The manufacturing science and technology (MSAT) team at a global biologics & pharmaceutical manufacturer works on small batch runs to test production and feasibility before moving to larger scale production.
Brooks Instrument mass flow controllers (MFCs) provide the gas flow control in the benchtop bioreactors the team uses to run the small batches. Emerson DeltaV™ is the automation platform used to run their distributed control system connecting their equipment. Recently, a decision was made to transition away from Profibus as their communication protocol to EtherNet/IP™, a modern, high-speed network protocol that has become a driving force behind today’s need for interconnectivity with the advent of Industry 4.0 and the Internet of Things (IoT).
Transforming Data Into Useful Knowledge that Drives Decisions
A key benefit of the EtherNet/IP protocol is that it provides users with access to an array of mass flow meter diagnostics and alarm features that provide robust, real-time process information. A critical alarm available exclusively from Brooks Instrument SLA Series mass flow controllers with EtherNet/IP is the Restricted Flow or Choked Flow alarm.
Restricted Flow (Choked Flow) Alarm: Alerts the operator to a loss of flow due to pressure droop or other causes of restricted flow, allowing the issue to quickly be resolved preventing potential batch loss.
The Challenge: Accessing the Data
The MSAT team was having trouble accessing the Restricted (Choked) Flow alarm from the mass flow controllers via their DeltaV platform. Later I learned the bioreactor OEM did not make those alarms and diagnostics available to read in the equipment setup.
Why was it so important to them to be able to access this alarm?
Process Benefit #1: Prevent Batch Loss & System Downtime
One of the issues the team was worried about was having multiple bioreactors running at the same time with a single lab gas input. One gas line was feeding multiple bioreactors and they were worried that a restricted (choked) flow or lack of gas flow, could cause one of their batches to fail. The financial and opportunity cost of an event like this is significant – preventing it from happening by knowing immediately that an issue is occurring could save the batch.
Process Benefit #2: Properly Diagnose the Root Cause of the Problem
The other issue that came up was having the ability to diagnose where the problem is occurring. Is it a mass flow controller? A pressure regulator? A software issue? Without knowing where to look, it could take days of precious time to diagnose the root cause of the problem. If you don't stock spare MFCs to keep the process going in the event of an emergency like this, the losses can build up quickly.
The Solution: Embedded Web-based Interface
I introduced the lab to a slick tool available only on Brooks Instrument SLA Series MFCs with EtherNet/IP or PROFINET digital communications, the embedded web-based interface.
Accessibility via Embedded Web-based Interface
Accessible via an ethernet cable plugged into the mass flow controller and a laptop, the interface allows for easy set up and configuration of 500+ mass flow controller attributes. Since each mass flow controller has a unique web address, the team is able to monitor the condition of each unit with ease.
Through the web interface and with some added help from the Brooks Instrument Technical Support team who wrote a script that was able to monitor and configure these thresholds, the team was highly impressed with the new capabilities, particularly the ease with which they could access alarms and warnings.
The Results
The introduction of SLA Series MFCs with EtherNet/IP led to several key process improvements:
Enhanced Reliability
The real-time monitoring of gas flow allowed this manufacturer to mitigate the risk of choked flow conditions, ensuring uninterrupted bioprocessing and minimizing potential batch failures.
Efficiency in Troubleshooting
With immediate access to alarm diagnostics, the team could swiftly identify and resolve issues, significantly reducing downtime and the associated financial impact.
Cost Savings
By preventing batch failures and reducing troubleshooting time, the solution not only safeguarded operational efficiency but also potential savings in both time and money.
The collaboration between Brooks Instrument and this manufacturer has resulted in a robust solution that enhances reliability in bioprocessing by leveraging advanced mass flow controller technology and comprehensive support from our customer care team.
Bonus: FAQs
Can I read through my PLC/DCS and the web server at the same time?
Yes. In this particular case, the bioreactor OEM did not make the MFC alarms and diagnostics available to read via the PLC/DCS. If that’s your situation, Brooks Instrument can help you determine what the MFC is thinking.
How can I get my OEM to setup my equipment to read MFC alarms and diagnostics?
Incorporating intelligent components into equipment requires a new level of equipment design collaboration between process instrument suppliers, equipment manufacturers and end users. At Brooks Instrument, we recommend a framework that is useful for the equipment and component suppliers to utilize so they create designs that align the data, information and diagnostics around the end customer’s needs.