WirelessHART Benefits Single-Use Disposable Bioreactor

Scott Broadley - President, Broadley-James

Presenters

Scott Broadley – President, Broadley James

Trish Benton – Consultant, Broadley James

Terry Blevins – Principal Technologist, Emerson

Introduction

Application of WirelessHART to Disposable Bioreactors

Background on WirelessHART Wirelesss Impact on Control Modified PID for Wireless Measurements Performance Comparison to Wired Transmitter Addressing Lost Communications Test results Disposable Bioreactor Installation at Broadley James

Disposable Bioreactor Technology

Disposable bioreactor technology has many advantages in new large-scale manufacturing and product development labs.

The benefits of using disposable bioreactors can be increased by switching to WirelessHART transmitters for pressure, temperature, pH, and dissolved oxygen measurement.

WirelessHART Transmitter

A large variety of WiressHART Devices are available in the market.

The benefits of using disposable bioreactors can be increased by switching to WirelessHART transmitters for pressure, temperature, pH, and dissolved oxygen measurement.

In a new facility, wireless technology provides immediate savings in the cost of wiring installation.

Advantages of WirelessHART

The flexibility of being able to work on reactors without disconnecting cables can provides on-going benefit by reducing the downtime and maintenance.

Also, the accuracy and reliability the pH and dissolved oxygen measurement may be improved since battery power wireless transmitter are not as susceptible to ground loops that often plague a wired installation.

WirelessHART is designed to support monitoring and control applications

WirelessHART Solution

Power consumption is minimized by transmitting the measurement value using the following rule:– The transmitter will periodically sample the measurement 4-

10x faster than the process response time.– The new value will be communicated as scheduled only if

the magnitude of the difference between the new measurement value and the last communicated measurement value is greater that a specified resolution or if the time since the last communication exceeds a refresh time

– Thus, the measurement is communicated only as often as required to allow control action to correct for unmeasured disturbances or changes in operation point.

Impact of Wireless Communication on Control Implementation

The underlying assumption in traditional control design is that the PID is executed on a periodic basis.

When the measurement is not updated on a periodic basis, then the calculated reset action may not be appropriate.

To provide best control when a measurement is not updated on periodic basis, the PID may be restructured to reflect the reset contribute for the expected process response since the last measurement update and to account for the non-periodic update in the rate calculation.

In DeltaV v11 new FRSI_OPT have been added to enable special PID features* to allow control using WirelessHART transmitters

*Patented – Emerson Process Management

CONTROL PERFORMANCE DIFFERENCE

Communications transmissions are reduced by over 96 % when the rules for wireless communication are followed.

The impact of non-periodic measurement updates on control performance is minimized through the use of the v11 DeltaV PID for wireless communication.

Installation at Broadley James

Hyclone 100 liter disposable bioreactor

Rosemount WirelessHART gateway and transmitters for measurement and control o f pH and temperature. Pressure monitored

BioNet Control system based on DeltaV

Installation at Broadley James (Cont)

Detail view of Rosemount pH WirelessHART Transmitter.

Battery powered – 3 to 5 year battery life expected.

Measurement made 1/sec, transmitted using exception reporting

Wireless SUB Temperature Loop Test Results

Wireless SUB pH Loop Test Results

Elimination of Ground Noise Spikes by Wireless

Wired pH ground noise spike

Temperature compensated wireless pH controlling at 6.9 pH set point

Incredibly tight pH control via 0.001 pH wireless resolution setting still reduced the number of communications by 60%

Summary

The benefits of using disposable bioreactors can be increased by switching to WirelessHART transmitters for pressure, temperature, pH, and dissolved oxygen measurement.

pH and temperature control of a disposable bioreactors Control using WirelessHART transmitters has been successfully demonstrated at Broadley James

The WirelessHART pH transmitters proved to be more reliable that the wired pH transmitter

Where To Get More Information

Visit www.plantwebuniversity.com and take the 20+ wireless courses available online

Visit www.emersonprocess.com/smartwireless Visit www.hartcomm2.org/index.html Greg McMillan, “Is Wireless Process Control Ready for Prime Time?”, Control,

May, 2009 Scott Broadley, Bob Karschnia, Mark Nixon, Terry Blevins “Using Wireless

Transmitters in Single-Use Disposable Bioreactor Control”, IFPAC Conference, January 25-28, 2009, Baltimore, Maryland, U.S.A

Greg McMillan, Michael Boudreau “Techniques for Wireless pH Controlof Bioreactors”, Interphex Conference, January 25-28, 2009, Baltimore, Maryland, U.S.A

Mark Nixon, Deji Chen, Terry Blevins, and Aloysius K. Mok, “Meeting Control Performance over a Wireless Mesh Network”, The 4th Annual IEEE Conference on Automation Science and Engineering (CASE 2008), August 23-26, 2008,, Washington DC, USA.

Chen, Nixon, Blevins, Wojsznis, Song, Mok “Improving PID Control under Wireless Environments”, ISA EXPO2006, Houston, TX