INGOLDLeading Process Analytics

For chemical, pharmaceutical, biotechnology and all

other process industries, maintaining high product

qualitywhileimprovingprocesssafetyandcontrolling

operating costs is a constant challenge. Increased

maintenancerequirementsforsensorsandunplanned

production downtimes resulting from the failure of

measurementtechnologyaresubstantialcostfactors.

Cutting-edge analytical measurement systems help

ensureproductqualityandyield,enhanceprocessreli-

abilityandreducesensorlifecyclecosts.

IntelligentSensorManagementThe Power of ISM

Whi

te P

aper

Improving manufacturing plant efficiency is vital to successful business operations. Part of that endeavor is ensuring production equipment is operating correctly and is well maintained. This is as true for analytical measurement systems as it is for any other plant asset. Failure to properly maintain measurement systems can have a significant impact on efficiency and production costs. Reduced product quality, batch failure or unplanned downtimes can easily result from poorly calibrated, dirty or failed sensors. However, supporting an effective maintenance regime is a time consuming burden on skilled staff. The answer is intelligent process analytic systems that can not only monitor themselves for wear and advise operators when maintenance is required, but that also improve process safety.

Intelligent Sensor Management (ISM) is an innovative technol-

ogy for all major process parameters that combines many fea-tures into a unique solution. One that is tailorable and adaptable to specific industry and production plant needs. ISM improves maintenance management and diagnostics, which translates into increased process safety and reduced operating costs.

DigitaltechnologyThe basis of ISM is a microprocessor in the head of the measur-ing sensor. This monitors the data coming from the measure-

Stableproductqualityandgreaterprocesssafetyatlowercost

2 METTLERTOLEDO

Inte

lligen

t Sen

sor M

anag

emen

t

ment tip and also retains calibration information. The integrated chip converts the measurement data to a digital signal which it exchanges with the connected transmitter. Not only is the digital measurement signal more precise than an analog signal, it is unaffected by moisture or cable length, guaranteeing accurate measurements are always received by the transmitter. From this foundation a wide range of features provides a wealth of tailor-able system possibilities.

PlugandMeasure–fastandsimplemeasurementWhen sensor replacement is required it may take a skilled opera-tor twenty minutes to calibrate and configure a new sensor. With ISM, sensors can be pre-calibrated via computer in a convenient location and stored for later use. Further, when connected to the transmitter, due to the configuration data held on an ISM sensor, the new sensor is instantly recognized. Now when an exchange of sensor is needed, the Plug and Measure functionality means a pre-calibrated sensor can be installed and be ready to measure in under a minute, therefore substantially increasing production capacity by avoiding longer interruptions, and allowing opera-tors to concentrate on more critical tasks.

PredictivemaintenanceDuring batch processes, the failure of a measuring sensor can be hugely detrimental. Ideally, operators want to know that a sensor will operate correctly until the batch is complete. ISM technology is able to provide expert diagnostic information that is particular to each measuring point. This information is available to opera-tors via the display on many METTLER TOLEDO transmitters in a detailed and yet clear manner.

The diagnostic tools allow a measurement point to be optimized on an ongoing basis and all critical situations to be predicted so that operators can respond before production is interrupted. One of the most useful diagnostic features offered by ISM is the Dynamic Lifetime Indicator (DLI).

Usethesensorordiscardit?The DLI provides operators with an indication of how much the exposure to the process has altered a sensor’s condition. In the case of pH electrodes, by constantly analyzing a probe's slope, impedance, the process conditions themselves and other factors the DLI calculates the remaining lifetime of the sensor. Sensors with a low expected lifetime can be replaced preemptively before they fail during operation, resulting in less frequent unsched-uled downtimes. As a result, the plant’s maintenance strategy can be changed from a passive, costly and unpredictable work-flow to a fully proactive, safe and controlled procedure.

ElectronicdocumentationandassetmanagementOptimizing the performance of analytical sensors enhances their reliability, improves process safety and reduces operating costs. iSense Asset Suite software offers accurate verification and calibration of ISM sensors in a maintenance shop. Calibration information is collected, managed, analyzed effi-ciently and documented consistently to satisfy regulatory re-quirements. The electronic user management logbook allows control and tracking of all sensor activities ensuring complete documentation of ISM assets over their whole lifetime.

The DLI and other vital sensor data is also viewable on iSense. Now you have a single point which records the condition of your installed sensor base. Asset management ensures you always have sufficient stock of healthy sensors and allows you to opti-mize maintenance planning.

