NIR-O and M508plus Process Analyzer Analog Inputs and Outputs

The NIR-O Full Spectrum Analyzer is a Dispersive NIR spectrometer with an IECEX/ATEX certified designed for Class 1 Div 1 and Div 2 environments. Every NIR-O comes equipped with Modbus for communicating with a  distributed control system (DCS). For customers that require 4-20mA outputs, or other analog or digital, I/O Guided Wave has engineered an optional accessory I/O enclosure.

The M508plus UV-VIS Process Spectrometer is an EX IIC T4 compliant design developed for the polymer industry. The IP65 rated enclosure can include up to 16 custom digital and analog I/O and Modbus. There is no need for an external accessory enclosure.

How Many Channels Are Included on Each Module?

Each Digital Input module can accept up to 4 input channels.

  • If you require only 1 digital input, then you need 1 Digital Input module. You will then will have the ability to add up to 3 more inputs in the future.

Each Digital Output module can process to 4 answers or outputs.

  • If you only have 2 measurement parameters, then 1 Digital Output module will meet your needs and allow up to 2 more outputs in the future.

Each Analog Input module can accept up to 2 input channels.

  • If you require only 1 analog input, a Wika RTD to monitor process temperature, then 1 Analog Input module will provide the ability to add up to 1 more input in the future.

Each Analog Output module can process up to 2 answers or outputs.

  • If you have 3 measurement parameters, then you need 2 Analog Output modules.

Configuring the I/O Part Number

The Fiber Glass Cabinet – I/O Enclosure includes the programmable logic controller, 16 position rack for I/O modules, and two power supplies (5V and 24V). The smart part number 40217-1XADO

X = the number of Analog Input modules
A = the number of Analog Output modules
D = the number of Digital Input modules
O = the number of Digital Output modules

PART NUMBERMODULES INCLUDED
40217-101331 x Analog Output, 3x Digital Inputs, 3x Digital Outputs
40217-101011 x Analog Output, 1x Digital Output
40217-106136x Analog Outputs, 1x Digital Inputs, 3x Digital Outputs

Need a Communication Protocol other than Modbus?

Be sure to mention this requirement when you request a quote and our Technical Sales Representatives will be sure to add the optional digital and analog I/O devices.

Announcing direct integration of EigenVector’s SOLO Predictor with Omniview V2.0 software

Eigenvector Research and Guided Wave have partnered to implement an API between the Omniview V2.0 software and Solo_Predictor. This enables NIR-O Full Spectrum Analyzer users who develop models using Eigenvector’s MATLAB® based PLS_Toolbox or stand-alone Solo to use the real-time prediction engine, Solo_Predictor. Contact Guided Wave or your local representative to access this free of charge software update.

Steps to for Existing NIR-O Users to Implement Solo_Predictor

Time needed: 15 minutes.

Steps to integrate Solo_Predictor and Omniview Software.

  1. Provide proof of runtime license for the Solo_Predictor program

  2. Download software update from Guided Wave onto built-in analyzer PC

    A zip file containing updated python scripts and a 64-bit Solo_Predictor version 4.0.4 installation executable will be provided by sharepoint or drop box.

  3. Follow the installation procedure

    The installation procedure for existing users, requires moving some files into place.

Purchasing a NIR-O and want SOLO_Predictor to be preinstalled?

Existing EigenVector customers just need to provide proof of the run-time license when placing their order with Guided Wave. This will allow our production staff to implement the API on the analyzer computer.

Probes and Flow Cells for High Temperature and Hazardous Polymer Measurements

Polymer manufacturing is a high-temperature process conducted under hazardous conditions. A safe and cost-effective method to monitor polymer synthesis is near-infrared (NIR) analysis. Using remote insertion probes connected to a NIR analyzer with intrinsically safe fiber optic cables, protects the operator from potential safety risks compared to the use of grab samples or sample conditioning systems. The single-sided insertion (SST) and shuttle probes were specifically designed to withstand these high temperatures and pressures with low maintenance requirements.

