P6: Implementing a Novel OPC Connectivity Solution for Improving Bioprocessing Monitoring and Control

OPC communication provides process automation connectivity and interoperability between various analytical instrumentation and supervisory control and data acquisition (SCADA) systems.  A novel OPC communication device, FlowWeb™ OPC Controller, was developed to improve and/or increase functionality of existing bioprocess SCADA applications.  This device was designed to interface multiple analytical devices, regardless of communication interface, to any OPC-enabled SCADA and facilitate a more comprehensive information management system for bioprocess monitoring and control.  Real-time data from an on-line biochemistry analyzer, in-line turbidity sensor, in-line gas analyzer and at-line analytical balance were simultaneously collected and integrated into a Sartorius BioPAT® MFCS SCADA application.  Each instrument required either a serial, TCP/IP or analog signal to send its respective data to the OPC Controller, which processed the streaming data for OPC communication.  OPC-tagged data were subsequently sent to the MFCS SCADA via the FlowWeb OPC Server/SCADA OPC Client interface.  The FlowWeb™ OPC Controller technology optimized bioprocess knowledge, monitoring and control by: 1) providing real-time data acquisition of in-line, on-line and at-line analytical instrumentation; 2) improving data management through integration and centralization of critical process information; and 3) allowing remote control of analytical instrumentation through the host SCADA application.