Critical plant systems such as reverse osmosis and chemical distribution systems can bring production down when they go down.  Over time plant utility usage can change, and previously reliable systems will have events that lead to production losses, regulatory compliance issues, and equipment downtime.

If you are in the pharmaceutical, biotechnology, or healthcare industries, you need to have properly maintained, calibrated, and validated equipment and facilities, not just for regulatory compliance but for reliable and profitable operations. To optimize current distribution systems, you need to do proper assessments, procedural changes, system repairs, and validation addendums.

flow mapping

What are the tests performed process solutions distribution?

Common tests/assessments for distribution systems include:

    • Flow/Pressure Distribution Test (System in recirculation (no utility usage)
    • Flow/Pressure Distribution Test (Maximum usage)
    • Temperature Distribution Test (Points of Use)
    • Maximum Supply Flow
    • Minimum Return Flow
    • Power Loss Tests
    • Alarm Tests
    • Recovery Time Tests

Other tests to consider based on your risk assessment include

    • Sensor Response Time
    • Control Loop Tuning
    • Dead-leg evaluation
    • Micro testing
    • Distribution Tank Switchover Testing
    • Emergency Generator Cutover Tests
    • Routine Use Tests

How is Process Flow Mapping done?

Process Flow mapping involves placing an array of pre-calibrated flop, pressure, temperature, and other parameter data-logging sensors in pre-defined locations on generation, distribution, and points of use.  You start the data-logging sensors and run the tests specified in your approved validation study protocol.  You want to run the process solutions flow validation study long enough to go through the various flow loading equipment, and end-users cause varying demand.  After the Process Solution Flow mapping study, the sensors are post-calibrated to assure that the sensors are still operating as expected.

How long does process flow mapping take?

A process flow mapping study takes one to two weeks, including the time to prepare and approve the protocol, pre-calibrate the sensors, the actual testing, and the post-calibration of the sensors.  Typical thermal mapping study execution times are in these ranges.

  • Solution Mixing and distribution tank(s) (run duration processing through generation and distribution of all tanks)
  • Distribution Loops (1 Week)
  • Points of Use (24 Hours to 1 Week)


The Process Solutions Flow mapping output is flow, pressure (and other parameters) versus time report at each location.  The final study report demonstrates that your equipment or facility can meet your specifications when you operate it as you intend to operate it.

PSC Biotech is the right Process Solutions Flow mapping service

If you need Process Solutions Flow mapping services, calibration services, and state-of-the-art wireless or wired equipment to do thermal mapping validation of your equipment and facility, contact PSC Biotech. Our process solutions flow mapping experience and supply of calibrated state-of-the-art wireless and wired sensors can meet all your Process Solutions Flow mapping needs.


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