6News

ProcessPerspectives in Liquid Process Analytics

INGOLDLeading Process Analytics

THORNTONLeading Pure Water Analytics

HighAPIQuality,LowMaintenanceAt Teva PharmaceuticalsProductqualityisofparamountimportancetoTevaPharmaceuticals.So

when its Czech subsidiary required in-line pHmeasurement for API

production,itturnedtoMETTLERTOLEDO.Now,APIqualityishigherplus

thepHsystemlooksafteritself.

BiggestproducerofgenericsWith an annual production of 73 billion tablets and capsules from over 70 manu-facturing sites, Israelʼs Teva Pharmaceu-ticals Industries Ltd. is one of the top ten pharmaceutical companies in the world and is the largest manufacturer of generic pharmaceuticals. Teva Pharmaceuticals CR, s.r.o., is a subsidiary of Teva in the Czech Republic. Its plant in Galena pro-duces a wide range of final products but the main focus is on API production.

LabmeasurementsarenottimelyIn one of the API production lines acid is gradually added to an alkaline API solu-tion in order to precipitate API crystals from the liquid. Grab samples and lab measurements were being used to deter-mine when sufficient acid had been dosed.

This method was time-consuming for personnel and Teva decided to acquire an in-line system that would allow automatic control of acid dosing and which would be simple to maintain.

Advancedin-linesolutionThe nature of the API production process posed a few issues for in-line pH measure-ment. Firstly, the large glass-lined reac-tion vessels cannot support side-entry installation of pH sensors and due to the height of the vessels, top-entry would be problematic. Secondly, precipitation of the API during the process would quickly coat an in-line sensor, necessitating regular cleaning.

METTLER TOLEDO proposed a measure-ment solution that would not only operate

2 METTLERTOLEDOProcess News 6

reliably in the conditions, but would also allow Teva technicians to monitor sensor “health” so that any sensor issues could be rectified before measurements were affected.

RobustsensorInPro 3100 i UD is a pH sensor specifically designed for pharmaceutical use. The “UD” suffix means that the InPro 3100 i can operate upside-down and therefore can be installed in the underside of process vessels.

ModulartransmitterThe M700 is a multi-parameter, two-channel transmitter. Three module slots allow it to be configured with two mea-surement parameters plus a choice of communications protocol. It can also

control the EasyClean 400 system men-tioned below.

AutomaticsensorcleaningsystemEasyClean 400 provides fully automatic pH sensor cleaning and calibration. It offers multiple control possibilities and can be extensively programmed for a broad range of application conditions and user requirements. In combination with the M700 transmitter and InTrac 777 e housing, it provides a highly flexible sys-tem for use with batch or continuous measurements.

RetractablehousingThe InTrac 777 e housing features an in-ternal flushing chamber for sensor clean-ing without interrupting the process. The Tri-Lock™ safety system prevents escape

of process and cleaning fluids, even when installed upside-down.

IncreaseduptimeThe InPro 3100 i UD and M700 transmitter feature METTLER TOLEDOʼs Intelligent Sensor Management (ISM®) technology. ISM simplifies sensor handling, enhances process integrity, and reduces sensor life-cycle costs. Plug and Measure ensures fast, error-free system start up, and predictive sensor diagnostics provide real-time data on sensor condition. This allows proactive maintenance leading to greater measure-ment point uptime.

ConsistentqualityandminimalmaintenanceThe complete METTLER TOLEDO solution has made a significant difference to Tevaʼs process: API quality is consistently high, sensor cleaning and calibration are con-ducted automatically, and when ISM indi-cates sensor replacement is required, thanks to Plug and Measure it is a quick and simple procedure. Teva now have plans to install similar systems elsewhere in its Galena facility.

Discover more at:cwww.mt.com/ISM-pharma23

Publisher/ProductionMettler-Toledo AG

Process Analytics

Im Hackacker 15

CH-8902 Urdorf

Switzerland

IllustrationsMettler-Toledo AG

Datwyler Group

Sivanagk, Robertmonsuuni, Nostal6ie |

Dreamstime.com

Subject to technical changes.

© Mettler-Toledo AG 08 / 14

Printed in Switzerland.

