Infusion Pump Mechanics & the Significance of Inaccurate Flow Rates

I am working on another post relating to FDA regulation of pain pumps, but expect it may be a week or two before I am able to complete it.  In the meantime, I thought I would share an article I recently came across----Disposable Infusion Pumps by Skryabina and Dunn.  It contains useful explanations of how some of the most common types of these pumps actually function.

These devices are used for many purposes beyond that of a "pain pump"--delivering local anesthetics post-operatively at or near a surgical site.  These include the delivery of other medications, including chemotherapy, antimicrobials, antibiotics, as well as the delivery of anesthetics or analgesics by other routes, eg., continuous epidural, peripheral nerve block, and i.v..  The authors provide concise descriptions of the mechanisms of several types of non-electric pumps including elastomeric, positive-pressure (spring-powered and gas-pressured powered), negative-pressure (vacuum), and patient-controlled analgesia (PCA) pumps. 

The flow rates of medications through disposable pumps are significantly inaccurate--typically within +/-15% or even +/-20%.  (Compared to +/-3% with electronic syringe pumps and +/-5% with electronic volumetric pumps).  I believe most pain pump manufacturers include the +/-15% figures in their written materials--see, eg. the flow rate table included in the product Insert for the On-Q Pump with Fixed Flow Rate. 

Nonetheless, I assume most surgeons who use a pain pump labeled with a 2 ml/hr flow rate are likely to believe that the device delivers only 48 ml of local anesthetic in the first 24 hours.  In fact, the same flow rate table in the Insert for the On-Q Pump (along with all other documents for the On-Q I've seen) shows that a 100 ml pump will actually deliver 65 ml in the first 24 hours.  For the first several hours, the flow rate is actually 2.5 ml or higher. 

If the anesthetic is 0.50% Marcaine, 65 ml means 325 mg.  The maximum 24 hour dose for Marcaine is 400 mg and, as I've stressed before, this is based on the risk of systemtic toxicity (neurological or cardiac) and not local (tissue) toxicity.  Surgeons commonly use additional injections of local anesthetics around surgical sites during procedures.  Thus, it would take only an additional 15 ml of 0.50% Marcaine, along with a 100 ml 2 ml/hr. pump, to reach a 400 mg dose in the first 24 hours after surgery. 

I believe many pain pump manufacturers have blithely assumed that any 24 hour dose of Marcaine as long as it remains less than 400 mg, in most any part of the body, regardless of the concentration, and regardless of the route of administration (continuous infusion vs. others), is inherently safe.  For all who have sustained injuries from pain pumps caused by local anesthetic toxicity, this has been a tragically flawed assumption. 

 

FDA's Failure to Demand More of Pain Pump Makers puts Patients at Increased Risk of Harm.

I have been reviewing the FDA's regulatory scheme over pain pumps and believe I've identified several  weaknesses which are likely to adversely affect patient safety.

Pursuant to 21 United States Code 360c, medical devices are divided into three classes for purposes of regulation: Class I, General Controls; Class II, Special Controls; and Class III, Pre-Market Approval.

The pre-market approval process is rigorous and the FDA requires a device manufacturer to submit considerable documentation regarding a device’s safety and effectiveness in order to obtain approval. Understandably, device manufacturers prefer to attempt to have their devices approved as Class I or II devices.

I was surprised to find that Class III is actually the default classification. Subsection (f) of 21 USC 360c provides:

Any device intended for human use which was not introduced or delivered for introduction into interstate commerce or commercial distribution before May 28, 1976, is classified in Class III unless—

(A) The device—

(i) is within a type of device (I) which was introduced or delivered for introduction into interstate commerce for commercial distribution before such date and which is to be classified pursuant to subsection (b) of this section or (II) which was not so introduced or delivered before such date and has been classified in Class I or II, and

(ii) is substantially equivalent to another device within such type…(emphasis added)

Pain pumps are classified as Class II devices pursuant to federal regulation 21 CFR 880.5725, which covers infusion pumps and is part of the overall regulation of general hospital and personal use devices.  Class II devices are subject to special controls and for pain pumps this concerns performance standards.  A pain pump manufacturer is required to certify in its application materials to the FDA that its device meets an industry standard relating to infusion pumps.  These standards include:  1) AAMI (Association for the Advancement of Medical Instrumentation),  Draft Infusion Device Standard; 2) UL (Underwriters Laboratory) 544 Standards for safety, medical and dental equipment; and 3) IEC (International Electrotechnical Commission) 601-1/ANSI (American National Standards Institute) ES1-1985 Safe Current Limits for Electromedical Apparatus. 

