 | |  | |  | |  | |  | |  |
Real-Time Equipment, Instrument, and Lab Data Integration
Batch Expert provides a platform to interface real-time, offline, and laboratory data. This data
becomes available for data warehousing and reporting, process control and monitoring, event
detection, alarming, and auditing. Interfaces are available to real-time instrument such as
controllers and distributed control systems. Off-line measurements, such as glucose and off-gas
analyzers can be brought into Batch Expert through a variety of interfaces. In addition, laboratory
assays directly enter through simple web browser or collected from laboratory information
systems (LIMS). In combination with batch header information that describes the initial culture
provides a means to streamline and optimize the process development or manufacturing process.
Data Historian and Electronic Batch Reporting
In many laboratories, it is difficult to quickly collect batch header, real-time, and laboratory
information regarding a particular batch run. Generating reports based upon this data is often an
arduous and time-consuming process. Based upon affordable off-the-shelf databases, it is
possible to centralize this data so that it can be archived and quickly retrieved in the future. This
includes batch-header information, real-time, and laboratory measurements. Batch Expert and its
database are configured specially for batch processes. This ensures data is efficiently stored and
easily retrieved. End users have a seamless and simple interface to configure batch runs to
collect data and retrieve historical data and their desktop. In a matter of moments, users can
query past data based upon such criteria as batch-id, operator or project name, culture type, and
more.
Event Detection and Auditing
Event detection is a key component in improving a process through real-time process
characterization and identification and is ultimately crucial for control of critical process
parameters. Events may be categorized as internal physical events occurring within the process
or external control events taken by either an automatic control system or manual human
intervention. Examples of physical process events include: the pH is increasing, a sharp peak in
DO, a process sensor has failed. Examples of control events include: the operator has inoculated
the fermenter, the operator has increased the agitation set point, the control computer is
ramping up the feed flow.
Once events are detected and logged to a database, they provide a unique audit trail of the
process and are used for process diagnosis and triggering control actions. Events can also be
used to create more abstract events. For example, by looking at a detected respiration peak, a
microbiologist (and hence the Batch Expert software) may infer that induction has begun.
Induction is now a new event that can be used for taking further control actions.
Recipe Based Control
Batch Expert includes a flexible environment to develop, implement, maintain, and transfer
supervisory control across multiple equipment units, data interfaces, and controller types. Control
strategies are implemented through batch recipes. Recipes are a means to manage and
implement different strategies based upon product type or experiment i.e. strain, culture, etc.
Recipe are based upon procedural elements that can include event-based control, PID control,
alarm configuration, semi-automatic operator interaction, etc. The recipes facilitate transitions
differing strategies are implemented based upon events. These events are as simple as the
current phase of the batch or as advanced as detecting and reacting to the current metabolic
phase in combination to batch age, feed rates, etc. The transparency of recipes is the best
means to develop, scale-up and transfer new processes from the bench-top to pilot or production
scale.
PID and Supervisory Control
PID (proportional integral derivative) control is the foundation of most control systems for the
control of single feedback control loops. In day-to-day operation, special considerations are often
needed to improve PID control. This is due to the transient nature of the process and desired set
points, the recipe and phases of a batch, and the heuristic events that define a batch such as
induction. Batch Expert’s PID controllers accommodate recipe-based batch phase transitions,
flexible set point profiles, event-based detection and reaction, and advanced applications such as
supervisory control, cascade control, and gain scheduling. Batch Expert is designed with both the
operator/technician in mind. Operators and technicians have flexible but limited capability to
make changes to set points across batch phases while developers can design advanced control
methodologies that can then be transitioned to operations.
Operator Recipe Interaction
Scientists and engineers can work with Batch Expert to create, edit, and modify various recipe
objects in the recipe library. These recipes specify how event detection, process control, and
alarms will be handled throughout the course of the batch process. End users such as operators
can choose and initiate these recipes when a particular batch is ready to run. Recipes include
features for semi-automatic transitions. These transitions require operator interaction. For
example, a phase change may require operator interaction or a change to equipment that
requires manual intervention.
Operator Alarms, Recommendations and Checklists
When running a new batch or beginning a new phase or step within a batch, a list of checklist
items is often useful to display to the operator. Batch Expert provides facilities for entering
checklist reminders to the operator before starting the batch or beginning a new batch phase or
step. While a batch is running, certain events may trigger alarms for the operators, which may
require some manual intervention to the process. Batch Expert provides a rich alarm display that
allows users to view, sort, acknowledge, and obtain further details on alarms. Events or alarms
may trigger more detailed recommendations for the operator, which are displayed in a
spreadsheet format.
Trending
The ability to view live and historical data in a trend chart is crucial for scientists, engineers, and
operators to visualize and analyze a batch process. Batch Expert provides configurable multi-pen
trend charts, which can display the real-time data or even allow the use to overlay historical data
with the real-time data. Different batches can also be displayed on the same trend chart for quick
visual comparisons.
Advanced Control and Process Monitoring
Batch Expert is a unique platform that can accommodate research and development in process
control, monitoring and optimization. The platform is built upon an expert system that can
combine rules and models. With minimal training and a basic understanding of computer
programming advanced users can develop either procedural based programs or utilize the built in
block programming language. Advanced control and monitoring application can combine models
such as neural networks with rules and events.
Technology Transfer
Batch Expert improves technology transfer and the effort required to develop process by
combining several features. The key features are system and data integration, recipe design and
implementation, data warehousing and retrieval, improved control, monitoring, and alarming, and
consistency of operation from the bench-top to the pilot scale.
