Slide 1

Wireless pH and Temperature Wireless pH and Temperature Control of BioreactorsControl of Bioreactors

Greg McMillan, Terry Blevins, Trish Benton, Michael Boudreau, and Scott Broadley

http://www.modelingandcontrol.com/http://www.easydeltav.com/controlinsights/index.asp

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2 Slide 2

Installation at Broadley JamesInstallation at Broadley JamesInstallation at Broadley James

Hyclone 100 liter Single Use Bioreactor (SUB) Rosemount WirelessHART gateway and transmitters for measurement and control of pH and temperature. (pressure monitored)BioNet lab optimized control system based on DeltaV

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WirelessHART Network TopologyWirelessHART Network TopologyWirelessHART Network Topology

Network Manager

Wireless Field Devices– Relatively simple - Obeys Network Manager– All devices are full-function (e.g., must route)

Adapters– Provide access to existing HART-enabled Field

Devices– Fully Documented, well defined requirements

Gateway and Access Points – Allows access to WirelessHART Network from

the Process Automation Network– Gateways can offer multiple Access Points for

increased Bandwidth and Reliability– Caches measurement and control values– Directly Supports WirelessHART Adapters– Seamless access from existing HART

ApplicationsNetwork Manager

– Manages communication bandwidth and routing

– Redundant Network Managers supported – Often embedded in Gateway– Critical to performance of the network

Handheld– Supports direct communication to field device– For security, one hop only communication

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WirelessHART FeaturesWirelessHART FeaturesWirelessHART FeaturesWireless transmitters provide nonintrusive replacement and diagnosticsWireless transmitters automatically communicate alerts based on smart diagnostics without interrogation from an automated maintenance systemWireless transmitters eliminate the questions of wiring integrity and terminationWireless transmitters eliminate ground loops that are difficult to track downNetwork manager optimizes routing to maximize reliability and performanceNetwork manager maximizes signal strength and battery life by minimizing the number of hops and preferably using routers and main (line) powered devicesNetwork manager minimizes interference by channel hopping and blacklistingThe standard WirelessHART capability of exception reporting via a resolution setting helps to increase battery lifeWirelessHART control solution, keeps control execution times fast but a new value is communicated as scheduled only if the change in the measurement exceeds the resolution or the elapsed time exceeds the refresh timePIDPLUS and new communication rules can reduce communications by >60%

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Traditional and Wireless PID (PIDPLUS)Traditional and Wireless PID (PIDPLUS)Traditional and Wireless PID (PIDPLUS)

PID integral mode is restructured to provide integral action to match the process response in the elapsed time (reset time is set equal to process time constant)PID derivative mode is modified to compute a rate of change over the elapsed time from the last new measurement valuePID reset and rate action are only computed when there is a new valuePID algorithm with enhanced reset and rate action is termed PIDPLUS

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Automatically Identified SUB Temperature DynamicsAutomatically Identified SUB Temperature DynamicsAutomatically Identified SUB Temperature Dynamics

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Wireless SUB Temperature Loop Test ResultsWireless SUB Temperature Loop Test ResultsWireless SUB Temperature Loop Test Results

Slight overshoot shown can be eliminated by the use of in Integral on error and Proportional-Derivative on PV

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Wireless SUB pH Loop Test ResultsWireless SUB pH Loop Test ResultsWireless SUB pH Loop Test Results

Slight overshoot shown can be eliminated by the use of in Integral on error and Proportional-Derivative on PV

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Elimination of Ground Noise Spikes by WirelessElimination of Ground Noise Spikes by WirelessElimination of Ground Noise Spikes by Wireless

Wired pH ground noise spike

Temperature compensated wireless pH controlling at 6.9 pH set point

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Top Ten Signs of a WirelessHART AddictionTop Ten Signs of a WirelessHART AddictionTop Ten Signs of a WirelessHART Addiction

(10) You try to use the network manager to schedule the activities of your children(9) You attempt to use RF patterns to explain your last performance review(8) You use so much resource allocation in your network manager, you eat before

you are hungry(7) You propose your wireless device for the “Miss USA” contest(6) You develop performance monitoring indices for your spouse(5) You implement network management on your stock portfolio(4) You carry pictures of your wireless device in your wallet(3) You apply mesh redundancy and call three taxis to make sure you get home

from your party(2) You recommend a survivor show where consultants are placed in a plant with

no staff or budget and are asked to add wireless to increase plant efficiency (1) Your spouse has to lure you to bed by offering “expert options” for scheduling

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For More on the Effect of Sample Time on PIDFor More on the Effect of Sample Time on PIDFor More on the Effect of Sample Time on PID

http://www.easydeltav.com/controlinsights/gm/AdvancedApplicationNote005.pdf

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ReferencesReferencesReferences

1. McMillan, Gregory, et. al., “PAT Tools for Accelerated Process Development and Improvement”, BioProcess International, Process Design Supplement, March, 2008

2. Blevins, Terry, and Beall, James, “Monitoring and Control Tools for Implementing PAT”, Pharmaceutical Technology, Monitoring, Automation , & Control, 2007

3. Boudreau, Michael and McMillan, Gregory, New Directions in Bioprocess Modeling and Control: Maximizing Process Analytical Technology Benefits, Instrumentation, Automations, and Systems (ISA), 2006

4. Boudreau, Michael, McMillan, Gregory, and Wilson, Grant, “Maximizing PAT Benefits from Bioprocess Modeling and Control”, Pharmaceutical Technology Supplement: Information Technology Innovations in the Pharmaceutical Industry, November 2006

5. McMillan, Gregory and Cameron, Robert, Advanced pH Measurement and Control, 3rd edition, ISA, 2005

6. Nixon, Chen, Blevins, and 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.

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

8. Chen, Nixon, Aneweer, Mok, Shepard, Blevins, McMillan “Similarity-based Traffic Reduction to Increase Battery Life in a Wireless Process Control Network”, ISA EXPO2005, Houston, TX