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Review of Process Analytics in 2012: Selected Highlights from IFPAC 2002 Presentation

This review highlights the demand for more difficult measurements and the growth of new process analytical technologies in the years leading up to 2012. It also discusses computing developments, predictive maintenance, and the role of technicians and engineers in maintaining and troubleshooting analyser systems. NeSSI, ConnI, and Appl-I are highlighted as key advancements in the field.

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Review of Process Analytics in 2012: Selected Highlights from IFPAC 2002 Presentation

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  1. A REVIEW OF PROCESS ANALYTICS IN THE YEAR 2012(selected highlights from IFPAC 2002 presentation) Rob Dubois Jeff Gunnell Dow Chemical ExxonMobil Chemical

  2. In the years up to 2012 the demand for more difficult measurements increased • Matched by growth in new Process Analytical technologies... • nanotech TDL lab-on-a-chip microGC NMR spectrometer-on-chip eNose CRD MS-on-a-chip • … but the old technologies remained... • GC MS FT-(N)IR CEMS water • … and it became impossible for one person to provide high level support such a wide range of techniques

  3. Computing developments which we used... • PDAs became a standard tool • wireless connectivity • human-machine interface for many devices • used with GPS to pinpoint equipment • Wearable PCs became common • Heads-up displays and data entry improved • voice entry of data • voice recognition “action” commands • The web ruled... • browser access to everything from everywhere • Security became better and easier • retinal recognition

  4. Level 4 Enterprise LAN ENTERPRISE DOMAIN Level 3 LAN c-LAN AnLAN  PROCESS CONTROL DOMAIN INFORMATION D0MAIN Level 2 LAN = Field LAN SAM - Highbandwidth data pipelines - Traffic routers send data to the “need to know” domains Level 1 SensorBus (CAN) eSAM  MEASUREMENT DOMAIN ConnI Architecture - 4 domains Courtesy of P. van Vuuren and R.J. O’Reilly

  5. Predictive maintenance replaces planned • Intelligent diagnostics watch analyser systems...all the time... • ‘I need help’ flags are sent in real time to wireless Personal Digital Assistants (PDAs) • ……………… • A typical troubleshooting task for a technician starts when her PDA buzzes and indicates a possible problem...

  6. Please help me... • A smart application in an analyser system has detected something strange - relevant information is sent out... • The technician taps down for more info...

  7. Background data and recent history is sent • Key sensor data have been monitored and unusual conditions have been detected... • The technician taps down for more details...

  8. Recent history is shown graphically • The technician starts to think about the cause of the problem… • …and sees the problem…clearly... • A pinched valve is quickly discovered and the problem resolved…pronto!

  9. Appl-I: Smart applications • Functions are part of a shell which is used by all analyser vendors…(much like Excel) • monitoring of key parameters • flow, pressure, temperature…as well as analytical • self-validation, both continuous and periodic • intelligent statistical tools identify abnormal events • users notified when trouble is suspected • data presented in a user-friendly way Excel is a registered trademark of Microsoft Corp.

  10. The technician takes her toolkit, including her wearable PC, out to the field... Courtesy of Oxford Technologies

  11. She has access to an on-line manual • The wearable PC means that useful information is readily available: • There are up-to-date descriptions of tasks • Video clips* show how jobs are done. • * Video Courtesy of Andy Jopek

  12. Links to other systems facilitate work • Equipment parts lists are linked to warehousing - both in house and external. • She identifies spares which she needs and orders them as she works using the manual and warehousing tool

  13. Record keeping is built in • Intelligent checklists and voice entry make record keeping easy: • The manual helps her fill in a work record - using voice data entry

  14. Wizards help with many tasks • On completion she runs the smart health check wizard • She requests two day data watch so she can personally check that everything is OK. A maintenance encounter is booked into her calendar

  15. Key points: Technician level • Technicians in plants retain the prime responsibility of maintaining analyser systems • Human knowledge, skills, thought processes are needed more than ever • Logic and intelligence in machines help technicians to use their human skills better • real-time health checks of systems • focus on predictive maintenance • data presentation helps troubleshooting • …and bureaucracy is unburdened

  16. Key points: Engineer level • Highly complex analyser technologies abound • Sites are spread all around the globe • Technical support and troubleshooting is a team game • collaboration tools facilitate virtual teams • support round the clock, round the globe • changes in • responsibility • behaviour • relationships

  17. This is life in 2012 - how did we get here? • NeSSI came through: • modular sample systems • integrated with analysers sensors • in smart, field mounted units • ConnI • delivered an architecture which linked everything together • Appl-I • provided a common application shell • …and collaboration delivered benefits for all

  18. Smart • artificially intelligent • analysers

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