Insitec X

Summary

General

In many processes, including fine chemicals and pharmaceutical production, explosive gases, vapors and dusts can be present. It is for these situations that Insitec X has been developed, the world's first intrinsically safe (IS) particle size analyzer.

• The Insitec is currently approved for Intrinsic Safety to European Standard EN50020:1994 and IEC standard IEC60079-11:1999. The levels achieved are EEx ia IIC T4. The IS approval for the Insitec enables its use in zones 0, 1 and 2 gas environments and zones 20, 21, 22 dust environments. Malvern Instruments Ltd. fully meets the requirements of the ATEX directive 94/9/EC (annexes IV and VII).

• Sira certificate no. sira01ATEX2152x/Sira01ATEX2151x - EEx ia IICT4/EEx ia IIC.

Please note: It is the responsibility of the client and the installer to ensure that the certification requirements regarding installation specification are strictly adhered to. Failure to satisfy this requirement will invalidate the certification.

• IP66 rated optical sensor comprising solid state laser diode, multi-element detector, high speed parallel processor, process sample flow cell, communications interface and interconnecting cables (150m). Range of fixed optical arrangements available, allowing different size ranges to be measured
• Flow cell suitable for inline or bypass eductor configurations, with range of path lengths for compatibility with process lines and particulate loading.
• Triclamp assembly of optical components for simplified maintenance. The flow cell comprises the central region of the instrument containing the sample measurement zone, the optical interfaces, the process interfaces and the instrument support pin.
• The cell windows are purged with dry clean air to protect them from contamination.
• The flow cell is made of 316L stainless steel. Sample measurement zone and flow path are of seamless construction to comply with cGMP requirements. All seals are rated to IP66.
• Process connection via tri-clamp fittings to BS4825
• Air panel for setting of motive and window purge air flow rates.
• Enclosure for electronic communication/repeater PCB (for instrument - PC communications) and power supply:
• DIN rail mounted electrical isolator switch and fuse
• Field connections by DIN rail mounted terminal blocks
• External indications for power and communications
• Mounting bracket with wall mounting kit
• Document holder
• Stainless steel 316L cabinet with lockable door. Industrial protection rating of IP68, equivalent to Nema 6 Dimensions (HWD) 400x400x200mm

Static unit - Fit to pipe or frame close by to sampling points

• Dispersion provided by 90° Stainless Steel Venturi Eductor
  (alternate dispersion systems available as options)
• 80cm Stainless Steel test flute with pre-drilled holes to allow rapid optimization of probe configuration.
• 2 meters flexible inlet pipe
• 2 meters flexible outlet pipe
• 3 fixed sampling point flanges + 80 cm standard flutes

• Inlet and outlet ball valves with triclamp fittings (Manual)

• Pneumatic inlet and outlet pinch valves replace the manual ball valves

Air Panel Assembly

• Three adjustable air flow meters (lockable to prevent inadvertent adjustment)
• Low-flow purge to protect windows when system is idle
• Cartridge filters
• Enables manual control of eductor and window purge flows. Housed in a lockable IP56 polyester cabinet with clear window.

Automation option only:

Air Cabinet

• Automated air panel housed in a lockable IP56 polyester cabinet.
• Three adjustable air flow meters, automatic valves and flow sensors.
• Boost air facility
• Pre-equipped with 4/2 air distributors plus pressure sensors enabling automatic operation of up to six pneumatic pinch valves
• All automatic functions configurable via Malvern Link

• Lockable IP66 rated cabinet - housing:
• Communication interface PCB - allows RS232 or RS422 connection to the PC.
• Maximum cable length is 15m using RS232. The RS422 connection should be used for longer length requirements.
• Diagnostic LED's at the Optical sensor
• Voltage is auto sensed in range 100 to 240 volts

• 10m of cable to connect between Optical Head and Interface box.
• 150m cable reel for connection between interface box and PC.