METTLERTOLEDOProcess News 6 3

M40

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allow a higher level of asset management that can significantly reduce operating costs.

As an example, a fieldbus can simplify the collection of device data for Plant Asset Management systems that track the condi-tion of the connected field devices and sensors. METTLER TOLEDO, as a manu-facturer of intelligent sensors and trans-mitters, rose to the challenge of providing real-time information on the installed sensor base.

RemotediagnosticsavoidneedlessmaintenancetripsWe fulfill this requirement with our unique Intelligent Sensor Management

(ISM®) technology. Contrary to conven-tional analog sensors, digital ISM sensors offer flexible integration of key diagnostics data into control systems for remote monitoring. Besides the transmission of the process variables via common com-munication protocols, sensor identifica-tion as well as the diagnostics can be directly accessed via control systems or standard asset management tools. Due to this direct access to information on field-bus instruments, unnecessary trips to the field can be avoided.

M400–acommonplatformforallapplicationsOur successful M400 transmitter series exemplifies our commitment to continu-ous improvement in order to meet cus-tomer requirements, especially in the area of digital communication.

The M400 is already available with HART and FOUNDATION fieldbus communica-tion protocols. Now, we have completed the portfolio with the introduction of our PROFIBUS PA version.

The M400, for all process industries, pro-vides excellent reliability and reduced total cost of ownership by offering diag-nostic utilities and a wide range of com-munication capabilities.

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

FieldbusesareprolificThe adoption of fieldbuses in the world of automation continues to grow rapidly across all process industries. It is a very well accepted technology and is installed by all major manufacturers worldwide.

Benefits including reduced wiring and installation costs are obvious. Less appar-ent are the long-term advantages of fieldbus networks that become clear many months after a facility has been commis-sioned. According to research by the ARC Advisory Group, the greatest benefits of fieldbus networks are realized in relation to maintenance and operation. This means fieldbuses themselves are often not a lasting cost-saver directly, but merely

NowforAllMajorBusNetworksthe M400 TransmitterByenablingreal-timemonitoringofsensorassets,fieldbusnetworkscanaddlong-term

value toproduction facilities.With theM400seriesofmulti-parameter transmitters,

advancedsensordiagnosticsinformationisavailableoverHART®,FOUNDATIONfieldbus™

andnowPROFIBUS®PA;helpingtoimproveprocessreliabilityandsafety,andlowering

operatingcosts.

HighlightsoftheM400PA• PROFIBUS PA communication• Covers wide range of parameters

including (optical) dissolved oxygen

• Multi-parameter capability re-duces inventory

• Mixed mode for easy transition from analog to ISM technology

• Available approvals for hazard-ous area use: NEPSI, ATEX / IECEx Zone 1.

4 METTLERTOLEDOProcess News 6

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LessComplexity,LessMaintenance,LessRiskLaser-Based Oxygen Analyzer Does It AllParamagnetic oxygen analyzers usedwith sample extraction and conditioning systemsmeasure

reliably,butmaintainingtheirperformancecanrequireagreatdealofmaintenance.ForoneofBrazil’s

major chemical facilities, switching to tunable diode laser (TDL) technology has simplified the

measurementsystem,reducedmaintenance,andincreasedprocesssafety.

One chemical company operating in Brazil is part of a major international player in the global chemical industry. At a facility in Southern Brazil a paramagnetic ana-lyzer with an extraction and conditioning system was being used to measure O2 levels in the off-gas of an oxidation column. Although the system measured depend-ably, it required frequent maintenance to keep it operational which involved taking the measurement off-line.

Also, there existed the possibility of cata-strophic failure of the system as the mea-suring cell of these analyzers is rendered useless if moisture enters them. Such an event would lead to extended downtime of the process and a high cost to restore the measurement.

TunablediodelaseranalyzersofferamajorimprovementThe expense of regular maintenance and worry over system failure led to the com-pany looking to replace the existing system with a tunable diode laser (TDL) solution. TDL analyzers are usually used in situ without the need for sample extraction or

conditioning. They achieve very accurate measurement of the target gas by analyz-ing the absorption of laser light that passes through the gas matrix. Nitrogen is used as a purge gas to keep moisture as well as dust away from the analyzerʼs optical windows, and there is no possibility of moisture or dust entering the instrument.

