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MFC Alarms, Alerts & Diagnostics

Optimize Process Performance with
Digital MFCs



Today’s digital mass flow technology gives operators and process engineers real-time insight into multiple data points in their systems. Brooks Instrument has configured an advanced, smart suite of alarms, warnings and error alerts, available via SLA Series MFCs, to identify areas where fluid flows might be dropping below critical thresholds.

Demanding industries such as biotechnology, chemical and petrochemical research, and thin film coatings and surface treatments depend on this real-time data to optimize their performance.


Using MFC Alarms, Warnings & Error Alerts

There are three key areas where sophisticated MFC alarms, warning and error alerts enable fast, focused diagnostics into system issues or process conditions when they fall outside critical thresholds.

Performance monitoring
MFC data on process throughput, efficiency, quality can be integrated into larger process analytical systems for a window into your system, highlighting long-term trends and opportunities for improvement.

Fault Detection
Diagnostics help identify faults or anomalies in processes through continuous monitoring of key process parameters.

Troubleshooting
Describes how to use MFC alarms and diagnostics to resolve problems faster. Easy to set up, custom-configure and integrate alarms, warnings, etc., to identify and isolate problem areas faster, addressing root causes.

Six Key MFC Alarms

Restricted Flow Alarm & Automated Response

A problem develops in a pressure regulator, restricting gas flow to the bioreactor. The MFC generates a restricted flow alarm, enabled by Ethernet-based networks, initiating an automated response by the bioreactor PLC to adjust and return the system to normal operating conditions.

How it helps
  • Eliminates need for manual operator intervention to resolve flow restriction
  • Increases bioprocessing system productivity and functionality
  • Decreases troubleshooting/diagnosis time and reduces system downtime
  • Supports easy configuration and setup for all users

Backflow Alarm

Enabled by digital MFCs and Ethernet-based network protocols, the backflow alarm alerts the operator to stop the process due to bioprocess liquid pushed backward through the flow path to the MFC.

How it helps
  • Occurs when bioreactor vessel pressure exceeds limits and overcomes positive pressure through the MFC
  • Enables fast response to potential problems within the bioprocess
  • Helps prevent the loss of valuable biologic material or damage to bioprocessing systems, including the MFC

Zero Drift History

How it helps
  • Enables zero flow thresholds allowing low-end process control
  • Easy access to flow, temperature and flow hours for reproducibility/lot analysis
  • Enables predictive analysis on flow performance

MFC Calibration Service Due

MFC generates alert (and triggers blinking light on device) to notify bioprocessing management system that device is scheduled for service or recalibration.

How it helps
  • Supported for EtherNet/IP and PROFINET systems
  • Notifies process management that device is scheduled for (or should be scheduled for) service or calibration
  • Incorporates alerts into preventive maintenance tools and processes
  • Prevents loss of quality, process drift, reduction in productivity; helps prevent unscheduled downtime

Setpoint Deviation Alarm

Digital MFCs automatically adjust to maintain proper flow rates. If the MFC over adjusts and exceeds established setpoints, there’s a strong risk that the bioreactor isn’t receiving proper amounts of gases like O2 and CO2 — throwing off pH and dissolved O2 and harming production of the targeted biologic.

How it helps
  • Setpoints critical/fundamental element of effective process control in any industry
  • Deviations alert operators to significant problems in gas delivery systems
  • Shows how to leverage MFCs to troubleshoot larger system issues

High/Low/No Flow Alarms

Bioreactor MFCs have specific flow rate “recipes” for each new biologic being processed. Preset alarms will trigger to alert operators if upper and/or lower thresholds have been crossed or there’s no flow at all.

How it helps
  • Processes that use gases like bioreactors have flow rate “recipes“
  • Critical to maximum process quality, yield and efficiencies
  • Real-time alerts that can trigger critical diagnostic and systematic troubleshooting for more rapid response to get processes back to optimal

Power of Digital Protocols

All digital protocols provide a range of warnings and alarms. However, the Brooks Instrument SLA Series with EtherNet/IP and PROFINET supports more than 500 process attributes to be configured. This broad range of diagnostics generates the in-depth, real-time digital data that highly automated industries need to fully realize Industry 4.0.

  • Restricted (Choked) Flow
  • High/Low/No Flow
  • Zero Drift History
  • Bad Zero
  • Setpoint Overrange
  • MFC Calibration Due
  • Overhaul Due
  • Invalid Process Gas Page
  • Temperature Sensor Failure
  • Backflow
  • Restricted (Choked) Flow
  • High/Low/No Flow
  • Zero Drift History
  • Bad Zero
  • Setpoint Overrange
  • MFC Calibration Due
  • Overhaul Due
  • Invalid Process Gas Page
  • Temperature Sensor Failure
  • Backflow
  • Restricted (Choked) Flow
  • Zero Drift History
  • High/Low/No Flow
  • Bad Zero
  • MFC Calibration Due
  • Setpoint Overrange
  • Overhaul Due
  • Invalid Process Gas Page
  • Temperature Sensor Failure
  • Backstreaming

Webinar: Optimizing Bioprocess Performance

Brooks Instrument has created an informative video webinar titled “Achieving Optimal Bioprocess Performance Through Intelligent Gas Management.” It details best practices that process engineers and scientists can use to leverage the sophisticated alarms and diagnostic capabilities of our digital MFCs to improve bioprocessing efficiency and productivity.

The video here details one example: how restricted flow or choked flow alarms enable operators to program automated PLC responses to restrictions in process gas flows detected by the SLA Series MFC.

Watch the Complete Webinar
Want to make better use of MFC alarms and diagnostic tools in your bioprocessing systems?

Talk to one of our application engineering experts.

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