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Exploring Connectivity for Process Analytical Systems: Navigating Challenges and Insights

This article discusses the system hierarchy and challenges of connectivity solutions in process analytical systems, presenting opportunities for enhanced action and data management. It also explores the NeSSI concept for integrated sensor systems.

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Exploring Connectivity for Process Analytical Systems: Navigating Challenges and Insights

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  1. Connectivity for Process Analytical Systems: Confusion or Opportunity Peter van VuurenExxonMobilChemicalEngineeringand Manufacturing ServicesBaytown, TexasJanuary 22, 2001

  2. Topics Analyzer Computing System Hierarchy • Proprietary vs. Open Connectivity Solutions • Level 0/1 Challenges • Level 1/2 Challenges :Data Domains • The Process Analytics Community 1M$? • Opportunity for Action

  3. PLANT AEWS AREA HM AM UNIT CAC AC GCC PLANT A FIELD SENSOR SS VMS ANALYZER COMPUTING SYSTEM AREA AM HM UNIT PIU CB PM FIELD A PROCESS CONTROL SYSTEM Process Control System/Analyzer System Perspective System within a System

  4. Analyzer Computing System Hierarchy PC -Based Workstation/ User Interface RemoteServer(s) RemoteWorkstation(s) PC-Based Data/Methods Archive and User Interface LEVEL 4 LAN = PLANT LAN DCS INFORMATION L3 MANAGEMENT (Gateway to External Data) LEVEL 3 an-LAN CENTRAL USER L2 INTERFACE Validated Measurements AND DATA MANAGEMENT LEVEL 2 FLAN Datalink DATA ACQUISITION L1 AND CONTROL GC FTIR FIELD DEVICES A L0 (SENSORS, VALVES, DETECTORS, ETC.) Sensor Sample System

  5. Analyzer Computing System Hierarchy (Level 0/1) Field LAN Level 1 All Additional Electronic and Computing Components Required to Generate Analytical Result Analyzer Controller Com Com Level 1 Bus DAAC DAAC A Level 0 All System Components in Contact with Sample including the Sensors Sample Conditioning System F T P Process Stream

  6. Analyzer Computing System Hierarchy (Level 0/1) Workstations Level 4 Server(s) Remote User Interface/Applications Level 3 Plant LAN Long TermStorage Applications and Data Management (Archiving) DCS L3 Level 3 Bus = AnLAN Workstations Level 2 DCS GatewayClient/Server(s) AnalyzerServer TPSCLM Central User and Operations Interface DCS L2 Level 2 Bus = Field LAN Level 1 Com Analyzer Controller All Additional Electronic and Computing Components Required to Generate Analytical Result DAAC Level 1 Sensor Bus F T P A Level 0 All System Components in Contact with Sample including the Sensors Sample Conditioning System Process Stream

  7. Challenges/Opportunities Workstations Level 4 Server(s) Remote User Interface/Applications Level 3 Long TermStorage Applications and Data Management (Archiving) DCS L3 Level 3 Bus = AnLAN Workstations Level 2 DCS GatewayClient/Server(s) AnalyzerServer TPSCLM Central User and Operations Interface DCS L2 F T P Plant LAN Level 1 Level 2 Bus = Field LAN Com Analyzer Controller All Additional Electronic and Computing Components Required to Generate Analytical Result DAAC Level 1 Sensor Bus A Level 0 All System Components in Contact with Sample including the Sensors Sample Conditioning System Process Stream

  8. Proprietary vs. Open Connectivity Solutions Workstations Level 4 Server(s) Remote User Interface/Applications Level 3 Long TermStorage Applications and Data Management (Archiving) DCS L3 Level 3 Bus = AnLAN Workstations Level 2 DCS GatewayClient/Server(s) AnalyzerServer TPSCLM Central User and Operations Interface DCS L2 = CommonSolutions A F T P Level 2 Bus = Field LAN Level 1 Com AnalyzerController All Additional Electronic and Computing Components Required to Generate Analytical Result DAAC Level 1 Sensor Bus Level 0 All System Components in Contact with Sample including the Sensors Sample Conditioning System Process Stream

  9. Level 0/1 Challenges Opportunities Workstations Level 4 Server(s) Remote User Interface/Applications Level 3 Long TermStorage Applications and Data Management (Archiving) DCS L3 Level 3 Bus = AnLAN Workstations Level 2 DCS GatewayClient/Server(s) AnalyzerServer TPSCLM Central User and Operations Interface DCS L2 A F T P Level 1 Com AnalyzerController All Additional Electronic and Computing Components Required to Generate Analytical Result DAAC Level 1 Sensor Bus Level 0 All System Components in Contact with Sample including the Sensors Sample Conditioning System Process Stream

  10. Level 0/1 Challenges Opportunities A NeSSI Concept (CPAC Initiative): Small Smart Integrated Sensor and Sampling system Modular Design based on Surface Mount Technology Ensure the Representativenes of Sample (Data Validation) F T P Com AnalyzerController DAA Level 1 Level 1Sensor Bus Level 0 Process Stream

