NeSSI*: Key Aspects of the NeSSI Gen II Specification

1. NeSSI*: Key Aspects of the NeSSI Gen II Specification *New Sampling/Sensor Initiative ISA - Houston, Texas, USA October 23, 2003 Peter van Vuuren Rob Dubois “the best way to predict the future is to create it”

2. Presentation Outline • Today’s Technology vs. the Vision of Success • NeSSI Development Roadmap & Generations • Key Aspects of the NeSSI Gen II Specification (from the End User’s Perspective) • Summary

3. Z-purge assemblies IS Solenoids Valve and Pneumatic Valves Manual P, F control Explosion Proof Fittings and Conduit Seals Custom each job Skilled electrician Armored rotameters and X proof flow switches Multiple fittings, valves tubed by skilled inst. fitter Today’s Technology

4. Vision of Success - I Move Analysis By-Line Typical Analyzer House - Dow Freeport, TX

5. Vision of Success - II Courtesy of J. Warwowski/D. Mitchell. Swagelok/Panametrics • Lego Like Assembly • Reduce Engineering Time • software “configurator” • Reliability Centered Maint. • Full Automation Courtesy of U. Bonne. Honeywell. Design, assemble & configure an analytical system on the work bench.

6. NeSSI Generation Segmentation Wireless, Advanced Gas & Liq. Sensors & Platform for microAnalytical End User Value Gen III Electrical Transducers using IS Multi-Drop Network Gen II Mechanical Components (with conventional 4-20 mA) Gen I

7. NeSSI Roadmap Analytical & Wireless Gen. III Smart/”Electrified” Gen. II Mechanical Gen. I uAnalytical Field Installations Simple Analyzers(H2O, O2, pH, UV/VIS, etc.) Smart Field Installations Design /Prototype - Gen II Smart/Heating/SAM Mechanical Field Installations Mechanical Component Availability e.g. filters, valves, etc. NeSSI/CPAC Vision & Roadmap ANSI/ISA SP76 Standard Approved 02 04 06 05 03 2000 01 Time (years) October 2003

8. Key Aspects of the NeSSI Gen II Specification A Conceptual and Functional Specification Describing the Use of Miniature, Modular (and Smart) Electrical Components for adaptation to the ANSI/ISA SP76 Substrate in Electrically Hazardous Environments Please refer to Gen II Spec draft version d6... http://www.cpac.washington.edu/NeSSI/NeSSI.htm

9. Ethernet LAN DCS CANbus V P A F SAM Auxiliary Heating/Cooling Programmable Substrate Heater Div 1/Zone 1 inside the Enclosure T T o&muser microClimate Enclosure NeSSI Gen II Elements Typ. Div/Zone2 Substrate

10. NeSSI Gen II Preferred Methods of Protection • Apparatus inside a microClimate Enclosure • Electrical Heaters & AC Power Wiring [Ex d] • miniTransducers (sensors & actuators) • Ex m** and Ex ia or Ex ib • Multi-drop serial network • Ex ia or Ex ib via IS barrier • Apparatus outside microClimate Enclosure • SAM [Ex d (condulet), Ex n] • PDA [Ex i] ** encapsulation minimizes surface temperature and allows higher power loads

11. Why a serial, IS network? (Why not 4-20 mA & discrete I/O?) Gen I+ PLC/HMI with 4-20 AI/AO, DI,DO (relay & SSR), RTD inputs, X-purged to be safe. This is costly and complex to design and build and not practical for use with a tightly packed miniature, mod. system. Courtesy of Dow Chemical - Fort Saskatchewan

12. …and therefore the need for a multi-drop, IS, simple network “Freedom 55” for process analytical practitioners (in electrically hazardous areas) is the ability to connect & disconnect an electrical device -without the need for conduits, electrical seals, cable glands, gas “sniff” tests, purging systems, interlocks or safe work permits. POCA* with 8M DeviceNet Connector (Honeywell) *POCA = Proof of Concept Apparatus

13. Global Certification of the Network - single agency • Approved for all Zone and Division geographies. (Europe and NA) • Why Intrinsically Safe? • Best safety for high risk areas (eg. inside an enclosure handling hazardous, flowing fluids such as ethylene.) • A globally approved method of protection • great for companies who are multi-national • However, the most compelling reason for IS is the ability to use plug and play miniature, modular sensors using “normal” wiring.

