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NeSSI * - Generation II “Revolution or Evolution?”

NeSSI * - Generation II “Revolution or Evolution?”. *New Sampling/Sensor Initiative. ISA 2001 - Houston, TX - September 10, 2001 INTERMAC - Tokyo, Japan - Nov. 8, 2001 Rob Dubois - Peter van Vuuren - Jim Tatera. Tatera and Associates. “the best way to predict the future is to create it”.

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NeSSI * - Generation II “Revolution or Evolution?”

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  1. NeSSI* - Generation II “Revolution or Evolution?” *New Sampling/Sensor Initiative ISA 2001 - Houston, TX - September 10, 2001 INTERMAC - Tokyo, Japan - Nov. 8, 2001 Rob Dubois - Peter van Vuuren - Jim Tatera . Tatera and Associates “the best way to predict the future is to create it”

  2. Tutorial Outline • Introduction, Drivers & History • A Vision and the Market Trends • NeSSI Generation I, II, III Comparisons • 10 Dimensions of a NeSSI Generation II System • What will a Generation II prototype look like? • Some recent developments… • NeSSI Roadmap & Summary • CPAC (Center for Process Analytical Chemistry) Review

  3. Process analyzer systems have been accused of being... • complex • expensive • proprietary • “big box” (battleship) • hi maintenance • suspect regarding data integrity • slow to change Edvard Munch “The Scream”

  4. A Brief History of • Operates under the umbrella of the Center for Process Analytical Chemistry (CPAC) • Originated from various CPAC focus sessions • IFPAC 2000 plenary paper presented NeSSI vision • Focus groups: Pittcon 2000; ISA Expo2000; IFPCA2001, Pittcon2001 • ISA2001 Houston: Kick-off of NeSSI Generation II

  5. Major Goals of • Facilitate the acceptance/implementation of... • modular, miniature & smart sample system technology • based on ISA SP76 standardization work • Promote the concept of... • field-mounted smart sampling/analytical systems • integration of sample systems with physical/chemical sensors • Lay the groundwork for... • open connectivityarchitecture for sensor communications (e.g. Ethernet, DeviceNet, etc.) • industry standard communicationprotocols (e.g. OPC, DeviceNet, CAN, etc.) • web enabled technologies (e.g. Browser based HMI) • Provide a technology bridge to the process for... • “sensor/lab-on-a-chip” micro-analytical devices

  6. A Modular Picture of Picture Courtesy John Thomas, Parker Hannifin Corp

  7. Imagine the Future after the

  8. What is Driving • Reduce Cost to Build • Design, Engineering, Manufacturing, Installation, Etc. • Reduce Cost of Ownership Maximize Sustained “Fit for Use” Data Generation System Validation Representative Sample Validation Measurement (Data) Validation Communication Validation

  9. Market Acceptance Cost Ease of Design System Reliability Where In the World Are We? • Critical Issues • acceptability by Process Analytical community • technical challenges • cost NeSSI Analyzer House • Value • Reduce capital costs by 35% ; 40% LTCO On the Post Time • Vision • Plug and Play - modular • At line/near line • A platform for microAnalytical • What’s going on in the world?. • Fast networks; robust electronics • “Lab on a chip”; lasers; wireless • Market Needs • Fast, reliable, rugged, reasonable cost

  10. Vision: The End of the Analyzer House System

  11. An Analytical System ...Will Look More Like Us! • Single Processor - Overall Control • Sensor Analytical Manager (SAM) • System will be Multifunctional • Equal emphasis on all sensors • System will be Adaptable • Predictive maintenance; self-healing • Capable of Multivariate Analysis • Use many sensors for analysis Courtesy of Ken Creasy, Honeywell. IFPAC 2001

  12. Intent…of the Gen II Spec • “The NeSSI Generation II specification is intended as a vehicle for alerting the marketplace to the need for these types of products.” "When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged. 1957.

