For information and reference only – not to be submitted as your own work.
This sample shows how a first-pass bioreactor P&ID can be documented for the VOMP3011 “From URS to PQ” module when a hand-drawn sketch cannot be reproduced on screen. The brief is on our live page, VOMP3011 P&ID-1: bioreactor sketch and performance requirements. For a step-by-step method, read the companion guide, how to draw a bioreactor P&ID. If you want structured support with a technical write-up, our report writing services page explains what we offer.
Everything below is a worked model, not a template to copy. Tags, setpoints and valve choices are illustrative, and your own drawing must reflect your lecturer’s brief and your own design decisions.
What this sample covers
Step 1-1 asks for a basic P&ID of a jacketed, agitated bioreactor with a bottom outlet pump and fourteen named connections. Step 1-2 asks for the primary performance requirements, each expanded in a sentence or two. A drawing is the right deliverable for Step 1-1, so this extract gives you the content that sits behind the drawing: an equipment list, a connection schedule that maps every one of the fourteen lines, and the tag conventions. Step 1-2 follows as a requirements table that also shows how each requirement would later be verified in qualification.
Step 1-1: layout of the bioreactor P&ID
Draw the vessel (R-101) in the centre of the page with the jacket shown as an outer shell. Place the agitator motor on top, the shaft entering through a mechanical seal, and the impeller inside. Put gas lines on the left of the page, liquid additions on the right, utilities at the top and the bottom outlet and pump at the bottom. Keep process flow left to right wherever you can, and avoid crossing lines. Symbols and instrument identification follow ANSI/ISA-5.1 [1], and sanitary design assumptions follow ASME BPE [2].
Equipment list
| Tag | Item | Notes (illustrative) |
|---|---|---|
| R-101 | Bioreactor vessel with jacket | 316L stainless steel, rated for steam sterilisation; working volume not specified in the brief |
| AG-101 | Agitator (motor, shaft, impeller) | Top-driven, mechanical seal with steam or condensate barrier |
| P-101 | Bottom outlet (harvest) pump | Low-shear hygienic pump, for example lobe or centrifugal type, chosen for the cell line |
| TCU-101 | Temperature control skid | Supplies heating/cooling fluid to the jacket |
| F-101 / F-102 | Sterile air inlet filter / exhaust filter | Hydrophobic 0.2 micron membrane filters, steam-sterilisable in place |
| RD-101 | Rupture disc | Vents to catch tank T-102 |
| T-102 | Catch tank | Receives over-pressure discharge, vented to a safe location |
| P-102 / P-103 / P-104 | Acid / base / antifoam dosing pumps | Peristaltic or similar, with feed vessels |
| ST-101 to ST-103 | Steam traps | On the steam, condensate and filter lines |
Connection schedule for the fourteen lines
Each row below is one connection from the brief. Use it as a checklist against your own drawing.
| No. | Connection | Route | Key valves and instruments (illustrative) |
|---|---|---|---|
| 1 | Aeration supply | Gas skid to F-101 to sparger in R-101 | Mass flow controller FIC-101, check valve, sterile filter F-101, steam connection to filter |
| 2 | Aeration vent/exhaust | Headspace to F-102 to vent | Pressure transmitter PT-101, pressure control valve PCV-101, PIC-101 loop, filter F-102 (heated or protected from wetting) |
| 3 | CIP manifold supply | CIP skid or manifold to vessel spray device | Automated diaphragm valve XV-103, double block and bleed against process lines |
| 4 | Inoculum supply | Seed vessel or bag to top nozzle | Steam-through connection, sterile connector, XV-104 |
| 5 | Media supply | Media preparation or hold vessel to R-101 via sterile filter | Sterilising grade filter, XV-105, flow indicator |
| 6 | Clean steam supply for SIP | Clean steam header to vessel and filter housings | Isolation valve XV-106, PT/TT on steam line, steam trap at low point |
| 7 | Contaminated condensate (SIP) return | Vessel and filter drains via ST-101 to drain or kill system | Steam trap ST-101, temperature element TE-102 on drain to confirm sterilisation temperature |
| 8 | Process water supply and return | Water header to rinse points and back to utility return | Isolation valves, check valve, flow indication |
| 9 | Over-pressure vent to catch tank | R-101 headspace to RD-101 to T-102 | Rupture disc with burst indicator PSE/PT, sized per relief calculation |
| 10 | Antifoam addition | Antifoam vessel to P-104 to R-101 top nozzle | Foam/level probe LSH-101 triggering dosing, check valve |
| 11 | Acid addition (pH) | Acid vessel to P-102 to R-101 | pH probe AE/AT-101 driving AIC-101 and P-102, check valve |
| 12 | Base addition (pH) | Base vessel to P-103 to R-101 | Same AIC-101 loop (split range), check valve |
| 13 | Bottom outlet to harvest manifold | R-101 bottom valve to P-101 to harvest process manifold | Zero-dead-leg bottom valve, steam block or double block and bleed at the manifold, FT/PT on discharge |
| 14 | Thermal-exchange fluid supply/return | TCU-101 to jacket inlet and back | TE/TT-101 in the culture, TIC-101 cascading to the skid, jacket isolation valves |
Instrument tag conventions
Under ANSI/ISA-5.1 [1], the first letter gives the measured variable (T temperature, P pressure, F flow, L level, A analysis) and later letters give the function (E element, T transmitter, I indicator, C controller, V valve, S switch, H high, L low). A tag such as TIC-101 therefore reads as temperature indicating controller, loop 101. Keep the loop number the same for all devices in a loop, so TE-101, TT-101, TIC-101 and the control valve are easy to trace. Check which edition of the standard your module uses, because current editions have been updated since the older 2009 version.
