{"id":15195,"date":"2022-05-25T16:11:10","date_gmt":"2022-05-25T21:11:10","guid":{"rendered":"https:\/\/blog.wika.com\/us\/\/?p=15195"},"modified":"2024-04-30T08:57:22","modified_gmt":"2024-04-30T13:57:22","slug":"wikas-next-gen-diaphragm-monitoring-system-offers-digital-connectivity-ease-of-use-for-sanitary-processes","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/applications\/wikas-next-gen-diaphragm-monitoring-system-offers-digital-connectivity-ease-of-use-for-sanitary-processes\/","title":{"rendered":"WIKA\u2019s Next-Gen Diaphragm Monitoring System Offers Digital Connectivity, Ease of Use for Sanitary Processes"},"content":{"rendered":"

Self-monitoring digital instruments are essential to the safe operation of Industry 4.0 manufacturing. The next generation of WIKA\u2019s diaphragm seal system offers foolproof monitoring with HART\u00ae communication protocol, ideal for sanitary processes in the pharmaceutical industry.<\/strong><\/p>\n

Diaphragm seal systems are the go-to pressure-measuring instruments for the pharmaceutical & biotechnology<\/a> and food & beverage<\/a> industries. This is because the clean media never comes into contact with the internal mechanisms of the gauge, thanks to the thin diaphragm that flexes to transmit pressure. Indeed, diaphragm seals offer an extremely safe and sanitary way to measure pressure<\/a>.<\/p>\n

However, there is one drawback for hygienic processes: the transmission fluid. Even if the system fill fluid is FDA approved and USP (US Pharmacopeia) compliant, a tiny leak will ruin the entire batch.<\/p>\n

How Product Contamination Led WIKA to Develop Our Diaphragm Monitoring System<\/strong><\/h2>\n

After vaccine manufacturers make an active pharmaceutical ingredient (API), they put the finished product in mobile tanks and ship it to facilities that fill the injection vials. Diaphragm seal systems monitor the internal pressure of the tanks, which are rigorously sterilized to ensure product purity.<\/p>\n

Diaphragm seals are built to withstand the strong chemicals and sprays of routine sterilizing, but they are not indestructible. Even if the diaphragm seal system suffers just minor damage, transmission fluid will leak into the filled tank and ruin that batch of API.<\/p>\n

This is what happened to one vaccine company. After the second of such contamination incidents, each of which cost them millions in lost time and products, they looked for a better pressure measurement solution.<\/p>\n

Against this backdrop, WIKA engineers came up with our patented diaphragm seal system with diaphragm monitoring<\/a>. It has two seals: a primary one that comes into direct contact with the media, and a secondary one that serves as a backup. In between is a vacuum that is monitored by our PGS23.063 pressure gauge with switch contact<\/a>. If the vacuum is ever breached, this gauge immediately sends out a warning. Meanwhile, the intact secondary seal allows the UPT-20 process transmitter<\/a> to continue monitoring process pressure \u2013 and separate the transmission fluid from the sanitary media \u2013 \u00a0\u00a0until the instrument can be repaired.<\/p>\n

WIKA Builds a Diaphragm Monitoring System for Industry 4.0<\/strong><\/h2>\n\n
<\/a>

The DMSU21SA diaphragm monitoring system<\/p><\/div>\n \n

Our original model had two separate measuring components: one instrument for monitoring the process media\u2019s pressure, and another instrument that monitored the vacuum. These two elements operated independently of each other and had their own signal outputs.<\/p>\n

When manufacturers started incorporating IIot (Industrial Internet of Things) into their facilities, WIKA engineers knew it was time to develop the next generation of our proven monitoring solution.<\/p>\n

Model DMSU21SA<\/a> is a diaphragm monitoring system with HART\u00ae<\/sup> communication protocol, allowing for easy integration into an existing HART\u00ae<\/sup> environment. This state-of-the-art instrument is an integrated system, transmitting data on process pressure, diaphragm status, and process temperature via one cable. There is no need to lay a second cable harness.<\/p>\n

Operators onsite can also easily see the process pressure on the transmitter\u2019s display, which refreshes every 0.2 seconds. On the monitoring element, if the pointer is in the green range, the outer diaphragm is intact. If it\u2019s in the red range, the outer diaphragm is defective and must be replaced. The status changes from green to red only if the specified set point lasts longer than 1.5 seconds; this is so that shocks or vibrations do not unintentionally trigger the alarm.<\/p>\n

Our patented double-diaphragm system is flexible, with options for different electrical connections and all the common process connections for sanitary applications:<\/p>\n