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

NeSSI* – An Enabling Platform for the Reduction in TCO ** of Process Analytical Systems (* New Sampling/Sensor Initiative ** Total Cost of Ownership). “the best way to predict the future is to create it”. Peter van Vuuren Application and Technical Consultant SpectraSensors Inc. IFPAC2008

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

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  1. NeSSI* – An Enabling Platform for the Reduction in TCO** of Process Analytical Systems(* New Sampling/Sensor Initiative** Total Cost of Ownership) “the best way to predict the future is to create it” Peter van Vuuren Application and Technical ConsultantSpectraSensors Inc. IFPAC2008 NeSSI Day29 January 2008

  2. PA/NeSSI Value Proposition $Measurement value$“Analyzer Credits” $Bottom-line Value$ TCO + TCO

  3. Cost to Build/Install/Own – Major Greenfield Project To Build/Install To Own J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV

  4. Total Cost Of Ownership – A More Detailed Look Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  5. What to DO? "When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged. 1957.

  6. A Three Phase Proposed TCO Optimization Strategy • Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate • Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensors • Phase IIIPromote/Apply Micro-Analytical Sensors onNeSSI Sampling Platform

  7. Intrinsically Safe NeSSI: Modular Smart Sampling System Pictures Courtesy ExxonMobil Chemical

  8. Benefits of Smart NeSSI Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • TCO Benefits of Smart NeSSI: • Push Validation down to Sampling System level • More reliable operation • Improves EQA of analyzer • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  9. DCS Field LAN o&muser Simplified Topographical Diagram of a Process Analytics installation GP Area Field –Classified Area(Typically ZONE2) Analyzer House Process Stream AN SS

  10. A Three Phase Proposed TCO Optimization Strategy • Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate • Phase II (Ready for Implementation Today)Utilize NeSSI as a Platform for Spectroscopic Sensorspreferably at the Sampling Point (By-line Mode) • Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode

  11. DCS F,T V P Auxiliary Heating/Cooling Programmable Substrate Heater T T o&muser The NeSSI Platform = Sampling & Communications Platform GP Area Field –Classified Area Ethernet LAN Sensor/ActuatorManager (SAM) IS NeSSI bus O2 Flow Channel Substrate PDA Micro- Climate enclosure

  12. DCS F,T R V P Auxiliary Heating/Cooling Programmable Substrate Heater T T o&muser Spectroscopic Sensors with NeSSI as Enabler GP Area Field –Classified Area TDL Ethernet LAN Sensor/ActuatorManager (SAM) RAMAN IS NeSSI bus O2 Flow Channel Substrate PDA Micro- Climate enclosure

  13. DCS Field LAN o&muser NeSSI: Enabling Topographical Changes GP Area Field –Classified Area(Typically ZONE2) Analyzer House AN Process Stream AN SS

  14. DCS o&muser NeSSI: Enabling Topographical Changes GP Area Field –Classified Area(Typically ZONE2) Control Room AN RAMAN Optograph Instrument Room Fiber Ne S S I Micro-Climate Enclosure Process Stream SAM AN TDL NIR Fiber Analyzer Shop

  15. DCS o&muser NeSSI: Enabling Topographical Changes GP Area Field –Classified Area(Typically ZONE2) Control Room AN RAMAN Optograph Instrument Room Fiber Ne S S I Micro-Climate Enclosure Process Stream SAM AN Other NIR Fiber AN TDL Analyzer Shop

  16. DCS Field LAN o&muser Cost Benefits of TOPOGRAPHICAL Changes GP Area Field –Classified Area(Typically ZONE2) X Analyzer House X AN Process Stream X X AN SS X X

  17. A Three Phase Proposed TCO Optimization Strategy • Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate • Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensorspreferably at the Sampling Point (By-line Mode) • Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode

  18. DCS F,T V P Auxiliary Heating/Cooling Programmable Substrate Heater T T o&muser NeSSI & Next Generation Micro Analyzers GP Area Field –Classified Area Ethernet LAN Sensor/ActuatorManager (SAM) IS NeSSI bus Micro- GasAnalyzer (UV, MIR, MS, GC, … Flow Channel Substrate PDA Micro- Climate enclosure

  19. DCS P o&muser NeSSI Enabled Spectroscopy/Micro-Analytics Topography GP Area Field –Classified Area(Typically ZONE2) Control Room AN RAMAN Optograph Instrument Room Fiber Ne S S I Micro-Climate Enclosure Process Stream SAM AN TDL NIR Fiber Analyzer Shop

  20. Spectroscopic/Micro-Analytics Design Requirements • Understand the NeSSI Platform Concept (Enabler)* Provides a Standardized Micro-Infrastructure Environment for Deploying micro-analytical sensors/Analyzers * At the same time, allows for IP protection • IS has to be designed in up front* NeSSI platform can be installed anywhere (Zone 0/1/2 GP) – no costly purge systems • Design for temperature accommodation/correction • Design for validation of results (Good Housekeeping Seal) • * Use all the analytical process information for validation • Design for no or little consumables • Design for mechanical simplicity – no or few moving parts • Design for extensive but smart diagnostics

  21. TCO: The BIG PICTURE of Cost Savings Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • TCO Benefits of Smart NeSSI: • Push Validation down to Sampling System level • More reliable operation • Improves EQA of analyzer • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  22. TCO: The BIG PICTURE of Cost Savings Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • TCO Benefits of Spectroscopic Analyzers: : • Inherent reliability, low EQA index • No consumables • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  23. TCO: The BIG PICTURE of Cost Savings Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • Cost to Build/Install Benefits of Spectroscopic Sensors: • Integrate Probe with NeSSI and Move to Sampling Point • Separate Probe and Analyzer Locations (Fiber-coupled) • No Consumables • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  24. TCO: The BIG PICTURE of Cost Savings Build Install Own Failure • Analyzer $/ SpareParts • Sampling Systems • Shelters/Panels • Data System • Shelters/Panels • Hookups :Utilities, Power, Cabling, Sampling Systems • Start-up & Commissioning • EQAT (Manpower) • Consumables* Standards* Support Gases • Spare Parts • Off-line TimeMissed Opportunity • Process UpsetLoss of Production • Cost to Build/Install Benefits of Spectroscopic Sensors: • Integrate Probe with NeSSI and Move to Sampling Point • Separate Probe and Analyzer Locations (Fiber-coupled) • No Consumables • Sample Tap / Transport Lines • Utilities (IA, Carrier Gases etc.) • Power • Cabling

  25. PA/NeSSI Value Proposition Revisited $Measurement value$“Analyzer Credits” $Bottom-line Value$ TCO + TCO

  26. Acknowledgements • All the Believers (all of you and many others) • My ex-colleagues at ExxonMobil • CPAC (adopted NeSSI as a new IURC “business model”) • Special Thank You to Rob Dubois

  27. Thank You

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