  13. NeSSI Generations • NeSSI Generation I (circa 2000) • an “arranged marriage” • NeSSI Generation II (circa 2001-2005) • a “courtship” - reengineering solution • NeSSI Generation III (circa 2005+) • wireless, analytical sensors

  14. Gen. I versus Gen. II

  15. The Penitent - We’ve come a long way! Courtesy of Health and Safety Executive, Sheffield, England

  16. 1. Heated Substrate 2. Physical Sensors 3. Actuators 4. SAM  5. HMI (Graphical) 6. Wired Bus 7. Wireless Bus 8. X Mini Power Bus 9. Packaging 10. Analytical Sensor Generation II Dimensions- Shopping List for NeSSI

  17. Heating Fluids (alternative) Furn. by substrate mfg. 1. Heated Substrate Div/Zone 1 GP. A-D Div/Zone 1 or 2 GP. A-D Conduction Heating - cartridge heater(s) - over-temperature cut-off AC Power AC Power

  18. 2. Physical Sensors for System Diagnostics • Doing analytical is just not good enough! • Miniature Flow, Pressure, Temperature • Gas and/or liquid service • Rugged construction • Encapsulated (IEC Ex m) • Intrinsically Safe (IEC Ex ib) • Div/Zone 1 Gp A-D; T4 (135 C) FLOW:  P, coriollis, thermal, other? COM A/D Substrate

  19. 2. Conceptual Sensor for NeSSI “Top Hat” Comm. Chip Parallel Ports - standard size/pin - daisy chain A B Body - encapsulated Comm. Digital “Smart” Sensor - engineering units - memory µP BARRIER - Process Seal - Electrical Isolation - Thermal Memory A/D Process Cavity - no unswept voids - low volume Insulation Skirt - engineered 1.50” Base - 316 SS - pressure rated Sensor

  20. 3. Electrical Actuators on the Substrate - COMBO COMBO Valve /w integral solenoid • Miniature substrate mount • Gas and/or liquid service • Wide P & T service • Rugged, encapsulated (IEC Ex m) • Intrinsically Safe (IEC Ex ib) • Div/Zone 1 Gp A-D; T4 (135 C) Comm. SV AIR On/Off and Proportional Act.

  21. 3. …or Direct Electrical Actuators on the Substrate • …solenoid valves • …motorized valves • …again suitable for Div/Zone 1 Solenoid or Motorized Valve Comm. On/Off and Proportional SV

  22. 3. Conceptual “Combo” Valve Parallel Ports - standard size/pin - daisy chain “TopHat” Comm. Chip B A Comm. D/A 3-way “pilot” solenoid valve - Intrinsically Safe Vent Solenoid Instrument Air Digital On-Board Actuator Actuator - NO or NC Vent Conventional pneumatic valve Valve Engineered Insulation Skirt Thermal Barrier

  23. 4a. Introducing SAM - Sensor Analytical Manager Standalone SAM Analyzer   Embedded SAM Analytical Sensor F Vv T Vv P F A

  24. 4b. SAM does 5 jobs! Gateway to an Ethernet LAN - OPC perhaps Field Interface - Graphical - Wireless - e.g. Bluetooth™, 802.11 Software Applets for Sample System Repetitive Tasks (Industry Common) Host to a Sensor/Actuator Bus “Open” Development Space for Custom Software

  25. 4. SAM - Provides a “Pick-list” of Common SS Tasks • Zero & span validation • Pressure regulation • Stream switching • Maintenance diagnostics • Temperature control • Interoperability • talk to all analytical systems Enabling Technology for microAnalytical SAM

  26. 4. SAM - Suggested Package Courtesy of Adalet

  27. 5. HMI (Human Machine Interface) PDA     Hello? PC F Vv T Vv P F A Vv=automatic valve; P=pressure sensor; F=Flow Sensor; A=Analytical Sensor;T=Temp. Sensor

