What are the differences between In-line, On-line, At-line and Off-line Analysers.

When it comes to performing routine testing of process samples there are 4 basic options of instrumentation, Inline, On-line, At-line and Off-line(laboratory). Please find following a brief description of each of these and a table
summarizing these differences.

Laboratory
Off-line

Sample
Results

Analysis results
> 60 mins

At-line
Analysis
results
30mins

In-line

Process
On-line
Analysis
results
5- 10mins

Factory Process Area

In-Line
In-line analysers are simple probes or measuring devices that are placed directly into a process stream. They
are used to measure such things as pH, temperature, pressure, density and flow.
Off-Line
Off-line Analysers are laboratory instruments designed to be in an environmentally controlled location and used
by technically trained personal. They offer the greatest versatility of analysis methods but require the most man
hours to perform an analysis and input the results ie they have the longest results turn around time.
Laboratory instruments are used when there is a large variety of test methods required and the result turn
around time is not critical.
At-line
An At-line Analyser, such as ProcessLab, sits in the production area and is used by an Operator. It is configured
to perform a series of tests on a variety of samples. For instance an Operator could collect 4 different samples
and load them into the instrument then press 1 external button and the At-line Analyser would perform a different
test or a different combination of tests on each sample and export the results automatically. Additionally
ProcessLab can be connected to a switch box with several buttons so that the operator could choose from a
variety of testing combination options by pressing a couple of buttons. The instrument can generate Alarms (DO)
if any of the results are out of specification or operate other external devices eg turn on/off a pump or valve for a

set period of time if a result is too low or high. At-line Analysers are generally placed in a central location in a
production facility so that the Operator can bring their collection of samples to the analyser press a couple of
buttons and walk away.
The analyser housing is IP 56 and the combined touch screen, keyboard and mouse pad are IP65. ProcessLab
has both an analog (4-20mA) and a digital interface. ProcessLab can be integrated into a local network, down
load data into a LIMS or be connected to the internet so that the instrument can be operated remotely, which is
particularly useful for remote locations.
The advantage of an at-line analysers is that no sample plumbing is required and that it can analyse multiple
samples from a variety of locations within the plant. At-line analysers are ideal for situations where 4-10
samples, collected from separate locations, need to be tested routinely during a shift with the results entered
automatically into a DCS, SCADA and/or central computer. By using an At-line analyser the work load on the
laboratory can be significantly reduced and the result turn around time is significantly increased.
On-line
On-line analysers are fully automated systems used to closely monitor (1-12 results per hour) the concentrations
of analytes that are critical to the production process. On-line analysers are able to control external devices
such as pump or valves as part of their analysis sequence and as the results are exported automatically the
analyser can also control external devices based on their analysis results eg turning on/off dosing pumps. The
Analysers can be operated remotely via a modem.
The Analyser is plumbed directly into the sample streams with one instrument able to monitor multiple samples
(1-10, It is possible to monitor more that 10 streams but this is not recommended because of the length of time
taken between testing a particular stream).
Our on-line analysers are IP 66 and can be Certified for use in Hazardous Areas Zone 1 or 2.
They can perform a variety of pre-treatments on the sample before analysis such as;

Filtration.
Cooling
Pressure reduction
Heat tracing.
Digestion with acid, heat and/or UV.
Dilution

Precipitation
Degassing
Homogenising
Flow metering
Phase separation

Other benefits on-line analysers provide include;

They generat results with a higher level of consistence and certainty as the human factor is removed
from the analysis procedure.
They increase the safety for Operators as they dont have to collect samples or work with potentially
toxic reagents.
They save man-hours by removing the burden of routine testing from laboratories and operators.

For more information on our range of Instrumentation please contact, James Whyte, 02 98 78 6900 or

jw@mep.net.au.

Summary, differences in Off-line, At-line & On-line

Installation site
Analyser Protection
Sampling
Sampling points
Analysis frequency
Turn around time
Parameters
Meas.-Range
Analysis type
Sample preparation
Analysis- Procedure
Operation
Maintenance
Control
Exchange of data

Off-line
Laboratory
IP 23
Manually
Many
Low
>60 mins
Many
Flexible
All
Manually
Manually
Lab assistant
Lab assistant
No
LIMS

At-line
Plant
IP 54/65
Manually
Many
Low-mid
~30 mins
1-4
Fixed
Routine
Manually
Automatically
Plant operator
Lab assistant
Simple control
LIMS/Process-signal

On-line
Process
IP 66, Hazardous Area Cert.
Automatically
1-10
High
5 -10 mins
1-4
Fixed
Routine
Automatically
Automatically
Automatically
Process technician
closed loop control
LIMS/Process signals