Batch Expert provides a platform to interface real-time, offline, and laboratory data. This data
becomes available for data warehousing and reporting, process control and monitoring, event
detection, alarming, and auditing. Interfaces are available to real-time instrument such as
controllers and distributed control systems. Off-line measurements, such as glucose and off-gas
analyzers can be brought into Batch Expert through a variety of interfaces. In addition, laboratory
assays directly enter through simple web browser or collected from laboratory information
systems (LIMS). In combination with batch header information that describes the initial culture
provides a means to streamline and optimize the process development or manufacturing process.
Data Historian and Electronic Batch Reporting
In many laboratories, it is difficult to quickly collect batch header, real-time, and laboratory
information regarding a particular batch run. Generating reports based upon this data is often an
arduous and time-consuming process. Based upon affordable off-the-shelf databases, it is
possible to centralize this data so that it can be archived and quickly retrieved in the future. This
includes batch-header information, real-time, and laboratory measurements. Batch Expert and its
database are configured specially for batch processes. This ensures data is efficiently stored and
easily retrieved. End users have a seamless and simple interface to configure batch runs to
collect data and retrieve historical data and their desktop. In a matter of moments, users can
query past data based upon such criteria as batch-id, operator or project name, culture type, and
more.
Event Detection and Auditing
Event detection is a key component in improving a process through real-time process
characterization and identification and is ultimately crucial for control of critical process
parameters. Events may be categorized as internal physical events occurring within the process
or external control events taken by either an automatic control system or manual human
intervention. Examples of physical process events include: the pH is increasing, a sharp peak in
DO, a process sensor has failed. Examples of control events include: the operator has inoculated
the fermenter, the operator has increased the agitation set point, the control computer is
ramping up the feed flow.
Once events are detected and logged to a database, they provide a unique audit trail of the
process and are used for process diagnosis and triggering control actions. Events can also be
used to create more abstract events. For example, by looking at a detected respiration peak, a
microbiologist (and hence the Batch Expert software) may infer that induction has begun.
Induction is now a new event that can be used for taking further control actions.
Recipe Based Control
Batch Expert includes a flexible environment to develop, implement, maintain, and transfer
supervisory control across multiple equipment units, data interfaces, and controller types. Control
strategies are implemented through batch recipes. Recipes are a means to manage and
implement different strategies based upon product type or experiment i.e. strain, culture, etc.
Recipe are based upon procedural elements that can include event-based control, PID control,
alarm configuration, semi-automatic operator interaction, etc. The recipes facilitate transitions
differing strategies are implemented based upon events. These events are as simple as the
current phase of the batch or as advanced as detecting and reacting to the current metabolic
phase in combination to batch age, feed rates, etc. The transparency of recipes is the best
means to develop, scale-up and transfer new processes from the bench-top to pilot or production
scale.
PID and Supervisory Control
PID (proportional integral derivative) control is the foundation of most control systems for the
control of single feedback control loops. In day-to-day operation, special considerations are often
needed to improve PID control. This is due to the transient nature of the process and desired set
points, the recipe and phases of a batch, and the heuristic events that define a batch such as
induction. Batch Expert’s PID controllers accommodate recipe-based batch phase transitions,
flexible set point profiles, event-based detection and reaction, and advanced applications such as
supervisory control, cascade control, and gain scheduling. Batch Expert is designed with both the
operator/technician in mind. Operators and technicians have flexible but limited capability to
make changes to set points across batch phases while developers can design advanced control
methodologies that can then be transitioned to operations.
Operator Recipe Interaction
Scientists and engineers can work with Batch Expert to create, edit, and modify various recipe
objects in the recipe library. These recipes specify how event detection, process control, and
alarms will be handled throughout the course of the batch process. End users such as operators
can choose and initiate these recipes when a particular batch is ready to run. Recipes include
features for semi-automatic transitions. These transitions require operator interaction. For
example, a phase change may require operator interaction or a change to equipment that
requires manual intervention.
Operator Alarms, Recommendations and Checklists
When running a new batch or beginning a new phase or step within a batch, a list of checklist
items is often useful to display to the operator. Batch Expert provides facilities for entering
checklist reminders to the operator before starting the batch or beginning a new batch phase or
step. While a batch is running, certain events may trigger alarms for the operators, which may
require some manual intervention to the process. Batch Expert provides a rich alarm display that
allows users to view, sort, acknowledge, and obtain further details on alarms. Events or alarms
may trigger more detailed recommendations for the operator, which are displayed in a
spreadsheet format.
Trending
The ability to view live and historical data in a trend chart is crucial for scientists, engineers, and
operators to visualize and analyze a batch process. Batch Expert provides configurable multi-pen
trend charts, which can display the real-time data or even allow the use to overlay historical data
with the real-time data. Different batches can also be displayed on the same trend chart for quick
visual comparisons.
Advanced Control and Process Monitoring
Batch Expert is a unique platform that can accommodate research and development in process
control, monitoring and optimization. The platform is built upon an expert system that can
combine rules and models. With minimal training and a basic understanding of computer
programming advanced users can develop either procedural based programs or utilize the built in
block programming language. Advanced control and monitoring application can combine models
such as neural networks with rules and events.
Technology Transfer
Batch Expert improves technology transfer and the effort required to develop process by
combining several features. The key features are system and data integration, recipe design and
implementation, data warehousing and retrieval, improved control, monitoring, and alarming, and
consistency of operation from the bench-top to the pilot scale.
 |
| |
 |
| |
 |
| |
 |
| |
 |
| |
 |
| |
 |
 |
| |
 |
| |
 |
| |
 |
| |
 |
Copyright © 2009 ILS