NeSSI...New Sampling/Sensor Initiative (NeSSI) CPA : May 7, 2 0 1 CPAC as a Multi-Purpose PA Forum...

New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001

NeSSINeSSI

(Ne(Neww SSampling/ampling/SSensorensor IInitiativenitiative))

2001 Spring Sponsor Meeting

Center for Process Analytical Chemistry


AgendaAgenda

•• Status and UpdateStatus and Update -- PV2PV2Introduction (Why CPAC)Introduction (Why CPAC)What is NeSSIWhat is NeSSIWhat has happened/is happeningWhat has happened/is happening

•• NeSSI Team GoalsNeSSI Team Goals -- RduboisRdubois

•• BluetoothBluetooth -- Mike Horton (Crossbow)Mike Horton (Crossbow)

•• ConnectivityConnectivity -- PV2PV2


CPAC as a MultiCPAC as a Multi--Purpose PA ForumPurpose PA Forum

•• Legal Umbrella for Sponsors to MeetLegal Umbrella for Sponsors to Meet

R&D: Long Range / Short RangeR&D: Long Range / Short Range

Information Clearing HouseInformation Clearing House

Enabling Mechanism to Address Other Common NeedsEnabling Mechanism to Address Other Common Needs

•• Focus Groups: Forum toFocus Groups: Forum to

Review R&D ProgramsReview R&D Programs

Present Industry Present Industry CommonCommon Needs Needs -- RFPRFP

Address Other Industry Common NeedsAddress Other Industry Common NeedsFieldbusFieldbus Datalink Specification Datalink Specification -- DoneDoneNeSSI /MicroNeSSI /Micro--Reactor Analytics Reactor Analytics -- In progressIn progressChemometrics OnChemometrics On--line/Connectivity line/Connectivity -- Future?Future?


What is NeSSI?What is NeSSI?

•• Adapt Modular Surface Mount Technology from the SEMI Adapt Modular Surface Mount Technology from the SEMI Industry to Sampling System Design in the Chemical Industry Industry to Sampling System Design in the Chemical Industry

•• Driving Forces for ChangeDriving Forces for Change

Cost to Build/ Cost of OwnershipCost to Build/ Cost of OwnershipTraditional Sampling System Designs Same for Last 20+ Years Traditional Sampling System Designs Same for Last 20+ Years Weak Link in Overall Analyzer ReliabilityWeak Link in Overall Analyzer Reliability

Integrate Other Sensors (Smart Sampling System)Integrate Other Sensors (Smart Sampling System)SampleSample ValidationValidation



Picture courtesy Swagelok®



New 5 Channel Design by Parker

Picture courtesy Parker


What is NeSSI? What is NeSSI? -- It is SMARTIt is SMART

VTP

A

SignalIn/Outto ACSensor

AnalyticalManager

(SAM)

Signal Wires Only

Shared Power Bus

PLegend:

Pressure Sensor Temp SensorValve Analytical Sensor

VA

T


NeSSI Vision (Now)NeSSI Vision (Now)


NeSSI Vision (Next Step)NeSSI Vision (Next Step)

VTP

A

Signalto ACSensor

AnalyticalManager(SAM)

Signal Wires Only

Shared Power Bus


Background and Chronology of Background and Chronology of NeSSINeSSI ActivitiesActivities

•• Oil&Petrochemical (O&P) Focus Group May 1999Oil&Petrochemical (O&P) Focus Group May 1999

Identified Sampling Systems as Common Area Of InterestIdentified Sampling Systems as Common Area Of Interest

Sponsored Tutorial for Nov99 Sponsor MeetingSponsored Tutorial for Nov99 Sponsor Meeting

•• Tutorial Nov99 CPAC MeetingTutorial Nov99 CPAC Meeting

Background/Reasons for InterestBackground/Reasons for Interest

Presentations by Suppliers/ End UsersPresentations by Suppliers/ End Users

•• Participation in IFPAC2000 MeetingParticipation in IFPAC2000 Meeting

Plenary/General Papers (SS Enjoyed High Profile)Plenary/General Papers (SS Enjoyed High Profile)

WorkshopWorkshop


Background and Chronology of Background and Chronology of NeSSINeSSI Activities (Activities (cnt’dcnt’d))

