1. NWU IT-ES/NWU IT-ELD Monitoring systems
Fridge and Ambient temperature monitoring, logging and alerting system
Presented by:Tinus Steenkamp

2. Why Monitoring?
Our clients in the pharmaceutical ,food and even hypertension department requested a solution to provide them with a monitoring system because :
Specimens like blood plasma's should be stored in a well managed and controlled temperature range to ensure the safety , purity and efficacy of pharmaceutically/biotech products.
GxP regulations for temperature controlled products requires quick response to prevent undesirable conditions for the specimens.
Results for research purposes should include environmental (such as ambient testing and storage) data to be deem reliable
Therefore temperature of specimens in fridges should be kept at a temperature range of normally -85 °C -+ 5°C ,-20 °C +-5 °C and ambient temperature should range around 25 °C

3. We also need to monitor to ensure:
Quick response to:
Fridges when
Temperature fluctuates beyond set variables
Warning for temperature reaches 5°C tolerance
Alarm if temperature drops beyond 5°C tolerance
Door open for longer than set periods (prevent drop in temperature )
Power failures to fridges
Ambient
Ambient temperatures fluctuates high around 25°C

4. Monitoring should also provide:
Logging of results
Results should be recorded and temperature logs should be made available to proof specimen validity
Monitoring should also provide:
Remote alarming via SMS system
Remote alarming via transmission of signals to local protection services (Will call the person on standby)
Remotely respond to alarm via sms send back to system from cell phone-Logs data to monitor callout response
Remote data acquisition (overall systems status or per fridge)

5. Decision parameters Costs Scalability and development Support
Capital outlay costs
Running costs
Development costs
Scalability and development
Extending the system beyond that of custom build solutions in terms of quantity
Extending the system capabilities due to client request
Monitoring capabilities such as acquisitions not part of custom build solutions
Support
Support not always available or quick due to geographical location

6. Decision time The decision was made to develop our own system because:
Our specific need such as temperature acquisition at any given time could not be met by custom build solutions at the time
Costs of custom build solution are high w.r.t installation and support
Scalability issues over the rest of the Campus
Client needs differ depending on the specimens
Client request for additional functions could be managed in house
Network issues with supplier hardware
Geographical location creates problems with respect to quick response for support (SLA's)

7. Long road to a solution started with research and lead us to investigate:
Custom build solutions by market leaders
Loggers
Portable meters
Software
Fridge on board sensors
Probes
SCADA (supervisory control and data acquisition)
Process control and instrumentation equipment
Building management
Automation technology

8. Implementing the decision with
Hardware
Beckhoff units such as
Digital inputs EL1 xxxx
Digital outputs EL2 xxxx
Analogue inputs EL3 xxxx (4-20 mA for temperature measure)
Analogue inputs (Pressure)
Embedded PC's (changed to normal PC's in the meantime)
Communication terminals EK xxxx
Probes
PT 100 (Resistance due to temp, .02 % -50 °C )
Thermocouples (dissimilar conductor materials creates certain V- drop,.02 % -85 °C,)

9. Hardware continue.. Software Transmitters for probes
Shielded CAT 5 cable
SMS communicator
Door sensor
Software
Beckhoff Ethercat software
Develop own in house software to manage data and logging

10. The result A system that can: Measure Monitor Handle data acquisitions
Send alarms according to predefined parameter
Log each and every activity
Store data (1 min interval logging)
A system that is
Scalable
Manageable
Sustainable (Modular addition and development)
Maintainable (Modules in store)

11. And
A very happy customer
As well as

12. Evidence?

13. Beckhoff Twin Cat 2 system manager

14. Twin Cat 2 linking of devices

15. Customer GUI

16. Rack with interface units

17. Interface units inside Rack

18. Fridge probe @ -85°C and door monitor

19. Ambient monitor Probe and transmitter

20. Power monitoring