER TOLEDO̕s Intelligent Sensor Management (ISM) platform.

This combination of technologies makes the InPro 6860 i the ideal choice for all DO measurement applications across the bio-pharma industry.

LowdriftThe main advantage of optical DO tech-nology is low drift, which is vital for ac-curate DO determination throughout long fermentation runs. When drifting occurs, the InPro 6860 i automatically compen-sates for it, ensuring outstanding mea-surement accuracy.

ShortresponsetimeFast response to changes in dissolved oxy-gen level means early corrective action of out-of-spec conditions.

LowmaintenanceAs the InPro 6860 i has no electrolyte, maintenance is very low. The OptoCap, which contains an oxygen sensitive layer, is the only element that requires periodic replacement. Coating on the

EasyHandling,ExceptionalPerformanceA New Benchmark in DO SensorsTheInPro6860icombinestheadvantagesofopticalmeasurementwith

exceptionalinstallationflexibilityandthebenefitsofMETTLERTOLEDO’s

IntelligentSensorManagement(ISM)technology.TheresultisaDO

probethatoffersunequalledperformanceinbiopharmaapplications.

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OptoCap prevents biofouling, ensuring easy cleaning.

PredictivediagnosticsFailure of a sensor during a fermentation run can lead to total batch loss. ISM pre-vents this by constantly monitoring the “health” of the InPro 6860 i. Historic and current process conditions are used by sophisticated algorithms to determine when sensor calibration and OptoCap re-placement will be required.

The Adaptive Calibration Timer (ACT) and Dynamic Lifetime Indicator (DLI) dis-played on the M800 transmitter and iSense Asset Suite software allow proactive main-tenance. The ACT and DLI provide assur-ance the InPro 6860 i will perform fault-lessly throughout the next batch.

DocumentationattheclickofamouseiSense Asset Suite software for PCs and laptops is the complementary tool for all ISM sensors. iSense and a simple USB connection between computer and sensor open an array of valuable features that greatly enhance sensor management.

Whenever an ISM sensor is connected to iSense, the software records and updates the sensor’s calibration and maintenance history. This data can be easily docu-mented electronically or by print out of a PDF. A user management and electronic logbook allows control and tracking of all activities ensuring a complete documen-tation of your sensor assets over their whole lifetime.

PlugandMeasureISM sensors retain calibration data in the sensor head. When connected to an ISM-equipped transmitter, this information is automatically uploaded and the transmit-ter configures itself appropriately. This Plug and Measure feature means mea-surement point start up is quick and error free.

With the InPro 6860 i dissolved oxygen sensor, METTLER TOLEDO has taken optical DO measurement to a new level.

Find out more at:cwww.mt.com/InPro6860icwww.mt.com/ISM

Dissolved oxygen sensor InPro 6860 i

Publisher/ProductionMettler-Toledo AG

Process Analytics

Im Hackacker 15

CH-8902 Urdorf

Switzerland

IllustrationsMettler-Toledo AG

Uhde GmbH

Icholakov, Aremac, Jgroup

| Dreamstime.com

Subject to technical changes.

© Mettler-Toledo AG 01/12

Printed in Switzerland.

METTLERTOLEDOProcess News 2 3

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commonly employed. However, utilizing conventional pH electrodes can be chal-lenging. Failure of an electrode during fermentation can lead to batch loss and the waste of an expensive reactor. In ad-dition, electrodes must be connected to a particular transmitter, as the transmitter retains the calibration data for a specific sensor. These issues present problems that production technicians would obviously prefer not to have. For one of the world̕s leading biotech companies, METTLER TOLEDO̕s Intelligent Sensor Management (ISM) technology has erased these concerns.

AdvancedsensorforthebiopharmaindustryOur customer uses 2,000 L disposable reactors for the production of specialty biopharmaceuticals. They use METTLER TOLEDO̕s InPro 3253 i SG electrode and M800 transmitter for pH monitoring. The InPro 3253 i is a low-maintenance sensor with pressurized liquid electrolyte. Pres-surization of the electrolyte prevents penetration of the fermentation medium into the electrode̕s reference system, ex-tending its lifetime. Pressurization also ensures constant cleaning of the dia-phragm due to the outflow of a very low quantity of fluid. The electrode features an integral platinum auxiliary electrode (solution ground) which eliminates ground loop problems and allows the sen-sor to simultaneously measure ORP (redox).

