Remote monitoring base unit in protective enclosure
By Rob Fusco, Director of Business Development, Sensaphone
When it comes to laboratory work involving critical samples, specimens, pharmaceuticals or other sensitive assets, the ambient lab environment and conditions within refrigerators and freezers play a vital role in preserving the integrity of these valuable resources.
Remote monitoring systems provide early warnings of changes in conditions that can impact laboratory safety and performance. These real-time notifications allow personnel to take fast action to correct the situation. In addition, cloud-based monitoring systems enable users to monitor current status, make programming changes and review data logs on a mobile device via a web page or app. With systems that are not cloud-based, users access status conditions through a local area network.
The systems also provide data logging to demonstrate that the area or cold storage unit is maintaining appropriate condition levels. Information is logged over time, which enables lab personnel to identify trends that could indicate equipment problems.
This article examines ways to use a remote monitoring system to maintain optimal laboratory operating conditions.
Ambient Environment in the Lab
Often laboratory processes require a controlled environment or clean room where operators must control factors like temperature, air flow, humidity and airborne particulates. These work areas must maintain specific parameters to ensure that environmental conditions do not compromise products.
Air flow and pressure management are important for controlled environments. Remote monitoring systems can be equipped with transmitters and sensors to help detect the absence or presence of cool moving air, track relative air flow, identify possible inefficiencies and provide information about air movement trends.
Air flow
Air flow transmitters mounted in the ductwork and connected to the monitoring device measure the rate of air flow. The transmitters monitor the presence or absence of cool moving air and measure relative air flow in meters per second. They are especially useful for monitoring air conditioning in ducts.
The connection from the transmitter to the host or node uses existing infrastructure wiring, and it can be installed in another room or floor away from the host device. If conditions fall out of the required range, the system immediately notifies designated personnel.
Wireless monitoring systems are also available that use built-in radio transmitters to communicate data readings from the sensors to the base device. These wireless systems are useful when wiring would be logistically cumbersome and costly, and they enable greater flexibility in the placement of sensors and the remote monitoring device itself.
Air pressure
To monitor air pressure, differential pressure sensors are used in two separate areas and signal if there is a difference between the readings. These sensors are ideal for laboratories where air pressure must be the same in both rooms to prevent a vacuum that could pull pollutants into the space upon opening a door.
Wall-mounted differential pressure sensors monitor positive and negative pressure from two wall mounts. Both sensors send data to the monitoring device.
High-accuracy duct-mounted differential pressure sensors are designed to tolerate overpressure and vibration to maintain calibration and reduce unnecessary alerts. These sensors monitor positive and negative pressure from two duct mounts.
Vibration
Vibration sensors monitor the vibration velocity on a nonrotating surface and can be permanently mounted on equipment to detect unusual conditions. Vibration fluctuations in HVAC systems can be early indicators of problems that can cause changes in environmental conditions. Because rotating equipment components have unique vibration characteristics, when a part begins to malfunction, the vibration pattern changes.
Vibration sensors communicate their real-time frequency readings to the remote monitoring system, which in turn sends notifications to selected users when an out-of-range value is detected. Operators can use the monitoring system’s data log to review vibration readings at set time intervals and analyze for trends that indicate potential malfunction of the HVAC system.
Other important conditions
Temperature and humidity control go hand in hand in maintaining optimal laboratory conditions. There are many temperature and humidity sensors available to manage ambient conditions in the laboratory. Because most monitoring systems can accommodate multiple sensors, lab personnel can also keep tabs on additional important conditions like smoke, power failure, water leaks and unauthorized entry.
Lab Cold Storage Equipment
Many laboratory samples, specimens, pharmaceuticals and analytes must be kept refrigerated or frozen. Therefore, refrigerators and freezers need to be carefully monitored to ensure these products are always stored according to the required conditions. To ensure consistent internal temperature, it is important to monitor the alarm panel on the refrigerator or freezer, the actual temperature inside the unit using a temperature sensor or probe, and for power failure on the circuit where the refrigerator or freezer is installed.
Temperature buffer
A temperature probe can be paired with a buffer that acts as a cushion against temperature fluctuations in a refrigerator or freezer. A typical buffer is a bottle filled with glycol solution or glass beads in which a probe is inserted. Without a buffer, the probe measures the atmosphere inside the cold storage unit, which can change rapidly through defrost cycles, doors opening and fans circulating air. Because the air temperature inside the unit changes much more quickly than the temperature of the stored products, using a buffered probe provides a more accurate representation of the temperature of the stored assets.
NIST certification
It is recommended that the temperature probes and sensors carry traceable calibration certificates that indicate they comply with standards provided by the National Institute of Standards and Technology (NIST), a U.S. Commerce Department agency.
NIST Traceable Calibration Certificates ensure that the sensor manufacturer is fully equipped to calibrate equipment to NIST standards, and its products match the NIST-maintained measurement criteria. NIST certificates include the necessary information to meet accreditation demands, including serial number, test points and test date. NIST-certified sensors are necessary for laboratories that must provide an audit trail proving their inventory is continually stored at specific temperatures.
Power Failure Monitoring
Lab personnel can use a remote monitoring device to receive notification if a monitored piece of equipment loses power. But if the outage affects the entire lab, the monitoring system can be impacted too. The safest choice is using a monitoring system with a built-in battery backup that will last for hours in the event of a power failure.
A cloud-based monitoring system continuously communicates a signal to the cloud to validate it is online. If the communication link is interrupted by a power outage or human error, the system sends an alert to designated personnel that the connection is lost. Users are notified about the disruption through phone, text or email. All data collected during this time is stored in the device and later uploaded to the cloud when the connection is restored. Be sure to confirm that the infrastructure used to maintain the cloud platform is monitored 24/7 by the monitoring system manufacturer and that there are multiple backups across the country to ensure the cloud system is never down.
Safe and Accessible Data Recording
In addition to keeping around-the-clock watch on laboratory conditions and equipment, remote monitoring systems also provide a data logging feature, which is quite helpful for laboratory management. For example, digital loggers keep a record of temperature data that personnel can download to provide an audit trail documenting proper cold storage of assets. The information can also denote trends that may suggest a refrigerator, freezer or HVAC system is malfunctioning.
Data loggers also remove human error and extra personnel time that come with manually recording information. They communicate with sensors at set intervals and automatically record data points, dates and times. Cloud-based digital data loggers send the data to an online dashboard for users to view in real time and can store and provide an unlimited number of records. Additionally, reports of cataloged information can be sent automatically to users responsible for proving compliance.
Final Thoughts
No matter the type of laboratory—research, medical, pharmaceutical, forensics, product testing—a remote monitoring system is a cost-effective lab management tool. From keeping 24/7 watch on valuable cold-stored samples and specimens to monitoring ambient conditions to providing digital data recording and reporting, labs can only benefit from using this important, user-friendly technology.
Rob Fusco is Director of Business Development with Sensaphone, a developer and manufacturer of remote monitoring and alerting systems. He can be reached at [email protected] or 877-373-2700.