NeSSI* - A Sampling and Connectivity Platform Comes of...

ISAExpo2003 ISAExpo2003 23 October 2003: Houston, TX

“the best way to predict the future is to create it”

NeSSI* -A Sampling and Connectivity

Platform Comes of Age(* New Sampling/Sensor Initiative)

Peter van VuurenPeter van Vuuren

ISAExpo2003Houston, Texas, USAOctober 23, 2003


Overview Topics

• Why NeSSI?

• NeSSI as a Sampling/Connectivity Platform

• Gen II Progress

• Path Forward


NeSSI Objectives

•• Facilitate the acceptance/implementation of...Facilitate the acceptance/implementation of...

–– modular, miniaturemodular, miniature & smart sample system technology& smart sample system technology

–– based on ISA SP76 standard substrate (based on ISA SP76 standard substrate (akaaka footprint) footprint)

•• Promote the concept of...Promote the concept of...

–– fieldfield--mountedmounted smart sampling/analytical systemssmart sampling/analytical systems

–– sample system integration with sample system integration with miniature physical sensorsminiature physical sensors

•• Lay the groundwork for...Lay the groundwork for...

–– open open connectivity architectureconnectivity architecture for sensor communications (e.g. for sensor communications (e.g. CANbusCANbus, Ethernet, etc.), Ethernet, etc.)

–– industry standard industry standard communication protocolscommunication protocols (e.g. OPC, etc.)(e.g. OPC, etc.)

•• Provide a technology bridge to the process for...Provide a technology bridge to the process for...

–– “sensor/lab“sensor/lab--onon--aa--chip” chip” micromicro--analytical devicesanalytical devices


Why NeSSI?

•• Overview of a Typical Process Analytics InstallationOverview of a Typical Process Analytics Installation

•• What is Wrong with Today's InstallationsWhat is Wrong with Today's Installations

•• Some Cost ConsiderationsSome Cost Considerations

•• NeSSI to the RescueNeSSI to the Rescue


Today’s Analyzer System

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical


Inside an Analyzer Shelter

Picture Courtesy ExxonMobil Chemical


Sampling Conditioning Systems



Sampling Conditioning System - Detail



What is Wrong with these Pictures

•• Nothing Nothing

Best we can do with the tools at handBest we can do with the tools at hand

•• And a LotAnd a Lot

Considering Considering Cost to BuildCost to BuildCost to OwnCost to OwnData ValidationData Validation



A Lot of Infrastructure(Brute Forcing the Installation)

A/C

Sample Conditioning

Systems

Sample Transport

Lines

AnalyzerShelter




Analyzers treated like Prima Donnas

We change the environment to meet their needs




Sample Conditioning Systems:* Custom designed, engineered and built* Poor standardization




Sample Conditioning Systems:* Custom designed, engineered and built* Lots of tubing/fittings* Many man-hours designing/building it* Lots of discrete components* Typically not smart

(Smart = knowing if p,t,f of sample arenormal, i.e validating sample)



Today’s Cost to Build

For a Major Greenfield ProjectFor a Major Greenfield Project

NumberK USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” ,

Plenary Session Paper, IFPAC2000, Las Vegas, NV


Today’s Cost of Ownership

Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” ,

Plenary Session Paper, IFPAC2000, Las Vegas, NV


What to Do?

• Think outside the Box/ Be Innovative

• Look across the fence how other industries do things:

SEMI SEMI -- Surface Mount TechnologySurface Mount Technology


What to Do?

Picture courtesy Swagelok®


Gen 1: Modular Sampling System = NeSSI IGen 1: Modular Sampling System = NeSSI I

Programmable Substrate Heater

V

P

F A

Substrate

SP76 Interface

Improvements:* Modular (minimum tubing)* Minimal man-hours

(design, eng, manufacturing)* Capable of self-validation (p,t,f)

SimpleSampling

System

Discrete analog signals


Gen 1: Modular Sampling SystemGen 1: Modular Sampling System



NeSSI “Sandwich/Rail” Platform Concept


Ethernet LAN

Analyzer

ControllerV

A

P F

SAM

NeSSI bus

Auxiliary Heating/Cooling

SubstrateT

T

Standard Sampling Interface

dcs o&muser

DevelopmentFocus can beon Sensors !