Commonly, TDLs are of a cross-stack de-sign, meaning that the unit that outputs the laser light is installed opposite the unit that receives and analyzes it. For this sys-tem to operate dependably the two parts must be very carefully aligned. Maintain-ing alignment can be difficult as changes in process temperature can cause the stack to warp, resulting in misalignment and a consequent drop in measurement integrity.

TheGPro500TDLticksalltheboxesMETTLER TOLEDO offers a TDL solution that not only eliminates the alignment problem, but also simplifies analyzer in-stallation and maintenance. The GPro 500 series of O2, CO, and moisture analyzers

ChemicalcompanystruggleswithparamagneticanalyzerBrazilʼs chemical industry is the 7th largest in the world. But, over recent years demand has outstripped production and imports of chemicals have been growing. In order to reverse the trend Brazilian chemical com-panies are investigating how to increase productivity while at the same time reduce operating costs and maintain process safety. To help achieve this they are look-ing to technical advances in production equipment.

METTLERTOLEDOProcess News 6 5

uses a unique design whereby the laser light emitted from the sensor head travels down a probe that is open to the process gas and is returned by a retroreflector back through the gas to a receiver which is also within the analyzerʼs head. This design means that alignment of the analyzer is not required, even if the process involves a significant temperature ramp.

As sender and receiver are in a single in-strument, only one flange needs to be in-stalled into the duct, greatly simplifying installation. A range of unique process adaptions (such as the wafer cell for very narrow pipes) significantly increases the range of applications for the GPro 500 se-ries.

AlmostzeromaintenanceandlowrunningcostsVerification of the GPro 500 is necessary only once a year, on average. And as the analyzer can be detached from the probe (which remains installed in the process) there is no downtime associated with ana-lyzer maintenance.

Compared with cross-stack TDLs, the run-ning cost of GPro 500 analyzers is very low due to the probeʼs narrow diameter, mean-ing far less purge gas is required. Of greater importance to plant managers is the GPro 500ʼs fast response (< 2 seconds), which improves process safety by rapidly identifying any increase in target gas levels.

Trouble-freeoperationSatisfied that a GPro 500 O2 analyzer would provide the accuracy and reliability needed, the chemical company installed a unit in the aforementioned oxidation col-umn in late 2013. The company reports that it has been providing dependable, trouble-free oxygen measurement since then.

The success of the GPro 500 in this ap-plication encouraged the plant operators to install two further units: at the entrance of the oxidation column and in a hydroge-nation process, and further installations are being considered.

Discover more about the GPro 500 at:cwww.mt.com/chem23-TDL

Best Practice

GasApplicationsforGPro500Analyzers

The GPro 500 series of O2, CO, and moisture analyzers is designed for ease of installation and low main-tenance operation in a wide variety of process applications.

This complimentary eBooklet is a convenient reference to a selection of the most common GPro 500 applications.

Download your copy today.

cwww.mt.com/GPro500-ebook

Free Guide

6 METTLERTOLEDOProcess News 6

2800

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r KeepingSilicaatBaywith a Low Maintenance AnalyzerSilica in boiler feedwater can lead to unplanned shutdownsandextramaintenance.

Brazil’sbiggestpaperandpaper-basedpackagingcompanyhasswitchedtoaMETTLER

TOLEDOsilicaanalyzer.Itsaccuracy,lowmaintenance,andeasyoperationaresaving

themmanymanhours.

unchecked increased silica build-up can result in unplanned shutdowns and extra maintenance.

PpblevelmeasurementsarerequiredSilica is in all water supplies and requires membrane separation and ion exchange for its removal. Direct, continuous silica measurement is the most effective means to protect against contamination from silica escape due to spent anion resin.

Silica is always present in cooling water so ppb level silica measurement provides excellent sensitivity in detecting small

condenser leaks and for monitoring con-centration of silica in the water / steam cycle.

Moreover, a growing number of turbine manufacturers are requiring ppb level silica limits in incoming steam as a war-ranty condition.