Automation

Option:

• Hardware supporting full Malvern Link functionality housed in a lockable IP56 polyester cabinet, containing
• Wago, analog and digital output modules
• Power Supply
• Switches for installation testing
• Terminals for field wiring
• Click here for more details

The following software is pre-installed as standard with each process system (and also on CD-ROM). They are compatible with Microsoft Windows NT4.0 and 2000 for use on Intel compatible PC and available in English, French, German, Spanish and Japanese languages.

• RTSizer for instrument configuration, data acquisition and particle size analysis; includes high concentration software module, patented technique to enable measurement under high or fluctuating process loadings (5-95% transmission)

• Malvern Link for instrument control and operator interface, including license for award winning Intellution iFix SCADA software.

• PCAnywhere for remote diagnostics. (Requires access to a telephone line)

Standard system only:

• Computer excluded. Malvern Process Systems can supply IP54 laptop on request.

Automation options:

• Malvern Link options such as Plant Optimizer, Batch Tracker...Access to Engineering Mode of Malvern Link.

• "Toughnote" IP54 laptop computer

• Installation & Training

• Includes two days training at Malvern office plus three days on-site training. Upon completion of training, Malvern Process Systems will offer on-site applications assistance at a 10% discount to our standard daily rate for the first twelve months. T&E charged at cost.

• Installation, commissioning and additional training days excluded. User is responsible for installation, commissioning and application development.

Miscellaneous

• Includes two days training at Malvern office plus three days on-site training. Upon completion of training, Malvern Process Systems will offer on-site applications assistance at a 10% discount to our standard daily rate for the first twelve months. T&E charged at cost.

• Installation, commissioning and additional training days excluded. User is responsible for installation, commissioning and application development.
  

The following documents are supplied on CD-ROM in PDF format and available in English, French, German, Spanish and Japanese languages.

• Installation manual
• User manuals

• Location for instrument to be specified (following consultation from Process Specialist engineers):

• On-line (eductor) configuration: Sample ports (supplied by Malvern Process Systems) to be connected to process line

• In-line (flowcell) configuration: Process line broken and flanges added to connect to instrument.

• A dry clean air or nitrogen supply of a minimum of 50m3/hour at 4 bar g (30scfm at 60 psi g) is required at instrument location to provide for window purge and motive air.

• A fused spur rated at 100-240 Volts AC, 5 AMPS and ground connection is required on site to provide power for sensor and interface enclosure.

• Local electricity supply

• Instrument - PC data communications (cable supplied with instrument) to be installed from instrument location to PC location

• PC to be installed in control room type environment free from particulates, and controlled temperature/humidity.

Specification

Choice of four size ranges (one lens is delivered as standard, others can be ordered as options):

EEx ia IIC T4.
Approved for use in zones 0, 1 and 2 (gas environments) and zones 20, 21, 22 (dust environments)

• 316L for all metallic parts, with high grade finish
• Glass windows (for measurement zone)
• Viton O-rings and EPDM triclamp gaskets (other seal materials can be supplied)

Triclamped for simplified cleaning

5 - 98 %

±2% on Dv(50) reported using the verification reticle

Dry, oil-free air containing no particulates
6 bar g (90 psi g) with a flowrate of 30 m³/h (1000 ft³/h) required as motive gas for eductor and for window purge

Note: other gases (e.g. nitrogen) can be used instead of air as appropriate

10 bar (g)

-10°C to +70°C

Dust-tight and waterproof: Optical head IP66, cabinets IP65

500 m

4

RTSizer (for instrument control)
Malvern Link (for system automation and data link)

All software runs on MS-Windows 2000 or above

Validation and 21 CFR part 11options

Options:

• PLC in cabinet
• 2-off analogue outputs (optional 4-off analogue inputs for logging extra process parameters)
• valve sequencing for automatic background, sample path cleaning, start / stop
• 8-off digital I/O (for valve switching and alarms)
• OPC server to plant DCS
  

Min 565 mm Max 1336 mm

Min 20kg Max 35.9kg