On-boardintelligenceThe InPro 3253 i is one of METTLER TOLEDO̕s expanding portfolio of ISM in-struments. Our customer recognized sev-eral benefits of using ISM pH electrodes. Previously, the only indication that a sen-sor was working properly was the slope. With ISM technology, information such as slope, glass impedance and speed of re-sponse are used by a sophisticated algo-rithm that runs on the sensor̕s on-board microprocessor. The resulting Dynamic Lifetime Indicator (DLI) tool predicts the remaining lifetime of the electrode. The DLI is shown on the M800 transmitter as part of the iMonitor display. Other ISM diagnostic tools shown on the iMonitor calculate when maintenance and calibra-tion will next be required.

Greateryield,fewerlostbatchesWith the adoption of METTLER TOLEDO ISM pH monitoring solutions, our cus-tomer has been able to improve measure-ments on over 15 large-scale disposable bioreactor systems. Product yield has been improved, lost batches due to a competitor̕s analog pH sensor have been eliminated, and technicians have greater confidence in their ability to manage the process effectively.

If you want to improve fermentation yield at your facility, go to:cwww.mt.com/InPro3250

GrowthindisposablebioreactorsThe rise of disposable bioreactors since the first models appeared in the late 90s has been dramatic. Current annual growth of 17 % to 20 % is predicted to continue, helped by manufacturers producing larger vessel sizes and adding more technically complex bioreactor technology.

Advantages of using disposable bioreactors for mammalian cell fermentations over conventional bioreactors are numerous, and include: reduced changeover time, multiple product development, increased safety and cleanliness, and higher ROI.

The development of single-use pH and dissolved oxygen analytical sensors for disposable bioreactors faces many techni-cal difficulties, so multiple-use sensors are

pH electrode InPro 3253 i

ReducedBatchLossesin Biopharmaceuticals ProductionMammalian cell fermentation using disposable bioreactors requires

highly reliable analytical sensors. For a major biopharmaceuticals

producer,IntelligentSensorManagementtechnologyhaseliminatedpH

measurement concerns, increased product yield and reduced batch

losses.

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er OxygenAnalysisMadeEasyWith Powerful In-line TDL Sensors

Whenitcomestoprocesssafetyforprotectingtheenvironment,peopleandassets,onlythe

bestequipmentwilldo.METTLERTOLEDO’snewO2solutioncombinestheconvenienceand

easeofuseofanin-linesensorwiththeperformanceofapowerfulgasanalyzer.Withthe

GPro™500,oxygenmeasurementissimplerandmorereliablethaneverbefore.

trial application analytical instrument design, to create a probe that delivers the convenience of an in-line sensor and the level of measurement confidence of a top-line analyzer.

Other TDL gas solutions are of a cross-stack design, meaning that the receiver must be positioned directly opposite the laser source. This causes installation dif-ficulties and requires regular, troublesome realignment. The GPro 500 incorporates a probe that reflects the laser beam back to the receiver in the sensor head, therefore alignment is never required. And because the laser beam travels twice through the gas stream, the optical path length is doubled, resulting in more accurate O2 measurement.

Built-inintelligenceMETTLER TOLEDO’s Intelligent Sensor Management (ISM) technology adds to the features of the GPro 500 by incorporating

predictive diagnostics that continually assess the optical path quality and indi-cate when cleaning is required, before measurements are affected. Other than yearly verification and occa-sional cleaning of the optics, no other maintenance is required. The GPro 500 can be left to provide real-time, continu-ous, accurate O2 measurements, assuring you of operational safety at all times.

The GPro 500 is the ideal choice for oxygen monitoring in process and safety applications.

Discover more about the GPro 500, at:cwww.mt.com/o2-gas

Lasertechnologyforinterference-freemeasurementAn oxygen sensor that provides faster measurement and more accurate data is always going to be of interest to the chemical industry. If it also has a signifi-cantly lower cost of ownership compared with other systems, it makes it a very at-tractive proposition.