For example, terephthalic acid (TPA) and dimethyl terephthalic acid (DMT) can both be synthesized by reacting P-xylene with cobalt–manganese–bromide catalyst, acetic acid, and air. Realtime quantitative monitoring of this caustic reaction is possible with the Guided Wave ClearView db analyzer along with an SST probe. The SST probe can be installed directly into the reaction vessel for continuous process monitoring and optimization. Additionally, in an extremely corrosive environment, the sample probe can be constructed out of Hastelloy C276.

In batch polymerization, DMT reacts with ethylene glycol in esterification to form monomer alcohol, which then polymerizes with TPA. The continuous method, on the other hand, involves a polymerization between TPA and ethylene glycol, so DMT is not necessary. Both methods involve heating either DMT or TPA with ethylene glycol to about 536 ºF for 30 minutes at atmospheric pressure, and then the mixture spends 10 hours under vacuum. near-infrared analyzers such as the ClearView db and NIR-O Process analyzers can be used to provide in-situ monitoring of the cross-linking under vacuum conditions. Out of specification product can be detected with a high temperature shuttle probe and near-infrared monitoring during melt transfer. By monitoring the molten polymer stream for acid number, cost savings can be realized by preventing the off-spec product from reaching the extrusion or pelletizer.

Rugged sample interface designs built to withstand harsh polymer process conditions, as well as the low maintenance requirements make Guided Wave probes and flow cells a cost effective, smart choice to help optimize polymer production, improve yields, ensure consistent product quality and enhance profitability. While Guided Wave’s probes and flow cells are optically matched for use with Guided Wave NIR or UV-VIS analyzers to provide top system performance, they are also compatible with many other analyzer brands.

Improve and Determine Yield During Diisocyanate and Urethane Synthesis

Diisocyanates are a family of chemicals used to make a wide range of polyurethane products. The most widely used aromatic diisocyanates are toluene diisocyanate (TDI) and methylene diphenyl diisocyanate (MDI). Less widely used, but still important, are the aliphatic diisocyanates, including hexamethylene diisocyanate (HDI), hydrogenated MDI (H12MDI), and isophorone diisocyanate (IPDI).


• TDI is mainly used to make flexible polyurethane foam that can be found in a wide range of everyday products, including furniture, bedding, carpet underlay, and packaging.
• MDI is used primarily to make rigid polyurethane foams such as insulation boards.

Multiple process points during diisocyanate production can benefit from real-time monitoring with NIR analyzers. For example, the yield of TDI and MDI can be determined. Additionally, the concentration of water which can cause off-spec products to form in the reaction vessel can also be monitored. Once the reaction is complete, the acid number (polyol value) of the prepolymer can be monitored to ensure the product is on-spec. Determining the urethane yield can also be achieved by NIR.

During polyurethane synthesis, isocyanate is reacted with an alcohol to form a urethane. This reaction process creates the carbamate functional group which forms the links in polyurethane. Along with acid number (polyol value), NIR analyzers such as the ClearView db photometer can be used to monitor the conversion efficiency of isocyanate to urethane. By monitoring these properties with an NIR analyzer, problems can be quickly detected and corrected, and as a result reaction yields will improve.

Improve Operational Safety through Phosgene Leak Detection

HSFC, high Safety Flowcell
High Safety Flow Cell

When processes involve extremely toxic or hazardous materials such as hydrofluoric acid, phosgene, isocyanates, etc., safety is paramount. Having a sample interface with built-in leak detection can help save human lives. Consequently, it is recommended that a High Safety Flow Cell be used when monitoring these situations. Constructed out of stainless steel or Hastelloy C276 with Kalrez seals, this flow cell is rated for 250 ºC typical operation at 300 psi. The safety sniffer port provided between o-ring seals allows for a connection to a leak detection system to be used as an indicator of primary seal failure.