  11. Level 0/1 Challenges Opportunities A F T P Level 1 Sensor Bus: True Plug and Play Installation/Configuration (a la USB?) Should ideally include Analytical Sensor (pH, Cond etc.) Potential for Inherently Safe Designs Com Analyzer Controller Level 1 DAA Level 1 Sensor Bus Level 0 Process Stream

  12. Level 1-2 Challenges A F T P Workstations Server(s) Level 4 Long TermStorage Level 3 DCS L3 Level 3 Bus = AnLAN Workstations DCS GatewayClient/Server(s) AnalyzerServer TPSCLM Level 2 DCS L2 Com AnalyzerController Level 1 DAAC Level 1 Sensor Bus Level 0 Sample Conditioning System Process Stream

  13. Level 1-2 Challenges: Domain Interactions L4 = EnterpriseWide Domain L4 L3 DCSDomain O&MDomain L2 Primary Data Path > Requires Maximum Integrity/Reliability Secondary Data Path > Requires HighIntegrity/Reliability Com L1 AnalyzerController DAAC Measurement Data(Validated)Status/Change Info DCS Data +:Raw DataCalibrationSQCDiagnostics/Alarms Limited Control Functions Configuration DataAll Control Functions Level 3 Bus = AnLAN Level 2 Bus = Field LAN Measure-mentDomain

  14. Level 1-2 Challenges: DCS Domain OPC Protocolon Ethernet DCS OPC Client Analyzer OPC Server(s) Measurement Data(Validated)Status/Change Info Limited Control Functions L3 Ethernet Level 3 Bus = AnLAN DCS GatewayServer(s) L2 DCS L2 Level 2 Bus = Field LAN Com AnalyzerController L1 DAAC

  15. Level 1-2 Challenges: DCS/O&M Domains Analyzer Server Platform Win2000/NTMultiple Servers/DriversDatabase OPC Protocolon Ethernet Level 3 Bus = AnLAN Gateway Server Platform Win2000/NTMultiple OPC Servers/Drivers GatewayServer AnalyzerServer WorkstationPlatform Win2000/NTBrowser Enabled Level 2 Bus = Field LAN Com AnalyzerController DAAC Physical Layer Ethernet TCP/IP(LonWorksProfibusModbus PlusDeviceNetEtc.) Application Layer(s) Protocols OPCHTTPFF (HSE)?Proprietary Scalable Analyzer/COMPlatforms WindowsCENT KernelWin2000/NTOPC ClientBrowser Client WS

  16. Workstations L4 Server(s) Long Term Storage L3 DCS L3 Level 3 Bus = AnLAN DCS GatewayClient/Server(s) AnalyzerServer TPSCLM L2 DCS L2 L1 Com AnalyzerController DAAC Level4 Access expose L2/L3 Analyzer Devices to Enterprise-wide Network L2/L3 must meet Enterprise-wide Security/Controls standards: - Logon authentication (Requires NT Domain Controller – not shown) - Software Isolation (Requires Win2000/NT Terminal Server) Level 4/3/2 Challenges: Remote Access & Security and Controls WS Level 2 Bus = Field LAN

  17. Connectivity: Summary OPC Protocolon Ethernet Long TermStorage Level 3 Bus = AnLAN DCSDomain AnalyzerServer DCS GatewayClient/Server(s) O&MDomain Level 2 Bus = Field LAN DCS L2 Com AnalyzerController DAAC Ethernet TCP/IP- OPC- HTTP- FF?- Proprietary Win2000/NT WindowsCENTKernelWin2000/NT Not discussed:Redundancy Wireless LAN’s Portable Terminals Win2000/NT Workstations

  18. The Process Analytics Community 1M$? ? ? BIG QUESTION ? ? How do we develop and agree on industry guidelines for the analyzer connectivity infrastructure which will ensure plug-and-play compatibility for all analyzers? Given the choices of: • controller, server and workstation platforms • communication protocols • database options (short term and long term) • security and controls needs (local & remote access)

  19. The Process Analytics Community 1M$? Considerations: • Convene an Open Process Analytics “Forum”(Sponsored by CPAC or MCEC or ISA AD?) • Develop a consensus about Proprietary vs Open Model (POM) (Learn from FF and OPCF?) • Confirm challenges to achieve POM goals • Establish a Workgroup to address each challenge(should NOT be a formal standardization effort) • Issue Guidelines • Keep Effort Evergreen

  20. Call to Action You are invited to an ad-hoc meeting on Tuesday 6:30 pm Explore/Test Process Analytics “Forum” Concept: • Connectivity (Plug and Play Integration) • Modular Sampling System Initiative (More at our Sampling System Session this PM) Opportunity is Knocking:

  21. Acknowledgements Mark Griffin - ExxonMobil Chemical Larry Washburn - ExxonMobil Chemical Jeff Gunnell - ExxonMobil Chemical Dan Podkulski - ExxonMobil Chemical Norm Kincade - LaPlace Technologies ABB Analytical SAAI Rosemount Analytical

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