14. Distributed Control is Essential- Sensor Actuator Manager • Gateway to an Ethernet LAN(DCS/maintenance systems) can use multiple com protocols • - OPC/HTTP/FF, etc. • - Remote Wireless (Gen III) • - 802.11 Wi-Fi • PDA Field Port • - Local Wireless • -e.g. Bluetooth™ Host Port for a… Sensor/Actuator Bus - Two Channels Software Applets for certain Repetitive Tasks (Appl-I) - System Health (P, T, F) - Analyzer Validation - Sample Conditioning/control SAM Provides “Open” Development Space for Custom Software The Bluetooth and the Bluetooth trademark are owned by Bluetooth SIG, Inc.

15. Maximizing the Number of Network Devices is Essential • NeSSI Gen II spec suggests a min. of 25 devices per channel/port for a Class IIC (worst case) hazardous environment • makes a system cost-effective • allows sharing among analytical systems • simplifies installations • justifies the use of multiple sensors • differentiates the “NeSSI-bus” from others

16. A Single, Low Voltage Power Supply opt. Integrated with IS Barrier • Minimizes complexity (packaging, wiring, costs) • Low voltage assists power budget • Single voltage spec gives clear design objective for component makers • Larger power supplies (e.g. 24 VDC takes up precious space) • NeSSI suggests 12 VDC max.

17. Key Network Attributes • Hot Disconnect (w/o shutting down) • Distance (typ within 30’ - max. 500’) • Approx. 10 updates/second • physical (analogue) transducers (P, T, F, Vo, Vm) - low data throughput • microAnalytical (chromatography, spectroscopy) - high data throughput • Mission Critical Performance in a Robust Environment

18. Key Transducer-Network Attributes • Industry standard connector • Simple diagnostics (traffic light analogy) • Simple Configuration • Transducer Ambiguous • Low cost - “Open” and Interoperable • Encapsulated transducer electronics [Ex m] • no potentiometers (software node ID) • Optical isolation [for certain devices which may need to be powered remotely]

19. Superb Power Management - I“Hazardous Intrinsic Power Profile*” We envision that each transducer, once certified, will have non-volatile embedded Power, Current, Inductance, Capacitance, T-rating and other parameters associated with its safe operation which helps define its Hazardous Intrinsic Power Profile. (HIPP) Once attached to a network the system manager (SAM) will automatically upload each device’s parameters and accept or reject the device according to built in limits set by the system. For example, SAM is configured for a Class IIC (hydrogen service) with a fixed pool of current/power, etc. and maximum temperature. * HIPP

20. Superb Power Management - II“Hazardous Intrinsic Power Profile*” Power management is analogous to memory management * HIPP

21. User Friendly Network • Adding a component to the network should be a simple & quick task. • Maintenance time is spread thin - a cumbersome or inflexible interface or needing expert assistance, for a simple job, will not be well accepted. • Wireless, PDA support

22. Related Applications • Pilot Plants/MicroReactors • Laboratories • Low Power Applications • battery powered systems • wireless • remote systems • Auxiliary analytical systems • heat tracing

23. Key Industries which Operate in Electrically Hazardous Locations • Petrochemical • Fine Chemical Manufacture • Refining • Oil and Gas Distribution • The “Oil Patch” • Industrial Gas Producers (e.g. hydrogen)

24. To Summarize - NeSSI Defines an Unmet Networking Need Current practice requires many skilled people and high cost to assemble, install and maintain our analytical systems in various global geographies. The introduction of a low cost IS network meets an unmet need in industry. Providing smart, fully automated systems could fundamentally change how we do process analytics.