For example, plant safety can be improved by monitoring the purity or concentration of phosgene using Guided Wave’s High Safety Flow Cell which is compatible with all Guided Wave analyzers and many other analyzer brands. Built into a Class 300 flange, using welded construction, the High Safety Flow Cell uses double o-ring sealed sapphire windows and a weep or “tattletale” port to self-monitor for o-ring failure. This safety mechanism allows the flow cell to be serviced once the process chemicals are detected in the space between the first and second o-ring seals. Moreover, by installing a High Safety Flow Cell on the input side of the reactor vessel and the recovery line, deviations in the amount of phosgene consumed by the process can be monitored, potentially alerting personnel to a hazardous leak in the facility. Thanks to the dual seals and a sniffer port, polymer manufacturers dealing with hazardous or corrosive samples, such as phosgene, can improve operational safety with the High Safety Flow Cell.

This is also compatible with all makes and models of process FT-NIR analyzers.

Market Trends: Solutions for the Plastic/ Polymer Industry

With the outbreak of COVID-19, this has been a year of uncertainty and rapid change. Apart from the direct economic impact, it is clear that this pandemic will create a shift in future socio-economic behaviors with more people working from home, increased expenditure on health and wellbeing, preference for online shopping, and reduced discretionary expenditure. For example:

  • There is now a widely held view that plastic products are safer and cleaner than the recycled and reusable versions, thus performing more favorably to fight and contain the spread of the virus.
  • Packaging for all goods and services has now become a priority in handling nearly everything from shipping and incoming inspection to handling the end product. More remote activities also mean more automation, such as robotic and computer usage. This will result in a greater need for laminates and other polymers to properly coat electronics and circuit boards.
  • Plastics will also benefit from increased spending on household cleaning, hygiene, and personal protection products, as well as higher domestic food packaging use, and disposable products.
  • Plastics used in healthcare can be both advanced medical grade polymer materials that comply with regulatory standards specifically engineered for medical usage, or commonly found plastics used in consumer packaging.

Regardless of the current state of the world, plastics will be at the forefront, offering exceptional and innovative products. Guided Wave and online process monitoring provide unique solutions to cost-effectively measure and control plastic/polymer manufacturing. As the industry moves forward developing these new plastics and polymers, Guided Wave will be can help customers maintain their competitive edge by continuing to solve challenging industrial process problems and accommodate market needs.

There is almost an endless list of medical applications for plastics 1

  • Polyvinyl chloride (PVC) can be found in approximately 40% of all disposable medical devices, including flexible fluid bags, tubing, oxygen, masks, surgical gloves, etc.
  • Polycarbonate (PC) is the material of choice for medical devices and equipment, given its clarity and ease of sterilization, replacing glass in items such as blood oxygenators, hemodialyzers, intravenous connectors, and high-pressure syringes, in addition to safety glasses and face shields.
  • Polystyrene (PS) is used for a wide range of applications, including tissue culture trays, test tubes, petri dishes, diagnostic components, and housings for tests.

REFERENCE
1: https://ihsmarkit.com/research-analysis/how-is-polymer-demand-impacted-by-the-covid19-pandemic.html;
May 12, 2020, Authors: Kaushik Mitra Martin Wiesweg

The Guide Post Fall Newsletter

Guided Wave’s fall issue of its customer newsletter, “The Guide Post” was recently released. This issue focuses on current trends in the plastic/polymer industry.

Due to the current state of the world, plastics will be at the forefront, offering exceptional and innovative products, from health and wellbeing to home office and automation. This issue will explore the ability of Guided Wave and online process monitoring to provide unique solutions to cost-effectively measure and control plastic/polymer manufacturing.

