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“How to Trust Your Process Analyzer"

“How to Trust Your Process Analyzer". Steve Doe Parker Hannifin. NeSSI™ Workshop May 11, 2006. Topics. Case Study New Tools to Improve Sample Handling System Reliability Field Results Next Steps. Case Study: Background. Lanxess Born of Bayer AG strategic realignment in 2004

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“How to Trust Your Process Analyzer"

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  1. “How to Trust Your Process Analyzer" Steve Doe Parker Hannifin NeSSI™ Workshop May 11, 2006

  2. Topics • Case Study • New Tools to Improve Sample Handling System Reliability • Field Results • Next Steps

  3. Case Study: Background • Lanxess • Born of Bayer AG strategic realignment in 2004 • Produces Performance Chemicals, Chemical Intermediates, Engineering Plastics & Performance Rubber • Sarnia, Ontario Plant: Butyl Rubber producer >60 years • Moisture analysis & control is key • Process Engineers & Plant Operators lacked confidence in analyzer results due to Sample Handling System (SHS) legacy problems • Plant shutdowns resulted – big bucks lost on several occasions!

  4. Case Study: Early 2004 • Analyzer PM had been properly completed within 48 hours of a moisture increase trend • Midnight callout from operations: “Your Analyzer Isn’t Working!” • Analyzer Engineer twisted operations arm over the phone: “Act On The Analyzer’s Results!!!” • Operations listened- and set a new production record that very day! • “High-fives” for everyone- but Analyzer Engineer reminded the team about the “dodged bullet” • Cross-functional team was created to increase SHS reliability and “customer confidence”

  5. New Tools for SHS Reliability • Robust, modular, remote actuation double block & bleed stream (DBB) switching valve

  6. New Tools for SHS Reliability • Differential pressure flow indication w/ integral relief function (I.S., 4-20mA output)

  7. New Tools for SHS Reliability • Smart, Proportional Heater & Purge Preheater

  8. Field Results • System Commissioned June 24, 2005 • Zero Downtime After Commissioning

  9. Field Results • Operations has authority via DCS stream switch reference gas to validate analyzer calibration DBB Stream Switch Reference Gas Dryer

  10. Field Results • Remote analyzer and bypass flow indication available to operators via DCS Bypass Flow Indication Analyzer Flow Indication Reference Gas Flow (9min 25sec) Switching valve cycled Sample Gas Flow (9min 25sec) Cycles repeated during commissioning

  11. Field Results • Process Engineers & Operations TRUST THE ANALYZER • Several analyzers in the Sarnia plant are running closed loop control • Plant Shutdowns HAVE BEEN AVERTED • 5 additional “smart” systems have since been commissioned in the Sarnia plant- more planned

  12. Next Steps • Incorporate Human Machine Interface (HMI) in field; Class 1, Division 2 compliant • Provides local host for “Smart Shelters”

  13. Smart Shelter Ethernet to Technician Workstation Onboard PLC Ethernet to HMI 4-20 mA to PLC - For Now! >

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