Time-consumingmaintenanceoncompetitor’sinstrumentA competitorʼs silica analyzer was installed at the power plant to monitor boiler feed-water, but its performance was not as good as instrument engineers were hoping for and it required regular, time-consuming maintenance. Having heard of METTLER TOLEDO Thorntonʼs 2800 Si Silica Ana-lyzer, the engineers asked for a demonstra-tion unit to gauge the analyzerʼs capa-bilities and maintenance requirement.

OptimizeddesignmeetssilicameasurementchallengesThe 2800 Si is a highly reliable on-line instrument designed for power cycle chemistry monitoring. It provides early detection of trace silica contamination with minimal operator supervision. In addition, the 2800 Si allows unattended automatic calibration at a user-configured interval. Its large-volume reagent con-tainers enable long-term operation before refilling becomes necessary.

HighlydamagingdepositsBrazilʼs largest producer of paper and paper-based packaging, exports its prod-ucts to over 70 countries. It has 14,000 direct and indirect employees across its 16 plants. At one of these, power plant engi-neers were having problems with silica deposition.

Silica has no significant corrosive effect on boilers, but its presence in water / steam is nonetheless very detrimental. It forms extremely hard coatings in water / steam passageways and on turbine blades lead-ing to reduction in heat transfer efficiency and unbalanced turbine blades. If left

METTLERTOLEDOProcess News 6 7

ImpressiveperformanceOver the test period, plant engineers were delighted not only with the analyzerʼs measurement accuracy, but also with its trouble-free operation and low mainte-nance. They also highly appreciated the

installation in early 2014, the analyzers have performed without any issues and their reliable data has led to improved production efficiency.

Featuresandbenefits• Large reagent containers enable a long

service interval and reduce mainte-nance time

• The full enclosure safely protects re-agent containers and components from the plant environment

• Simultaneous display of silica and measurement timing provides conve-nient analyzer status at a glance, sav-ing operator time

• Continuous reaction chamber temper-ature monitoring ensures reliable operation

For more information visit: cwww.mt.com/Thornton-silica

2800 Si Silica Analyzer

automatic calibration feature which would save them many man hours.

After the successful test, three 2800 Si Analyzers were ordered for the paper plant. Instrument engineers report that since

8 METTLERTOLEDOProcess News 6

PurifiedWater

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HighConfidenceinWFIQualityfor a Leading Supplier of Pharmaceutical SealsToensurecleanlinessofsealsandenclosuresforpharmaceuticaluse,theyarerinsedinWater

forInjection.TechniciansatDatwylerGroup’sItalianproductionfacilitybecamefrustratedwith

theunreliableperformanceoftheirtotalorganiccarboninstrumentwhichwascausinguncertainty

overWFI quality. Their search for a dependablemeasurement led them toMETTLER TOLEDO

Thornton’s5000TOCi.Now,TOCmeasurementisaccurateandfast.

ceptionally clean, the seals are washed with WFI. Facility technicians need to be confident that the water from the WFI system is always within specification. Total organic carbon (TOC) is a vital in-dicator of water purity, and to be consid-ered WFI its level must be no higher than 0.5 mg C / L.

Datwyler were using an on-line TOC in-strument to monitor WFI quality and regularly noticed that TOC levels were higher than permissible. However, lab measurements always indicated that TOC was below the threshold value. Further investigations revealed that trace sub-stances, not detrimental to the WFI, were causing the on-line sensor to report inac-curate readings.

On-linebeatslabmeasurementsDatwyler strongly prefer on-line measure-ments to those from the lab as they mini-mize the risk of contamination and provide real-time data, allowing any required corrective action to be conducted quickly. Because the existing system was consis-tently reporting erroneously high TOC levels, technicians could never be certain of the WFI quality without conducting lab

measurements. As a result, facility man-agers began looking for a new solution. They were resolute in finding a sensor that would not only be dependable, but would also provide rapid TOC analysis and be easy to maintain.

ImmunetotracecontaminantsMETTLER TOLEDO Thornton introduced them to our 5000TOCi Sensor. This device accurately determines TOC by first mea-suring the conductivity of the sample water. Next, the sample passes through a glass coil where it is exposed to ultraviolet light which breaks down any organic material in the sample. This causes an increase in the sampleʼs conductivity which is then measured by a second con-ductivity sensor. The difference between the two conductivity readings correlates to the TOC level in the WFI.