•• AdAd--hoc O&P Meeting @ Pittcon2000hoc O&P Meeting @ Pittcon2000

EndEnd--users Discuss Initial Target Designsusers Discuss Initial Target Designs

•• CPAC2000 Spring MeetingCPAC2000 Spring Meeting

Formed SS Focus GroupFormed SS Focus Group

Defined Information Package (basis of RFP)Defined Information Package (basis of RFP)

•• Distributed Request for Proposal (RFP) (July 2000)Distributed Request for Proposal (RFP) (July 2000)

Clarification Meeting at ISAEXPO2000 (40 attendees)Clarification Meeting at ISAEXPO2000 (40 attendees)

Received Proposals/Feedback from Swagelok, Parker,Received Proposals/Feedback from Swagelok, Parker,AutoflowAutoflow,, ABB Analytical, SAAI, Rosemount AnalyticalABB Analytical, SAAI, Rosemount Analytical



•• CPAC2000 Fall MeetingCPAC2000 Fall Meeting

Previewed Previewed SwagelokSwagelok/Parker Proposals/Parker Proposals

MicroMicro--Reactor Proposal (MicroReactor Proposal (Micro--Analytics)Analytics)

Planning (CD Deliverable, IFPAC2001, Planning (CD Deliverable, IFPAC2001, PittconPittcon etc.)etc.)

•• IFPAC2001IFPAC2001

Sampling System Session at IFPAC2001Sampling System Session at IFPAC2001Review and Summary of NeSSI Effort (RD/PV2)Review and Summary of NeSSI Effort (RD/PV2)Papers by Swagelok, Parker, Autoflow, ABB, RosemountPapers by Swagelok, Parker, Autoflow, ABB, RosemountAdAd--hoc Meeting (Standing Room only Interest)hoc Meeting (Standing Room only Interest)



•• Pittcon2000 MeetingPittcon2000 Meeting

NeSSI AdNeSSI Ad--hoc Forum Meetinghoc Forum MeetingConfirmed viability of NeSSI designsConfirmed viability of NeSSI designsIntroduced the Role of Wireless (Introduced the Role of Wireless (BluetoothBluetooth))Focus on Special Issues/ProblemsFocus on Special Issues/Problems

SwagelokSwagelok, Parker, ABB Highlighted Special Problems, Parker, ABB Highlighted Special Problems4 4 SubteamsSubteams (Intrinsic Safety, Component availability etc.)(Intrinsic Safety, Component availability etc.)

•• Miscellaneous/In the PipelineMiscellaneous/In the Pipeline

Proposal for Additional ResourceProposal for Additional ResourceJim Jim Tatera Tatera (retiree from Dow Corning)(retiree from Dow Corning)PartPart--time to lead key subtime to lead key sub--team activitiesteam activitiesDeliverables/schedule definedDeliverables/schedule definedReport at next CPAC Meeting (Nov)Report at next CPAC Meeting (Nov)More details of proposal etc. at SSFG (Wednesday)More details of proposal etc. at SSFG (Wednesday)



•• Miscellaneous/In the Pipeline (Miscellaneous/In the Pipeline (cnt’dcnt’d))

Testing/EvaluationTesting/EvaluationTwo Systems in Design Phase (EMCC)Two Systems in Design Phase (EMCC)Rosemount Laboratory Tests Completed (see SSFG)Rosemount Laboratory Tests Completed (see SSFG)

Test System AvailableTest System AvailableMore Participation by EndMore Participation by End--users neededusers needed

NeSSI Deliverable CompletedNeSSI Deliverable CompletedCD IssuedCD IssuedNeSSI Website UpNeSSI Website Up--toto--datedate

NeSSI Promotional effortsNeSSI Promotional effortsDistribution List > 150 namesDistribution List > 150 namesPresent Hour Tutorial at ISA2001 Meeting (Sept01)Present Hour Tutorial at ISA2001 Meeting (Sept01)Globalization effortsGlobalization efforts

CPACT Presentation Apr01 (high interest, additional names)CPACT Presentation Apr01 (high interest, additional names)Paper tentatively accepted for INTERMAC Meeting (Nov01)Paper tentatively accepted for INTERMAC Meeting (Nov01)Extending SP76 to IEC standard Extending SP76 to IEC standard


AcknowledgementsAcknowledgements• Dow Ron O’Reily/Brian Worthington/Walter Henslee