IN THIS ISSUE:      

MARKET TRENDS  – Solutions for the Plastic/Polymer Industry

  • APPLICATION FOCUS
    • Multiple Monitoring Points for Polymer and Polyurethane Synthesis
    • Improving and Determining Yield during Diisocyanate and Urethane Synthesis
    • OH Application Note
  • SAMPLE INTERFACE
    • Probes and Flow Cells for Polymer Measurements
    • Improve Operational Safety through Phosgene Leak Detection
  • PEOPLE / PLACES           
    • European Office Manager Retires after 29 Years
    • New Distribution Offices Expand Service
  • PRODUCTS
    • New Full Spectrum Laboratory Analyzer

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OmniView Process Software V2.5 – Lab Wizard Module

In June 2020, the engineering team completed testing on version 2.5 of the Omniview Process Control Software for the NIR-O Full Spectrum Process Analyzer. In addition to several bug fixes, this version introduces a wizard to help guided users on how to collect data for model creation and validation. The Lab Wizard is accessible from the analyzer setup window and acts as an alternative to Demand Scan functionality that has existed since version 1 of Omniview.

The lab wizard supports two use cases. The first mode is for the collection of data which will be used to create a new NIR calibration. The second mode is for QC operations and enables users to scan a series of samples with an existing NIR calibration. In both modes, the multiple scans can be exported into a single csv file for post-processing or manual submission to a LIMS system.

Overview

The Lab Wizard module was designed to allow users with a NIR-O process analyzer to collect on-demand scans and export them into a single file that is accessible by other software (Unscrambler© software, LIMS systems, etc.). The functionality of the Lab Wizard runs in parallel to the normal process software functionality. Changing channel configuration settings such as the number of scans to average (coadds) will also change the settings for the spectral data collected by the Scheduler. Additionally, the Scheduler can remain active while the Lab Wizard is running. This enables users to collect on demand scans on specific channels with minimal impact to ongoing operations.

Using the Lab Wizard

1) To enable the Lab Wizard button, click the Lock button,in the Analyzer window.

Omniview V2.5 screen shot of analyzer setup
Omniview V2.5 screen shot of analyzer setup

2) Click the Lab Wizard button to begin,

Omniview V2.5 screen shot of analyzer setup

3) The Setup tab of the Lab wizard allows for the general scope or data-set of the on-demand scans to be defined. A user with Technician level privileges can only select a previously defined data-set from the drop down list. A user with Engineer level privileges can select an existing data-set or create a new data-set by clicking the plus button.

Omniview V2.5 screen shot of lab wizard tab1

Parameters that define a dataset include: file name prefix, file path to export scans to, selecting which channel spectra will be collected on, if any lab reference values will be supplied, if any existing models/methods should be called.  Additionally, lab required meta information such as the time that a sample was pulled can be entered as a lab reference value. The Procedure drop down list is currently a place holder

Omniview V2.5 screen shot of lab wizard tab 1 defining datasets

4) Once a data-set is selected, click the Next button to proceed to the Scan Setup tab.

5. The Scan Setup tab allows for modification by a user with Engineer privileges to change the channel configuration.  

Omniview V2.5 screen shot of lab wizard tab 2

6. The ZERO Scan tab allows for the collection of ZERO scans and follows the same logic as the ZERO Wizard. Both Technician and Engineer users can collect a new zero or proceed with the existing zero scan.

Omniview V2.5 screen shot of lab wizard tab 3

7) The Collect Scans tab allows for data to be collected as defined by the previous tabs. If reference values were setup on the data configuration tab, the user will be prompted for them once the scan is completed. If a sample collection time is to be entered use the date format. Additionally, users will be prompted to provide a comment.  The comment can be a sample name or any other information that may be useful.  Both fields can be left blank. To collect a scan click the Perform Scan Button.

Omniview V2.5 screen shot of lab wizard tab 4

7) The lab reference value or sample scan time can be entered in the popup:

Omniview V2.5 screen shot of lab wizard - defining reference value

8) Once a scan is complete the spectrum will appear in the chart and tabulated data in the table above it. Additional scans added to the collection will appear in both the table and chart.

Omniview V2.5 screen shot of lab wizard populating a data collection

9) To export the collection of scan to a file, click the Export Collected Scans button.  The collection of scans and tabular information will be exported according to the previously selected file format (csv, gwj, etc)

10) Selecting scans in the table enables the deletion button. Scans removed from a collection are still stored in the database. Removing a scan simply removes it from the collection.  The entire collection can be deleted using the Clear Collection button.

