ISM analytical sensors are easy to maintain

Breakthrough technology from Mettler Toledo allows users of process analytical equipment to reduce maintenance costs of pH and other measurement loops, using Intelligent Sensor Management technology

Mettler Toledo has introduced a new line of pH, Turbidity and Oxygen measurement loops that utilise our unique ISM (Intelligent Sensor Management) technology.

The new ISM sensors are easy to maintain and allow cost-efficient predictive maintenance.

Historically the lifetime of a sensor is determined by its exposure to process conditions and this is often subject to extremes of temperature or exposure to particularly corrosive or abrasive process material.

Sensors equipped with ISM technology from Mettler Toledo are continuously monitored for defects and wear, and can therefore anticipate failure before it happens.

For pH loops, predictive maintenance is easy with the adaptive calibration timer that calculates the time to the next calibration, based on actual sensor load, and the real-time wear in-process.

This allows the sensor to accurately predict when it will need to be changed out or calibrated.

The historic data of each individual sensor is stored automatically so maintenance can be scheduled more efficiently.

Whereas conventional sensors need careful and time-consuming calibration in the field, ISM sensors can be pre-calibrated in-lab via a USB connection to a computer and then simply returned to the process.

A New Maintenance Concept.

ISM sensors can be calibrated under controlled conditions in the lab and since the calibration data is stored in the sensor, the sensor only needs to be replaced at the measuring point location on-site.

This eliminates the need to handle sensor and calibration solutions in the plant - often under unfavourable atmospheric and lighting conditions at hard-to-access measuring points.

ISM sensors can be quickly and easily replaced on-site, which allows users at a central location to use the ISM diagnostic tools to analyse the sensor.

This determines whether and for how long the sensors can continue to be used following cleaning, conditioning, and recalibration.

In the event of measurement problems, ISM diagnostics facilitate easy troubleshooting solutions.

ISM-enabled sensors are digital, with integrated electronics for signal conditioning in the sensor head.

The fully digital and low-impedance signal transmission secures a trouble-free, humidity-insensitive communication with the transmitter.

Traditionally calibration data was stored only on the transmitter, meaning each time a sensor was exchanged, a new calibration would have to be performed.

ISM sensors store data, including both their serial number and comprehensive calibration data, and automatically upload the information to the transmitter upon connection.

In order to fully utilise the benefits of ISM, the iSense Asset Suite is the ideal lab complement for the ISM loop.

iSense allows the user to maximize the performance of ISM sensors over their entire lifetime.

Simply connect the ISM sensor to a USB port on a PC or laptop and get access to various intuitive analysis, calibration and documentation applications.

The goal of ISM is to perform maintenance work only when necessary, thus reducing maintenance costs.

Achieving this goal requires precise knowledge of the behaviour of the sensors under a wide range of process conditions.

With over 50 years of experience in manufacturing quality sensors for pH, turbidity and oxygen measurement, Mettler Toledo has developed algorithms for predictive maintenance.

Actual process conditions, such as pH value, temperature, number of CIP and SIP cycles, membrane and diaphragm resistance (pH), and resistance between anode and cathode (oxygen), are monitored continuously.

These values are then used to generate a wear matrix for a particular sensor.

This simplifies diagnostics in the event of measurement problems, while also providing information about the timing of the next required calibration or adjustment.

Furthermore the remaining lifetime of the sensor is monitored to allow accurate predictive maintenance schedules to be developed.

As is typical with modern navigation systems, these calculations are performed dynamically and in real time.

ISM essentially eliminates complex configuration and parameterisation operations at the measuring point as well as labour-intensive, time-consuming calibration and maintenance procedures.

Measured values are more reliable and accurate, and system availability is increased - which in turn improves process reliability, yield, and quality, while reducing costs.

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