I'm sure these standards are important and applicable to the safe-functioning of many types of infusion pumps. I'm also sure they're relevant to the types of adverse events in infusion pumps the FDA recently announced it was seeking to combat through tighter regulation.  (My post on this is here ).  However, most pain pumps are much less mechanically-complicated than the infusion pumps used to deliver insulin or chemotherapy drugs (to name a few types).  So, these standards really don't get at the main safety concerns with pain pumps which involve the basic threshold question of whether they are reasonably safe for their intended use of continuous infusion of local anesthetics.  As a result, I don't see the FDA's classification of pain pumps as Class II devices conferring any benefits for patient safety.

To my knowledge, all pain pump manufacturers have received approval from the FDA by utilizing the substantial equivalence provision mentioned above.  In this process, the FDA requires device manufacturers to submit a Section 510(k) Pre-Market Notification of intent to market the device. If approved, the FDA issues a letter (see example here) with the following operative language: “The FDA finding of substantial equivalence of your device to a legally marketed predicate device results in a classification for your device and thus, permits your device to proceed to the market.”

In March 1993, the FDA issued Guidance on the content of Pre-Market Notification [510(k)] Submissions for external infusion pumps. Section II D is on device description. The description is required to provide a clear statement of the intended use(s) of the infusion pump, including specifying the route(s) of administration and if the infusion pump is labeled for use with a specific drug/biologic the applicant must supply information demonstrating that use of the drug/biologic with the device is consistent with the approved drug/biologic labeling.

Pain pumps are clearly labeled for use with local anesthetics. However, as I have argued in a previous post, the continuous infusion provided by pain pumps is not an approved use of local anesthetics, especially the most commonly used—Marcaine.

For example, in its 1998 510(k) submission for its PainBuster pump, I-Flow reported that there are no specific drugs referenced in the labeling for the PainBuster infusion system, but that it is intended for use with general local anesthetics. I suspect that most, if not all, 510(k) submissions for pain pumps list only a similar general statement.

The FDA could insist that pain pump manufacturers provide evidence in their 510(k) submissions demonstrating how these devices are consistent with the uses approved in local anesthetic labeling. Manufacturers would then be forced into attempting to characterize the use of local anesthetics in their devices--continuous infusion--as akin either to local infiltration or a peripheral nerve block (PNB), which are approved uses. 

Local infiltration involves the injection of a small amount of local anesthetic, typically near a surgical site. Far too much anesthetic is delivered by a pain pump for a manufacturer to claim it is similar to local infiltration.

A PNB likely utilizes a larger amount of anesthetic than in local infiltration, but typically does not approach the volume used in a pain pump. Also, a PNB involves the insertion of a catheter at some distance from an incision site, while a pain pump catheter is intended to be inserted close to an incision. Traditionally, PNBs were accomplished with a single dose of local anesthetic. However, in recent years continuous PNBs have begun to be used by anesthesiologists. Dr. Brian Ilfeld is one of the leading researchers on this technique; here's an article by him on PNBs

It is unclear to me whether continuous PNBs are really an approved use of local anesthetics, per the manufacturers' labeling. However, the articles I’ve seen indicate a greater degree of safety than with pain pumps. I would think this has much to do with continuous PNBs being performed by anesthesiologists as opposed to pain pumps which are typically placed by surgeons. A catheter which will deliver a local anesthetic at a greater distance from a surgical site is less likely to produce wound healing problems. Also, an anesthesiologist is likely to pay closer attention to the volume of local anesthetic used in a continuous PNB than a surgeon utilizing a pain pump.

The incidence of adverse events involving pain pumps has certainly been such that much greater regulatory scrutiny is warranted. These events extend far beyond chondrolysis in shoulder surgeries.  (See my prior post).  The FDA's recently announced requirements that pain pump manufacturers and local anesthetic manufacturers must revise their product labels to highlight the risk of chondrolysis in shoulder surgeries leaves unaddressed the more basic question of whether continuous infusion is a safe use.  The FDA should require pain pump manufacturers to provide detailed evidence about why their devices are consistent with the uses approved by local anesthetic manufacturers. 
 

Does New FDA Oversight Include Disposable Pain Pumps?

I am still a bit confused as to whether the new oversight regime the FDA announced yesterday applies to the disposable local anesthetic infusion surgically-implanted pumps that are my focus in this blog.