METTLER TOLEDO’s GPro 500 represents a leap forward in oxygen sensors. Packed with state-of-the-art technology it offers exceptional measuring performance and easy installation, and requires little or no maintenance.

Tunable Diode Laser (TDL) gas analyzers are a significant improvement over extrac-tive analysis systems. Firstly, no sample extraction or conditioning is necessary. Secondly, they are immune to interference from moisture, dust or background gases. And thirdly, drift is extremely low.

ThebestofbothworldsMETTLER TOLEDO has combined TDL technology with our expertise in indus-

Rugged probe design for in-situ use

METTLERTOLEDOProcess News 2 5

Purge nozzle Modular process adaptions

Laser diode with built-in reference

Laser and detectors in one sensor head

Folded optical path for enhanced accuracy

Applications• Safety control• Refineries• Flares• Oxychlorination in VCM and EDC plants• Vapor recovery systems• Combustion boilers• FCC units

Benefits• Low installation costs• Minimal maintenance• No sample extraction or conditioning required• Measurements unaffected by dust, moisture or background gases• High reliability• Predictive diagnostics for proactive maintenance planning

GPro500sensorshowingkeyfeatures

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itter SensorDiagnosticsOverHART®

New 2-Wire ISM TransmitterTheM4002-wire,multi-parameterISMtransmitterprovidesthehighest

reliabilityandeasiesthandlinginhazardousareaapplications.Advanced

sensor diagnostic tools available over HART or via the transmitter’s

secondanalogoutput,leadtoreducedoperatingcostsandhelpimprove

productivity.

variety of applications. Thanks to the mixed-mode input, which accepts analog or ISM sensors, the M400 offers a unique and smooth technology transition from conventional to digital sensors and pro-vides a future oriented investment in your plant.

QuickandsimplifiedsensorhandlingWith the advanced ISM functionality im-plemented in the M400, the transmitter series provides additional valuable bene-fits. Using METTLER TOLEDO̕s iSense Asset Suite software, sensors can be very accurately pre-calibrated in a convenient location such as a workshop and stored for later use. When a pre-calibrated probe is

connected to the M400, the calibration data is automatically uploaded to the transmitter and the system is ready to measure in a few moments. This Plug and Measure feature minimizes the risk of installation troubles and simplifies sensor commissioning and replacement.

ImprovedprocesscontrolatlowercostMeasurement data and sensor diagnostics tools such as the Dynamic Lifetime Indi-cator (DLI), Adaptive Calibration Timer (ACT) and Time to Maintenance (TTM) can be output to the process control system via two 4 to 20 mA analog output signals. Together with the M400̕s HART commu-nication capability, system integration is easily achieved, enabling more efficient maintenance of the measurement system. Unplanned shutdowns due to unforeseen sensor failure no longer occur, and the resulting increase in process availability and reduced maintenance lead to im-proved productivity and lower operating costs.

Find out more at:cwww.mt.com/M400

OutstandingreliabilityWith its rugged design and approvals for hazardous area use, the new M400 2-wire transmitter series provides operating assurance even in the most challenging conditions. In combination with METTLER TOLEDO̕s advanced Intelligent Sensor Management (ISM) technology, this means the M400 2-wire unit offers greater process reliability in chemical, pharmaceutical and gas phase applications.

FitstoyourprocessThe M400 transmitter is a single-channel unit for pH / ORP, oxygen and conductivity sensors. Its multi-parameter ability en-sures the new series̕ suitability for a wide

M400 transmitter

METTLERTOLEDOProcess News 2 7

2300

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zer AdvancedSodiumAnalyzer

Highest Assurance of Water and Steam PurityReliable, automatic on-line analysis of sodium in water and steam

sampleshelpspreventdamagingcorrosionanddepositsinpowerplant

purewatersystemsandsteamturbines.Thornton’snewsodiumanalyzer

providesthehighestconfidenceinwater/steampurity.

The Thornton 2300Na sodium analyzer offers a new design for a traditional mea-surement for pure water treatment and power cycle chemistry monitoring. This analyzer provides assurance of water pu-rity to minimize corrosion and maximize water production. Early detection of trace contamination is enabled with minimal operator supervision.

