Production laboratories differ widely in the way they are organised depending on the industry involved and the test routines employed. For process industries such as petroleum and petro-chemical sectors, plants run continuously 24 hours per day, seven days per week, each week of the year unless shutdown for maintenance. In such laboratories, there is a high degree of automation possible, as many tests utilise gas or liquid chromatography.
The analytical system often uses gas sampling valves or automatic samplers on the GC’s, automatic data handling via a chromatography data system (CDS) and links to LIMS or other plant control system which may be uni-directional or bi-directional. In addition, most commonly, GCs or LCs are dedicated to one specific analysis thus increasing throughput and simplifying operations by eliminating the need for changing chromatographic conditions and columns.
Given this level of automation, many companies use shift workers to load routine samples onto the appropriate GC rather than have laboratory chemists or technicians employed for the task. Chemists’ time is spent investigating results that may indicate a problem or an out of specification condition, which improves the allocation of manpower and resources.
Despite this, CDS user interfaces in practice can be somewhat daunting to non-chemists since most commercial systems must support a variety of applications found in many industries including the needs of method development and research departments. For example, a method development laboratory will need to investigate the use of different method parameters including adjusting the quantitative aspects of peak measurement. This is not ideal for a production laboratory, since methods typically remain unchanged for several months and even years. The CDS must take account of both of these two extremes.
The user interface can also define a back-up chromatograph if the normal system becomes unavailable for any reason, e.g. scheduled maintenance. System preparation allows the definition of chromatographs, methods, tests, samples and the combination of these that are routine in nature.
On completion of the run, the user interface transfers the final results back to the LIMS or plant control system.
Besides the automation of routine samples, the user interface is able to create and run ad-hoc samples when required, using the Sample Generation screen. This enables non-routine samples to be entered and placed into the appropriate sample queues without having to change any of the routine methods and conditions. This eliminates the need to edit existing methods on a frequent basis, thus saving time and aiding throughput.
As can be seen, a minimum of operator knowledge is required for this operation and hence training times are reduced and many costly errors are avoided. Chemists need only spend time investigating and resolving problems rather than running routine samples.
Production laboratories need to maximise automation and minimise the interaction of the user with potentially complex software. The running of 24/7 operations creates high- demands on data processing. Therefore a system that returns results to plant controllers quickly helps maintain production at desired yields with high quality and will benefit the entire organisation.
A user interface such as the one described must be suitable for non-expert users of a CDS with little training required.
Consequently the automatic operation of chromatographic systems involving queuing, prioritising and running of samples is now more practical than before and offers significant time and cost saving benefits. This may be further augmented by bi-directional links to external systems such as a LIMS, which has a positive impact on data integrity and further time saving benefits.