Drawing notes that markers look for
Put sterile filters on both the air inlet and the exhaust. Show the steam trap at every low point of the SIP route so condensate leaves and does not pool. Show the exhaust pressure controller, since without it the vessel cannot hold a set pressure. Show RD-101 discharging into T-102, not to atmosphere. Keep pipe stubs short to avoid dead legs, a general hygienic design principle covered in ASME BPE [2], and let the vessel drain completely through the bottom outlet.
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Step 1-2: primary performance requirements of a bioreactor
A performance requirement is a measurable statement of what the bioreactor must do. Written in the user requirements specification (URS), each one becomes a design input and later a test. The EU GMP Annex 15 treats the URS as the reference point for the whole qualification lifecycle, with OQ checking performance across the operating range and PQ confirming performance under normal conditions [3]. The values below are illustrative only; your own limits would come from the process.
| Requirement | Why it matters | How verified (OQ/PQ) |
|---|---|---|
| Sterility and containment | Any contaminating organism can destroy a batch, and a leak can release the production organism. Sterile boundaries and closed operation are central to sterile manufacturing expectations [4]. | SIP temperature mapping with biological indicators, filter integrity tests, pressure-hold test, media-fill or growth-promotion run at PQ |
| Temperature control: range and stability | Growth and product quality depend on a narrow band. For example, a mammalian process might hold 37 °C within plus or minus 0.5 °C (illustrative). | OQ with water at low, high and normal setpoints, alarm tests, PQ with real or simulated culture |
| pH control | pH affects growth rate and product quality. A deadband of plus or minus 0.1 pH unit around 7.0 is typical for illustration only. | Calibration, acid/base dosing response test at OQ, control stability at PQ |
| Dissolved oxygen control and oxygen transfer (kLa) | Cells consume oxygen faster than air dissolves, so the vessel must supply enough through sparging and agitation. Volumetric mass transfer coefficient (kLa) is the standard measure [5]. | kLa determination across agitation and gas-flow ranges at OQ, DO control test, PQ at peak oxygen demand |
| Mixing and shear | Uniform mixing avoids gradients in pH, nutrients and temperature, while excessive shear damages fragile cells. Tip speed and power input per volume are the usual design checks [5]. | Mixing-time test, agitator speed accuracy, cell viability at PQ |
| Pressure rating and over-pressure protection | The vessel must withstand SIP and operation, and the rupture disc and catch tank must protect people and equipment. | Documentation of design pressure and relief sizing at IQ, burst-disc verification, functional tests of pressure alarms at OQ |
| CIP/SIP cleanability and drainability | Residues cause cross-contamination and bioburden. Sloped lines, no dead legs and spray coverage support cleaning. Cleaning validation must show effective removal of residues [3]. | Riboflavin or equivalent spray coverage at OQ, drainability inspection, cleaning validation swabs and rinse samples |
| Materials and surface finish | Product-contact surfaces must not shed, react with or harbour contamination. Austenitic 316L stainless steel and controlled surface roughness are standard practice under ASME BPE [2]. | Material certificates, surface finish reports and weld documentation at IQ |
| Data integrity, alarms and records | Process data must be attributable, time-stamped and protected from unauthorised change. Electronic records are expected to follow 21 CFR Part 11 [6] and EU GMP Annex 11 [7]. | Audit trail, user access and alarm tests at OQ; electronic record review at PQ |
How the requirements link to qualification
The ISPE Baseline Guide on commissioning and qualification describes a risk-based approach where requirements are confirmed through verification, rather than testing every item the same way [8]. In practice, the URS drives the design and the P&ID, factory and site acceptance tests follow, then IQ, OQ and PQ. A requirement you cannot test is a requirement that needs rewriting.
Common mistakes in this task
Students often draw all fourteen lines but forget instrumentation, so the drawing shows plumbing and no control. Others mix up the SIP condensate return with the process water return, or leave out the sterile filter on the exhaust. In Step 1-2, vague phrases such as “good mixing” lose marks; tie each requirement to a measurable parameter instead.
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Further help
If you would like a second pair of eyes on a P&ID assignment, see our coursework help page or the university assignment help overview. We provide model answers and guidance, and you remain responsible for what you submit and for your institution’s rules.
About the expert
Mary Jones holds a master’s degree in Chemical Engineering from the National University of Ireland, Galway. Her profile lists process design and reaction kinetics among her specialisms and more than ten years’ work as a chemical engineer, including on pharmaceutical plant projects.
References
- International Society of Automation (2024) ANSI/ISA-5.1-2024, Instrumentation and Control – Symbols and Identification. Available at: https://www.isa.org/products/ansi-isa-5-1-2024-instrumentation-and-control-symb
- American Society of Mechanical Engineers (2024) ASME BPE-2024, Bioprocessing Equipment. New York: ASME.
- European Commission (2015) EudraLex Volume 4, EU Guidelines for Good Manufacturing Practice, Annex 15: Qualification and Validation. Brussels, 30 March 2015.
- European Commission (2022) EudraLex Volume 4, Annex 1: Manufacture of Sterile Medicinal Products. Brussels: European Commission.
- Doran, P.M. (2013) Bioprocess Engineering Principles. 2nd edn. Waltham, MA: Academic Press.
- US Food and Drug Administration (n.d.) 21 CFR Part 11: Electronic Records; Electronic Signatures. Available at: https://www.ecfr.gov/current/title-21/chapter-I/subchapter-A/part-11
- European Commission (2011) EudraLex Volume 4, Annex 11: Computerised Systems. Brussels: European Commission.
- International Society for Pharmaceutical Engineering (2019) ISPE Baseline Guide: Commissioning and Qualification. 2nd edn. ISPE.
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