• Dow Corning Jim Tatera�/Gary Bokerman�

• DuPont Joe Adrisani, Chuck Miller, Bob Bucher, BruceJohnson

• Rohm&Haas Joe Sung

• Honeywell Ken Creasy, Ullrich Bonne, Troy Francisco

• ExxonMobil Dan Podkulski/Rajko Puzic/PaulHromadka/John Cumbus/Jeff Gunnell

• Swagelok Dave Simko/Rick Ales & Colleagues

• Parker Steve Doe, Frank Ruiz & Colleagues

• Rosemount John Gajewski & Colleagues

• ThermoOnix Jerry Evans

• CPAC Lloyd Burgess/Larry Ricker

• Others ABB, Panametrics, AAI, Sterling Chemicals


…. and they lived happily ever after…. and they lived happily ever after

FINIFINI


O&P Focus Group Meeting May 99O&P Focus Group Meeting May 99

• Recognized Modular Sampling System Efforts in Semi Conductor Industry (Standard)

• Vendors like Autoflow, A+, Swagelok etc. promoted modular designs

• Recognized that current implementations of sample systems designs have not changed for many years

• CPAC has promoted Versatile Micro Analytical Systems (VMAS) as abasis for future micro-analytical techniques

• O&P decided to sponsor a SSISSS (Small Smart Integrated Sensor and Sampling System) Tutorial at CPAC Nov Meeting


Nov99 CPAC SSISSS TutorialNov99 CPAC SSISSS Tutorial

• ExxonMobil/DuPont Provided Introduction to Tutorial

Validation of Sample System Performance

Integration of Sensor with Sampling System

• Four Suppliers of Sampling/Analyzer Systems Participated in Tutorial:

A+, Autoflow, Swagelok, Rosemount

Many components commercially Available

GCX example of self-contained miniaturized GC (GC on a pole)

• Recognition

Modular Sampling System can be a platform to integrate VMAS

Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers


Driving Forces for ChangeDriving Forces for Change

• Reduce Cost of Ownership

Non Recurring Costs = Cost to Build

Operating Cost

• Data Validation (Fit for Use)


A

F

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PAnalyzer Analyzer

ControllerController

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NFi

eld

LAN

Integration of Sample System and SensorsIntegration of Sample System and Sensors

Sam

ple

Con

diti

onin

g Sy

stem

Sam

ple

Con

diti

onin

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stem

Level 0Level 0 Level 1Level 1

Pro

cess

Str

eam

Pro

cess

Str

eam

All System All System Components Components in Contact in Contact with Sample with Sample including the including the SensorsSensors

All Additional Electronic All Additional Electronic and Computing and Computing Components Required Components Required to Generate Analytical to Generate Analytical ResultResult

Mainly a Trust ConfigurationMainly a Trust ConfigurationNow a Trust & Verify ConfigurationNow a Trust & Verify Configuration


Inte

grat

ed S

ampl

ing/

Sen

sor

Syst

emIn

tegr

ated

Sam

plin

g/Se

nso

r Sy

stem

A

F

T

P

Level 0 Subsystem IntegrationLevel 0 Subsystem Integration

Sam

ple

Con

diti

onin

g Sy

stem

Sam

ple

Con

diti

onin

g Sy

stem

Level 0Level 0

Pro

cess

Str

eam

Pro

cess

Str

eam

Purpose:

Prepare and Verify a Representative Sample (Compatible with Analyzer Sensor)

Opportunity:

Packaging as an Integrated Sensor and Sampling System

• Size

• Cost

Issues:

• Size

• Standardization

• VMAS


A

F

T

PAnalyzer Analyzer


Fiel

d LA

NFi

eld

LAN

Separation or Integration of Level 0/1 SubsystemsSeparation or Integration of Level 0/1 Subsystems


Pro

cess

Str

eam

Pro

cess

Str

eam

Inte

grat

ed S

ampl

ing/

Sen

sor

Syst

emIn

tegr

ated

Sam

plin

g/Se

nso

r Sy

stem

Objective:Objective:

Close to Close to Sample TapSample Tap

Options:Options:

•• RemoteRemote

•• Separate but CloseSeparate but Close

•• IntegratedIntegrated


Integrated Sampling/Sensor/Controller SystemIntegrated Sampling/Sensor/Controller System