TailorableRequirements between industries can vary significantly, and one of the major benefits of ISM is that system functionality can be modified to meet specific industry needs.

For the pharmaceutical and biotech industries the accuracy of calibration that ISM provides, plus comprehensive sensor trace-

3METTLERTOLEDO

ability via electronic documentation, are of importance. Whereas in the chemical and petrochemical industries it is the ability to pre-calibrate in a maintenance shop and optimized mainte-nance management for improved process reliability and reduced maintenance costs that are of greater value. Further, as men-tioned above, diagnostic tools can be modified for each measur-ing point to accommodate the conditions of individual processes.

Whether you operate in biopharma, chemical, refining, or food and beverage, ISM offers a solution to meet your needs.

AdaptiveA further significant benefit of ISM is its adaptability to indi-vidual plant control system requirements. Fieldbus integration via transmitters, direct integration using digital to analog con-verters and a variety of wireless solutions are all available. This means ISM solutions are compatible with legacy installations as well as the latest Ethernet-based technologies.

A range of advanced multi-parameter, dual-channel and mixed-mode (accepts digital or analog sensors) transmitters further ensure the adaptability of ISM solutions to your requirements.

The invaluable diagnostic data that ISM provides does not stop at the transmitter. Seamless integration into control systems

Inte

lligen

t Sen

sor M

anag

emen

t

Spider diagram provides clear sensor diagnostics on the M700 transmitter

DynamicLifetimeIndicator(DLI)The Dynamic Lifetime Indica-tor estimates in real-time the remaining lifetime of the sensor. A unique algorithm uses actual and historic measurement and calibration values to calculate a real-time lifetime indicator.

AdaptiveCalibrationTimer(ACT)Based on the above algorithm the sensor predicts the time until the next calibration will be needed.

TimetoMaintenance(TTM)The sensor also indicates when you will have to perform the next maintenance.

CIP/SIPCounterCIP and SIP cycles are interpreted with a proprietary, patented algo-rithm.

CalibrationHistoryCalibration history is stored in the sensor and can be used for diagnostics.

MaximumTemperature/OperatingDaysIndicator�Information about the maximum temperature the sensor has ever been exposed to and the number of operating days.

TTMTime to Maintenance

DLIDynamic Lifetime Indicator

ACTAdaptive Calibration Timer

TTMTime to Maintenance

DLIDynamic Lifetime Indicator

ACTAdaptive Calibration Timer

TTMTime to Maintenance

DLIDynamic Lifetime Indicator

ACTAdaptive Calibration Timer

CIPCIP/SIP Counter

00/NNMax. °CDays of operation

MAXMax. Temperature/ODI

Calibration History

CAL

CIPCIP/SIP Counter

00/NNMax. °CDays of operation

MAXMax. Temperature/ODI

Calibration History

CAL

CIPCIP/SIP Counter

00/NNMax. °CDays of operation

MAXMax. Temperature/ODI

Calibration History

CAL

Detailed sensor diagnostics shown on the M800 transmitter's iMonitor

ISMDiagnosticTools

Visit for more informationMettler-ToledoAGProcess AnalyticsIm Hackacker 15CH-8902 UrdorfSwitzerland – 08 / 10

www.mt.com/pro

www.mt.com/ISM

allows real-time monitoring of sensor performance from the convenience of a control room. This means that if production staff are away from the process and a measuring point needs attention, it will be noticed instantly.

ConclusionContinuous improvement in process equipment efficiency is an important business driver. Process analytic measurement solu-tions that enhance product quality and yield, while simultane-ously reducing operating costs, are going to be of increasing value.

ISM’s numerous features and benefits mean that increased mea-surement accuracy, reliability of signal transmission, fast error-free sensor commissioning and real-time diagnostic information combine to create a powerful tool for improving process control and maximizing process equipment availability.

Inte

lligen

t Sen

sor M

anag

emen

t

FeatureoverviewforISMsensors:• More precise measurement signal compared

with analog sensors• Advanced sensor diagnostics• Predictive maintenance functions• Plug and Measure functionality• Digital IP 68 connector• ATEX, FM compatible• CIP / SIP counter

The flexibility offered by a wide range of solutions and further planned developments guarantees ISM will remain at the fore-front of process analytic measurement technologies.

Further information on ISM can be found on our website: