Insacal®

The Conductivity Master MeterFor Fast and Easy Validation of In-Line Sensors

People - Ideas - Solutions

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“Insacal provides us with an easy to use, fast and foremost flexible approach to validate the customers’ applications regardless of their set up. With no “background” programs to tamper with, results are transparent and well documented.” Calibration Technician, Danish Calibration Company

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Insacal®The Conductivity Master MeterIntroductionWith the Insacal Conductivity Master Meter you will be able to validate your conductivity sensors in-line.Insacal is primarily used in the pharmaceutical industry where there are high requirements for documentations of water purity. But it would also be useful in other industries like biotechnology or nuclear power. The Master Meter weighs only 4 kg and is easily transported to the location of your conductivity. The Insacal can be used for in-situ calibration in closed loop, saving you hours on total calibration time.

How it worksThe calibration can be carried out in two ways either in an open beaker or in-situ to prevent risk of contamination of the Unit Under Test (UUT). In both cases the calibration is carried out by comparing the UUT to the Insacal Master Meter. The advantage is that the Master Meter can be used in a beaker in the laboratory and afterwards it can be used in a closed loop in the production.

OperationInsacal was developed for the pharmaceutical industry. The casing is made from AISI 304 and is cleanable for cleanroom use according to industry standards. The Insacal is equipped with a flow fitting for the sensor to avoid influence from the surroundings when used for in-situ calibrations. All wetted parts are CIP (Cleaning-In-Place) and SIP-able (Steam-In-Place).

Service and SupportMaintenance is limited to a yearly calibration. Instrument user training can be facilitated at product delivery. If you choose to sign a service agreement with us, we will take responsibility for timely cali-bration of your instruments.

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Traditional Calibration Interrupts Production – Risks ContaminationTraditionally when calibrating a conductivity sensor you will need to dismount it from the production line and then calibrate it in a standard solution either online or in a calibration laboratory. This operation has a number of disadvantages, as it interrupts the production. The dismount introduces some uncertainties in the calibrations as some sensors are sensitive to their installment. Furthermore you risk contamination of your production line.

Save Hours on Your Total Calibration TimeWith the Insacal from Insatech Pharma you will be able to validate and calibrate sensors in line without removing the sensor from production, eliminating the above mentioned disadvantages. At only 4 kg the meter is easily moved to the site in need of calibration, and it facilitates use in your laboratory. Connect to a power supply, and to the test loop or beaker; Insacal is ready to calibrate. The calibration is precise and easy, with easily documented results, which will save you hours on your total calibration time, thereby minimizing your costs.

Several Insacals are already in use by our customers, world wide, and our calibration engineers use it frequently.

INTRODUCTION

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When calibrating conductivity, the calibration method must represent the way the equipment is used on-site. In some cases the calibration setup must be an exact copy of the field installation; otherwise the sensors must be calibrated in a closed loop.

Two Methods of CalibrationCalibration can be carried out in two ways, either in an open beaker or by closed loop sampling. In both instances the readings from the Unit Under Test (UUT) are compared to the readings of the Insacal Master Meter.

BeakerWhen calibrating in a beaker both the Insacal sensor and the UUT are placed in a stirred vessel/container. This setup is most suitable when you need to calibrate values above 5 μS/cm.

Closed LoopIf you are calibrating in a closed loop the Insacal is connected to the production piping via a pre-installed test valve. This method is always recommended when measuring low conductivity values.

Insacal T9 Calibration TankThe optional Insacal-T9 calibration tank for the Insacal Master Meter can help you perform loop calibration of your sensor. Your sensor is easily connected to the tank and the Insacal. The tank holds up to 9 liters of calibration fluid and a pump circulates it through both the Unit Under Test and the Insacal, making it effortless to calibrate your sensors.

HOW IT WORKS

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The Insacal Conductivity Master Meter is delivered tested and calibrated, ready for use. It can be used in all non-hazardous areas on site or in the laboratory and can be used to calibrate conductivity measurements from ultra pure water (like WFI) up to chemical solution levels.

Easily Transported and No Permanent Installation RequiredThe Insacal is handy and weighs less than 4 kg. The sturdy design together with the solid handle makes it easy to transport to the point of use and well suited for use anywhere on-site. Since the Insacal can be inserted into a beaker or valve no permanent installation is required.

Intuitive Touch Screen OperationThe Master Meter is equipped with a touch screen and operating it is very intuitive. The reference, temperature and conductivity are presented on the display. Furthermore, transmitter settings can be password protected to avoid unintended changes in settings, e. g. cell constant. The software supports multiple languages.

Made for the Pharmaceutical IndustryInsacal was developed for the pharmaceutical industry. The casing is made with AISI 304, it is dust tight and cleanable for cleanroom use according to industry standards. The Insacal is equipped with a flow fitting for the sensor to avoid influence from the surroundings when used for in-situ calibrations. All wetted parts are CIP (Cleaning-In-Place) and SIP-able (Steam-In-Place).

Is the Standard Solution Insufficient?If the standard Insacal is insufficient for your specific use, we can work out a User Requirements Specification (URS) in accordance with your requirements as a pre-order.