Omniview V2.5 screen shot of lab wizard exporting data collection

11) A trend chart of Lab Wizard answers can be displayed by opening the Answer window and selecting the data from the list of available answers. At this time, lab reference values cannot be displayed inside of the OmniView process software. To generate a ‘Predicted vs Actual value chart, use the exported file of the collection.

Omniview V2.5 screen shot of answers trend chart

For more information on how to use OmniView software see our YouTube Channel.

European Sales Manager Retires After 29 Years

Guided Wave recently announced the retirement of André Van Den Broeck, Regional Sales Manager of Guided Wave’s European office located in Aalst, Belgium. André’s retirement was celebrated with a virtual farewell party at the end of June where the entire staff thanked him for his 29 years of dedication to the company. Susan Foulk, Guided Wave President, stated: “Andre will be greatly missed. His knowledge and leadership have been instrumental in our success throughout the years with not only the European office but locations in the Middle East and Asia as well.  We sincerely thank André for all he has done and taught us.”

In 1991 André started as a Customer Support Engineer for Guided Wave and Perstorp Analytical. His duties included hardware and software training in Belgium, the Netherlands, and Luxembourg on NIR spectroscopic analytical systems. Later, the region was extended to encompass Europe, India, and China. After helping create and set-up the sales and support offices in India and China, his responsibilities changed to a focus on Europe and the Middle East.  In 2005, André opened the Guided Wave office in Belgium and was promoted to Regional Manager EMEA (Europe, Middle East, and Africa). At this time, he also became responsible for sales in the region. André was at the forefront of all new product introductions and installations in the EMEA region. From the introduction of the Hydrogen Peroxide Monitor in 1997 to the release of the NIR-O spectrometer in 2018, he was there to support and train customers and new sales representatives on every product. According to Debra Hall, Guided Wave’s Sales and Marketing Director, “André’s experience has been invaluable in the mentoring of the next generation and his legacy will be carried on through our younger Guided Wave specialists worldwide.” She continued, “Thank you Andre for your contributions throughout the years!” Jim Low, Director of Sales and Support,added, “I’ve had the pleasure of working in partnership with André during his entire 29-year tenure, and I’m certain that Guided Wave’s success would not have been possible without him. André, you most certainly will be missed!”

ORTIX Design

André plans to spend his retirement enjoying more time with his wife and family. He is especially looking forward to finally having the time to help his son in Austria with his business, OTRIX, which specializes in graphic design for cars and motorbikes. As Guided Wave loses a talented manager and salesman OTRIX will surely gain from André’s skills and passion.

OTRIX Design

Please join us in congratulating André on his illustrious career and newfound retirement! With sincere appreciation we say good-bye André, and thank you!

Guided Wave Releases Sterilization Market Outlook in Spring 2020 Customer Newsletter

Guided Wave’s spring issue of its customer newsletter, “The Guide Post” was recently released. This issue focuses on current trends in the sterilization industry.

Medical issues that are arising from the COVID-19 pandemic have put sterilization technology at the forefront of the battle. Although many technologies are being considered to help sterilize and disinfect various health and medical items, vaporized hydrogen peroxide (VHP) is one of the few sterilization methods that is effective for virus deactivation and microbial reduction.

As the industry quickly adapts and creates new products to meet this healthcare crisis, this proven and accepted technology can reduce the time to market and ensure safe, reliable results.

In this issue we address the ability and power of NIR online process monitoring, along with Guided Wave’s VHP Analyzer systems, to well-equip the marketplace to meet the current and future sterilization challenges.

In this Issue of The Guide Post Newsletter:

  • Sample Interface – G-SST Vapor Probes for Hydrogen Peroxide Vapor
  • People/ Places:
    • Intern from US Department of Defense Joins GW
    • Dr. Terry Todd Retires
  • Education – Why Pathlength is Important for Sample Interface
  • Events:
    • HPV Analyzer Helps NASA Keep Planets Clean
    • Saybolt Analyzer with Free Fiber and Flow Cell

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