EarlydetectionofsodiumcontaminationiscriticalSodium is responsible for corrosion in high-value turbine blades and other parts of the cycle. Early detection of contamina-tion allows time for planning corrective action before condenser leaks enlarge and serious damage occurs. The design of the Thornton 2300Na sodium analyzer is based on extensive instrumentation expe-rience and is optimized to handle these measurement challenges.

The new sodium analyzer uses a particu-larly simple automatic calibration method and also provides the ability to measure grab samples easily, in addition to mea-suring pressurized samples from process streams. Its implementation with an op-erator interface common to other param-eters including conductivity, dissolved oxygen, pH, TOC and ORP makes it espe-cially convenient for installation and op-erator training. According to Thornton’s senior product manager and power indus-try specialist David Gray, “This analyzer’s automatic sensor recognition system is a

ground-breaking measurement and maintenance concept that improves ac-curacy, simplifies sensor handling, en-hances reliability and reduces sensor life-cycle costs.”

Featuresandbenefits:jFully automatic, unattended calibra-

tion assures reliable operation while saving time

jReagent addition confirmation by pH to secure consistent measurement results

jConvenient grab sample measurement for additional samples and quality control checks from other areas of the plant

jSimultaneous display of sodium, ad-justed pH, temperature and calibra-tion progress provides convenient ana-lyzer and sample status at a glance

jChoice of enclosures: fully enclosed and lockable for dirty plant environ-ments or partially-enclosed with ac-cessible controls for clean sample rooms

jFour analog outputs for sodium, ad-justed pH and temperature with choice of scaling to enable full integration into data acquisition or control systems

For more information, visit:cwww.mt.com/pro_power

SodiumleveliskeytowaterpurityIn the power plant, long-term efficient generation depends on minimizing corro-sion and deposition within the steam /water cycle. As a leader in meeting strin-gent deionized water quality requirements with other measurements, METTLER TOLEDO Thornton has expanded its port-folio to include sodium measurement, the key parameter for initiating regeneration of cation exchange resin and for assuring water purity.

2300Na sodium analyzer

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self as a reference. And because the refer-ence system is sealed from the process, there is no possibility of sensor poisoning from chlorine, or diaphragm clogging from salt or impurities. Unfortunately, there is a drawback to this design: pNa / pH electrodes output a very high impedance signal that is easily altered by surrounding electrical equipment. Additionally, the cable between sensor and transmitter acts like a radio antenna, which also affects the signal received at the transmitter and limits the length of cable that can be used. METTLER TOLEDO̕s new InPro 4850 i sensor has solved this issue.

NomoremeasurementconcernsThe InPro 4850 i is a high-quality pNa / pH electrode that is uniquely different to other probes for chlor-alkali use, because the InPro 4850 i outputs a digital signal. The electrode is one of METTLER TOLEDO̕s expanding portfolio of Intelli-gent Sensor Management (ISM) instru-ments. ISM significantly improves sensor handling, reduces the maintenance re-quirement for measurement systems and increases process availability, leading to greater productivity. Central to the way ISM sensors operate is a microprocessor in the sensor head. This digitizes the analog measurement signal which it then ex-changes with the transmitter. Because the signal is digital, it is unaffected by electri-cal interference and remains unchanged, even over very long cable runs.

IncreaseYourChlorineProductionWith a New, Highly Durable pH SensorReliablymeasuringpHlevelsduringchlorineproductionisverydifficult

toachieveconsistently.Forthefirsttime,anewMETTLERTOLEDOsensor

hasremovedthebarrierstoprecise,long-termpHdetermination.Chemical

groupSolvayhasnoticeda“dramaticimprovement”inpHmeasurement.

WidelyusedelementChlorine is one of the most commonly used chemical elements, with uses rang-ing from water treatment to synthesis of PVC to silicon chip manufacture. Produc-tion can be achieved through a number of methods, but the membrane cell process, during which brine is electrolyzed in large cells, is becoming most common for envi-ronmental reasons.