Standard Connectivity

Interface

next

PDA


Analytical Cluster Concept: Analytical Cluster Concept: Sensor Arrays with NeSSI as EnablerSensor Arrays with NeSSI as Enabler


Ethernet LAN

Analyzer

ControllerV

A

A A

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

Cond

Multiple AnalyticalSensors !

pH DO

SAM

PDA


Analytical Clusters Concept > Going Micro All the Way

Macro-Analyzers Micro-Analyzers

Micro-HouseMacro-House

Pictures Courtesy of Dow Chemical Freeport, TX

Analytical Cluster = A Process Stream Requiring Multiple Analyte Measurements

Examples: On-line Propylene CertificationCEMS (Stack Analysis)Cooling WaterWaste Water Treatment/Effluents

Byline Analytical Cluster = Multiple Analyte Measurements done on a Single NeSSI Platform


Potential Cluster Applications - NeSSI Workgroup

• Metal Treatment/Aerospace ApplicationsBruce Peterson (Boeing)

• Ethylene, Propylene, Acetylene/MAPD ConvertersPeter van Vuuren (ExxonMobil)

• Chlorine, Ethylene Glycol, Ethylene Oxide

• Boiler Feed Water/Cooling WaterSteve McMillan (ABB)

• Refining including “Sulfur” ApplicationsDon Young (Chevron)

• CEMS ApplicationsDave Simko (Swagelok) , Bob Sherman (Circor)

• Gas PlantsFrank Schweighardt (Air Products)


Addendum: NeSSI History

• Concept of Modular Sampling System based on SEMI design conceivedat ISA AD Meeting in 1998

• Groundwork for NeSSI started at Nov 99 CPAC meeting

• NeSSI (CPAC Initiative) initiated in June 2000 (Issued RFP)/SP76 Standarddeveloped in parallel (CPAC Legal Umbrella for end-users to work together)

• NeSSI promoted mainly at ISA and IFPAC meetings

• Honeywell submitted DoE Proposal in 2002; CPAC forum for coordinating consortium of end-users (e.g. Dow, ExxonMobil, Air Products, Dupont, UOP, Honeywell, Eastman Chemical)

• Gen II Draft Specification Published; POCA delivered to Dow and ExxonMobil

• Chronology of events trail at NeSSI Website:http://www.cpac.washington.edu/NeSSI/NeSSI.htm


Gen II Progress

• Honeywell developed Proof of Concept Assembly (Apparatus)(alpha design)

•• Technical HiTechnical Hi--LitesLites

–– First “binary” MiniFirst “binary” Mini--Sensors (P/T; F/T)Sensors (P/T; F/T)

–– Introduced Absolute Pressure TransmitterIntroduced Absolute Pressure TransmitterGC sample loop compensation, BP controlGC sample loop compensation, BP control

–– First “First “combicombi--valves” (Enabler for PID control)valves” (Enabler for PID control)

–– Enclosure and Substrate HeaterEnclosure and Substrate Heater

–– Early SAM hardware & SAM software (Laptop Early SAM hardware & SAM software (Laptop Implementation)Implementation)

–– First Demonstration of IS First Demonstration of IS CANbusCANbus communicationcommunication((ZenerZener--diode based; prefer galvanic isolation)diode based; prefer galvanic isolation)


The Path Forward

• Published Gen II Draft Specification in Collaboration with DowAvailable on NeSSI Website; Finalize Working Copy

• Start on IS NeSSI-bus Design, Certification- Critical path- Finalize selection of NeSSI bus/protocol

IS CAN/DeviceNet probably not feasible- Promote at CPAC/IFPAC Meetings, Nov 2003/Jan 2004

• Promote Cluster Application Concept- CPAC, ISA, Internally, Vendors, NIST- Identify and Facilitate Development of Sensors

* Through CPAC* IFPAC* NIST, Nat Labs etc.

• Start Gen III Wireless Design/Justification

NeSSI* - A Sampling and Connectivity Platform Comes of...

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