Reading the New York Times article on the announcement led me to think these devices might be excluded, as it focuses on IV-implanted, programmable devices used to provide insulin, chemotherapy, and pain medications (but patient-controlled).  There have been over 56,000 adverse events and 710 deaths involving these devices in the past 5 years.  These are truly staggering numbers.  Regarding the types of problems reported, the FDA Press Release indicates: The most common types of reported problems have been related to:

* software defects, including failures of built-in safety alarms;
* user interface issues, such as ambiguous on-screen instructions that lead to dosing errors; and
* mechanical or electrical failures, including components that break under routine use, premature battery failures, and sparks or pump fires.

Failures of infusion pumps have been observed across multiple manufacturers and pump types. The FDA says that many of the reported problems appear to be related to deficiencies in device design and engineering.

I saw nothing about shoulder chondrolysis or other injuries from local anesthetics. So far, all of this sure seemed outside the scope of pain pumps. 

The next step up in document complexity is the FDA's White Paper on its Infusion Pump Improvement Initiative.   I read  "In general, an infusion pump is operated by a trained user, who programs the rate and duration of fluid delivery through a built-in software interface" and it confirms my initial belief.   However, then among the pump mechanisms elastomeric is listed and this is one of the most common types for disposable pain pumps.  Finally, at the end of the paper I see among the footnotes:  1 This document does not pertain to implanted infusion pumps, which are surgically placed in the body.  Okay, now I'm pretty sure this significant announcement doesn't apply to the devices with which I'm familiar.  However, there are several additional documents the FDA has included and, for completeness sake, I read on.

The letter to infusion pump manufacturers from Jeffrey E. Shuren, Director of the FDA's Center for Devices and Radiological Health (CDRH) also focuses on software, design, human factors, and manufacturing problems. 

There's detailed information about CDRH's software research on infusion pumps.  I had no idea the FDA has a software engineering laboratory. 

Ultimately, there's the agency's Guidance for Industry and Staff regarding 510(k) Pre-Market Notification Submissions.  This is a draft document (34 pages in PDF form) which will be entering a 90-day comment period.  When complete it will replace the Guidance on the Content of Premarket Notification [510(k)] Submissions for External Infusion Pumps, issued March, 1993.  

My confusion was finally resolved (I think) by reading the Scope section of this document.  It makes clear that all infusion pumps addressed by 21 C.F.R. 880.5725 will be covered by the new guidelines. This includes numerous types of devices including all Elastomeric Infusion Pumps (products coded MEB), and excludes only the following: gallstone dissolution pumps (MHD), opthalmic infusion pumps (MRH), and analytical sampling infusion pumps (LZF).   Just to be sure, I double-checked the most recent 510(k) Submission for the On-Q Painbuster, which confirms the same regulation (880.5725) and product code (MEB). 

So, it does indeed look like I-Flow, Stryker and company will have to learn how to comply with considerable new requirements and provide alot of additional information in future premarket submissions to the FDA.   This is certainly good news, but I have lingering confusion because of the lack of mention in any of these new documents from the FDA of the adverse events involving these devices with which I'm familiar.   An Appendix to the Guidance document lists the following categories of "Risks to Health" with infusion pumps:  Overdose, Underdose, Delay in Therapy, Incorrect Therapy (wrong medication or correct medication but wrong dosage or infusion rate), Air Embolism, Trauma (burns, cuts, abrasions, bruising), Electric Shock, Infection, Allergic Response, and Exsanguanation.  Perhaps the numerous cases of chondroylsis and tissue necrosis are intended to be included in one of these categories (Infection? Allergic Response?). 

When I think again about the number of adverse events--56,000--reported involving all types of infusion pumps over just the last 5 years, I realize that the number involving local anesthetics, even if it's 500 or more, is likely to be less than 1% of the overall events.  Where do local anesthetic infusion pumps and the injuries they appear to cause fit into the broader regulatory and safety scheme involving this class of devices?  My initial reaction is that the problems with pain pumps don't have much to do with design, human factors, or manufacturing issues (and certainly not software).    I will certainly reserve judgment and keep an eye on how the new oversight regime takes shape.  Of course, it will also be interesting to see how these developments may affect litigation involving injuries and deaths from PCA and other programmable pumps.  I can envision claims which were initially viewed as malpractice expanded to also (or instead) focus on the liability of the pump manufacturer.