A

F

T

PAnalyzer Analyzer


Fiel

d LA

NFi

eld

LAN

Integration of Level 0/1 SubsystemsIntegration of Level 0/1 Subsystems


Pro

cess

Str

eam

Pro

cess

Str

eam

$$$$










• Recognition


Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers


Nov99 CPAC SSISSS Tutorial (Vendor Presentations)Nov99 CPAC SSISSS Tutorial (Vendor Presentations)

Autoflow

RosemountA+

Swagelok










• Recognition


Bridge between Process Sample (Macro world) and Micro Fluidics Sensors/Analyzers


IFPAC2000IFPAC2000

• ExxonMobil Presented Plenary Paper Promoting SSISSS

Sample System Infrastructure accounts for 50+% Cost to Build

Proposed Conceptual Design for SSISSS

Highlighted sensor and analyzer transmitter configurations

• Sampling System Session

Presentations by A+, Autoflow, etc.

Sampling Systems enjoyed a High Profile

• CPAC/ExxonMobil sponsored Workshop

Confirmed high interest in Modular Sampling System

Provided input for the ISA Standardization effort


TODAY’S COST OF BUILDTODAY’S COST OF BUILD

For a major For a major greenfieldgreenfield projectproject

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


TODAY’S COST OF OWNERSHIPTODAY’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


IMAGINE THE FUTUREIMAGINE THE FUTURE

A

T

PAnalyzer Analyzer


Fiel

d LA

NFi

eld

LAN


Pro

cess

Str

eam

Pro

cess

Str

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F



FLAN (Optical Fiber)

Sensor/Signal Bus

IA Controller(ASIC) & Interface

Module

Original Picture of Gas Delivery System courtesy Valin Corporation;

A

T

PF

Sensor = Moisture Probe



A

T

PF

Sensor = RAMAN Probe

Interface

Module


IFPAC2000IFPAC2000

• ExxonMobil Presented Plenary Paper Promoting SSISSS

Sample System Infrastructure accounts for 50+% Cost to Build

Proposed Conceptual Design fro SSISSS

Highlighted sensor and analyzer transmitter configurations

• Sampling System Session

Presentations by A+, Autoflow, etc.

Sampling Systems enjoyed a High Profile

• CPAC/ExxonMobil sponsored Workshop

Confirmed high interest in Modular Sampling System

Provided input for the ISA Standardization effort


Pittcon2000 (New Orleans)Pittcon2000 (New Orleans)

• O&P Ad-Hoc Meeting of Sponsor End-users

DuPont, Dow, Dow-Corning, CPAC, Rohm&Haas, ExxonMobil

• Main Goal: Identify Typical Sample System Designs as Candidates for Modular Design

Reviewed some typical gas/liquid sample System Designs

Rob DuBois Presented a Modular Component/Service Matrix

• Discussed next steps

Present Sample System Data at May CPAC Meeting

Next Step is to Open Up Discussion (3rd parties)

Leverage ISA Meeting in New Orleans (Aug00)

• Role of CPAC in Facilitating Development/Testing of a Prototype System

Larry Ricker/Lloyd Burgess to Present Proposal


StatusStatus• CPAC Meeting May 1999 Done

O&P Identified Modular Sampling Systems

• CPAC Meeting Nov 1999 Done

O&P Sponsored Tutorial

• IFPAC2000 Meeting Done

Plenary Presentation Promoted SSISS

Session on Modular Sampling Systems

CPAC Sponsored Workshop

• Pittcon2000 Done

Ad-hoc O&P Meeting

Propose Candidate Sampling System Descriptions

• CPAC Meeting May 2000 TBD


What is Next?What is Next?

• CPAC Meeting May 2000 (Sampling Focus Group – Wednesday)

Review and Agree on Sample System Information Package

Involvement of 3rd parties

How do we distribute package (Distribution List, Meeting?)

Expectations for proposals from Suppliers (Paper designs?)

Joint Effort with ISA (Meeting in Aug, New Orleans)

Evaluation of Designs - Recommendation

• Prototype design/manufacturing/testing at CPAC

Larry Ricker/Lloyd Burgess proposal

• Program to Evaluate Test Platforms fro Micro Analytical Devices

CPAC Proposal – Lloyd Burgess

NeSSI...New Sampling/Sensor Initiative (NeSSI) CPA : May 7, 2 0 1 CPAC as a Multi-Purpose PA Forum...

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