We provided a 5000TOCi for Datwyler to test. Within a month, facility technicians were confident in the sensorʼs ability to measure TOC quickly and accurately without being affected by the trace sub-stances in the WFI. However, reliability was not the only aspect of the sensor that impressed them.

GlobalsupplierofsealingproductsSwitzerlandʼs Datwyler Group is a leading producer of sealing solutions for a wide variety of industries. They are the worldʼs second largest supplier of rubber and aluminum closures for pharmaceutical use. In the companyʼs Pharma Packaging facility near Milan, Italy, Datwyler manu-factures rubber parenteral components for sealing glass vials and flasks.

WFImustalwaysbewithinspecTo ensure their finished products are ex-

METTLERTOLEDOProcess News 6 9

PredictivediagnosticsforproactivemaintenanceThe 5000TOCi features METTLER TOLEDOʼs Intelligent Sensor Management (ISM®) technology. ISM is an innovative concept for process analytical measure-ment solutions that simplifies sensor handling, enhances process integrity, and reduces sensor lifecycle costs. ISM features in the 5000TOCi include advanced diag-nostics that predict when maintenance will be required. Advance notice of main-tenance means that it can be scheduled for a suitable time rather than having to take the sensor off-line after a failure has al-ready occurred. In addition, the sensor stores up to four calibration and system suitability test (SST) reports, further simplifying maintenance.

NomorelabtestingA 5000TOCi was purchased and installed and is now providing Datwyler with a level of confidence in their TOC measurements that they never had before. So much so, they no longer conduct lab measurements.

If you need continuous and reliable TOC measurements, go to:cwww.mt.com/toc

Highlightsofthe5000TOCiSensor

• Meets USP < 643 >, < 645 >, EP 2.2.44, Ch P and JP 16 requirements for

the pharmaceutical industry

• Drastically reduces record keeping through simplified data collection with

innovative Peak and Average TOC measurements

• Improves the quality and reliability of calibration and System Suitability

Testing (SST)

• Interfaces with the M800 multi-parameter analyzer / transmitter

10 METTLERTOLEDOProcess News 6

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rs NoClogging,NoMaintenanceJust Accurate Conductivity Measurement

METTLERTOLEDO’sinductiveconductivitysensorscombinehighperformancewith

lowmaintenance.Theelectrodelessdesignprovidesveryaccuratemeasurementin

mediumtohighlyconductingprocessfluids–nomatterhowharshtheconditions.

METTLER TOLEDO’s InPro 7250 in-ductive conductivity sensors never clog and are highly resistant to coat-ing. Their robust design ensures maintenance- and trouble-free operation.

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

Conductivity sensors are invaluable in monitoring industrial wastewater, and acid and caustic concentrations in chemical processes. However, standard designs can easily become clogged, necessitating regular cleaning.

Your benefits

WidemeasurementrangeHigh linearity from 0 to 2000 mS / cm for process control across a wide range of applications.

EasyinstallationA variety of process adapters allows sim-ple installation into almost every type of process.

ChoiceofbodymaterialsAvailable in PEEK for very aggressive chemical environments or in PFA where strong acids are present.

METTLERTOLEDOProcess News 6 11

InPro 7250 inductive conductivity sensors

Get in-line with METTLER TOLEDO

Visit for more informationwww.mt.com/pro

AskanExpertJim Knows Best

Industry expert Jim Cannon can help you with your questions regarding pharma-ceutical waters regulations, applications, and calibration.

cwww.mt.com/jim-knows-best

CostSavingsCalculatorfor pH and DO Systems

Find out how much time and money you can save by switching to Intelligent Sensor Management (ISM®) pH and dissolved oxygen measurement systems.

cwww.mt.com/ISM-pharma-calc

ComplimentaryGuideWater Compliance for Global Pharmacopeia Requirements

In this free guide we review the upcom-ing requirements of USP < 645 >, USP < 643 >, and the acceptable cali-bration methods and procedures that support the advantages of on-line testing.

cwww.mt.com/tho-compliance-guide

Mettler-ToledoAGProcess AnalyticsIm Hackacker 15CH-8902 UrdorfSwitzerland