Documentation from Basic to Full ValidationInsatech documents the various components, the interaction between the components and the total delivery as agreed to with the customer. We work according to well recognized standards, e. g. Good Automation Manufacturing Practice (GAMP).

The extent of our documentation is as per agreement with the customer, and goes from the basic operations manual to full validation in accordance with common practice of the pharmaceutical industry.

OPERATION

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Minimal MaintenanceThe Insacal Conductivity Master Meter is developed for pharmaceutical use and therefore easy maintenance and cleaning are of the essence and can be done according to industry standards. Maintenance is limited to a yearly calibration of the conductivity sensor.

Maintenance and recommended spare parts may differ depending on the specifications, but will always be described in the delivered documentation.

Service and Support is Readily AvailableWe know that the after sales experience is important to you and your total product experience, which is why we have a well staffed service department ready to help you if challenges should arise. We perform repairs on location or in our workshop depending on what is most beneficial in the given situation. Accredited calibration will be performed in our calibration laboratory.

The Insacal is built with standard components which makes spare parts easily obtainable. If you choose a service agreement with us, we will take responsibility for timely calibration of your instruments.

TrainingThe ever increasing complexity of measuring equipment makes proper training very useful. Insatech Pharma can offer equipment and application training either at your- or our facilities. Furthermore the training will be targeted towards your various working situations ensuring that you get the highest benefit possible.

SERVICE AND SUPPORT

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Over the years Insatech has become a trustworthy and competent partner, supplying technical solutions and giving advice to the process industry.We have great experience with the particular applications and high requirements for documentation in our primary market pharma, biotech, and food industry.

A TRUSTWORTHY ANDCOMPETENT PARTNER

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OUR CUSTOMERS

Our customers consist of a broad range of pharmaceutical production companies with both small and large capacity. Our main customers are Danish based, but our solutions have also reached diffent parts of Europe and South America.

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At Insatech Pharma we develop, produce and sell products within the fields of measuring and calibration. Our products are highly customizable and we are certain that we can meet your User Requirements Specification (URS). We have, for example, delivered products with DANAK Accreditation, for use in hazardous areas (ATEX) as well as meeting Functional Safety requirements IEC 61508 and IEC 61511. If you want to know more please contact us and let us know what we can do for you.

In addition to the Flow Calibration Rig you might be interested in the products below.

Flow Calibration RigThe Flow Calibration Rig provides a risk free and swift way of calibrating flow meters in-line. Carrying out the calibration in-line eliminates costs from lost production, saves hours on the calibration process, and minimizes the risk of contamination by Active Process Ingredients (API). An added bonus is the check of the total test loop, which eliminates uncertainties that could occur in the laboratory.The rig is a plug and play solution: Easily maneuvered into the production area, connected to the Unit Under Test (UUT) and a power supply. Highly accurate and stable Coriolis mass flow meters ensure exact measurements of the flow. The flow rig can be delivered with a traceable DANAK accreditation, accuracy of < 0.3% of the measured value, and covers a flow range from 5 to 40.000 kg/h. Cleaning can be performed according to industry practice and all wetted parts are CIP-able. The Calibration Flow Rig is in use at a range of Danish pharmaceutical production sites.

Pressure Calibration RigThe Pressure Calibration Rig is the cost effective alternative to traditional calibration of transmitters in the laboratory. Use of the Pressure Calibration Rig eliminates costly transportation time between production and laboratory. It reduces calibration time to about half an hour while the accuracy of the in-situ calibration is increased to laboratory level. The rig is a plug and play solution: After being connected to the pressure gas, Unit Under Test (UUT) and a power supply, the rig is ready to calibrate. The highly accurate and stable pressure controller prevents over - and undershooting. The Pressure Calibration Rig, -1...20 Barg / 0...21 Barg has an accuracy of 0.2835 mBarg and 0.2838 mBara (K2) and assures one year stability of the calibration. The rig is build with materials that are AISI 304 or optionally AISI 316L which allows cleaning according to industry practice.

Quantity Calibration RigThe Quantity Calibration Rig can be used for calibration of loading cells for level measurement equipment in e.g. production and fermentation tanks, by dispersing a pre-defined batch of fluid on the basis of volume or weight. The calibration is highly accurate and stable, the skewed distribution of calibration points helps target certain flow ranges.The rig is user friendly, mobile, and is easily maneuverable for in-line calibration, thereby reducing down time and the risk of contamination by Active Process Ingredients (API). The flow rig can be delivered with a traceable DANAK accreditation, accuracy of < 0.3% of the measured value, and covers a flow range from 5 to 17.000 kg/h. Cleaning can be performed according to industry practice and all wetted parts are CIP-able. The rig can be produced to operate in hazardous areas (ATEX Zone 1).Insatech Pharma has delivered several rigs to various pharmaceutical sites in Denmark, Brazil and France.

WHAT WE DO

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ContactInsatech Pharma GroupNæstvedvej 73C4720 PræstøDenmark+45 5537 2095mail@insatech.comwww.insatechpharma.com