HarshconditionsforpHprobesThe pH level throughout the chlor-alkali process is crucial to maximizing yield and minimizing damage to the expensive membranes that are used in the electroly-sis cells. The combination of chlorine in

the electrolyzed brine, crystallized salt, precipitated impurities and elevated tem-peratures is very demanding on standard pH electrodes. To maintain reliable pH measurements requires regular cleaning and calibrating of electrodes, and even then sensors typically have a short lifetime.

SodiumreferencesolvesoneissuebutcreatesanotherA more reliable alternative to conventional pH electrodes is probes with a hermetically sealed sodium (pNa) reference system. Because the brine concentration in the chlor-alkali process remains fairly static, these pNa / pH electrodes use the brine it-

METTLERTOLEDOProcess News 2 9

InPro 4850 i pH electrode

By combining a sealed reference system with Intelligent Sensor Management̕s digitized signal along with ISM̕s other significant advantages, the InPro 4850 i provides unequalled measuring perfor-mance, requires little maintenance and is exceptionally durable.

“Dramaticimprovement,”saysSolvayWith 17,000 employees and revenue of over 7 billion Euros in 2010, Solvay is one of the world̕s major chemical companies. At their plant in Jemeppe, Belgium, Solvay produce chlorine through the membrane cell process.

Technicians were frustrated with the per-formance of their pH measurement equip-ment and were eager to try the InPro 4850 i electrode. Systems were in-stalled at a number of cells where the anolyte exits. pH measurement is particu-larly problematic here as the brine still contains some chlorine which enters and poisons the reference system of conven-tional pH electrodes.

After a few weeks it was obvious to Solvay technicians that they had found the an-swer to their pH measurement difficulties. The InPro 4850 i sensors were operating flawlessly in the process and the digital ISM signals were unaffected by interfer-ence from surrounding equipment.

Neil Breton, Process Analytical Technolo-gies Engineer at the facility is delighted with the electrodes̕ performance, “Chang-ing to the InPro 4850 i has dramatically improved the reliability of our pH mea-surements. In the past, we were recalibrat-ing some probes every week and changing them every two months. We are now simply checking them every two weeks. To this day, we have never suffered from probe failure.”

If you need durable pH measurement systems at your chlor-alkali facility, go to:cwww.mt.com/pro-chlor-alkali

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M80

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itter EasyTraceability

Keep Track of Your SensorsThemulti-channel,multi-parameterM800transmitterplatformcovers

allmajormeasurementparametersinoneinstrument.Logbookand

usermanagementfeaturesprovideexcellentsensortraceabilityand

operatingsecurity.

Touchscreen technology and the in-tuitive user interface provide incom-parable ease of use. And for the first time, you are able to use both Ingold and Thornton sensors on the same platform.

Find out what the M800 can do for you – go to:cwww.mt.com/M800

You need a record of the performance of your sensors, you have to ensure operating security, and you want to monitor a number of process mea-surements from one point. Now, this is all possible with one transmitter. The M800 combines a wealth of valuable features to make your life with our sensors even simpler.

Your benefits

LogbookandusermanagementTwo levels of user-selectable security restrict access to sensitive menus or functions. For additional security, the internal logbook records the last 250 transmitter operations and alarms.

Multi-parameterandmulti-channelThe M800’s multi-parameter abilities give you greater flexibility, less complexity, and less training and inventory. Two- and four-channel models provide multiple measurements from a single unit.

IntelligentdiagnosticsWith its unique iMonitor predictive diag-nostics functionality, based on METTLER TOLEDO’s ISM technology, the M800 tells you not only what is wrong with a sensor but how to fix it – before an issue arises.

METTLERTOLEDOProcess News 2 11

M800 multi-parameter, multi-channel transmitter

Visit for more informationwww.mt.com/pro

Get in-line with METTLER TOLEDO

Heads– I use the sensor again,tails– I don’t.

Don’tleaveittochance!

No more guessing if a sensor will survive through the next production run. Intelligent Sensor Man-agement’s predictive diagnostics analyze process conditions and sensor health to provide you with accurate information on when sensor replacement will be needed.

c www.mt.com/ISM

IntelligentSensorManagementfromMETTLERTOLEDO

ISM – True Predictive Diagnostics

Mettler-ToledoAGProcess AnalyticsIm Hackacker 15CH-8902 UrdorfSwitzerland