  28. ? Analyzer Controller P V A T V T P A Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor 6. Standalone “SAM” with Wired Sensor/Actuator Bus Analyzer System Ethernet LAN • IEC Ex ib intrinsically safe • Leverage FISCO power concept • Standard Plug & Play Conn. • DeviceNet or SDS SensorAnalyticalManager(SAM) 

  29. ? P V A T V T P A Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor 6. Embedded SAM With Wired Sensor/Actuator Bus • IEC Ex ib intrinsically safe • Leverage FISCO power concept • Standard Plug & Play Conn. • DeviceNet or SDS Analyzer System Ethernet LAN  Analyzer Controller w/ Embedded SAM Functionality

  30. Analyzer Controller V T P A 7. Wireless Signal (Gen III?) Analyzer System Ethernet LAN • Bluetooth or 802.11 • Plug and Play! • Power & I.S. • X-proof miniature power bus  SensorAnalyticalManager(SAM)  P.S.

  31. 8. What the world need is... Sensors (typ) • …a Miniature wiring method • “plug & socket” • Division/Zone 1 • MTL (England) Mini-Power Bus AC Power AC/DC

  32. 8. Mini X-proof connector- Div/Zone 1 Can we make this small?

  33. 9. Enclosure/Package Convection Heater X-Proof (OPTIONAL) Div/Zone 1 GP. A-D Div/Zone 1 or 2 GP. A-D Temp. Sensor Intrinsic Safe AC Power No Purge or Pressurization NEMA or IP Rated Enclosure - insulated

  34. 10. Analytical Sensors Fiber Optic SAM  One sensor per component “lab on a chip” AT One Sensor and Multiple Analytes “laser scanning device” A F Vv T A

  35. Connectivity! - CPAC “ConnI” Initiative

  36. Elements of a NeSSI Gen II Smart Prototype • Programmable, heated substrate • Digital sensors: F, P & T; serial bus • Division/Zone 1 • SAM; control algorithms • Wireless/graphical HMI • Packaged for outdoor installation

  37. Globalize, harmonize... • IFPAC • 2001. USA. • CPACT • 2001. Europe. • ISA 2001. • 2001. USA. • INTERMAC • 2001. Japan.

  38. Design & certify to global requirements... • NEC, UL, FM (USA) • CEC, CSA (Canada) • CENELEC (Europe) • ATEX Directive (Europe) • CE Mark

  39. New Developments!

  40. New O2 Measurement Courtesy of Panametrics & Swagelok Co.

  41. New First NeSSI H2O Probe Courtesy of Panametrics & Swagelok Co.

  42. New First pH Sensor Courtesy of Rosemount Analytical

  43. New Mass Flow Controller Courtesy of Porter Instruments and the Swagelok Co.

  44. New First Optical Cell Courtesy of Applied Analytics, Inc.

  45. IGC-II c/w Elastomer Seals New Courtesy of the Swagelok Co

  46. Petrochemical installs... Courtesy of a majorTexas gulf coast petrochemical facility

  47. A 5 year Roadmap • A Plan to Achieve the Vision North America Europe Asia

  48. 01 02 03 04 06 05 NeSSI Roadmap Definition Analytical & Wireless Gen. III Smart/”Electrified” Gen. II Mechanical Gen. I  Analytics/Sensors (e.g. laser based)/Wireless Simple Analyzers(H2O, O2, pH, etc.) Prototype - Physical Sensors/Heating/SAM Mechanical Components e.g. filters, valves, etc. NeSSI/CPAC Vision Mech. Field Trials Smart Field Trials SP76 Substrate Available 2000 Time (years)

  49. Dow Danny Quevillon Reg Hartwig Christoph Kleimeier Walt Henslee Bac Vu (SP76) David Gay Syncrude Ian Verhappen ExxonMobil Chemical Dan Podkulski (SP76) Jeff Gunnell John Cumbus Rajco Puzic CPAC Mel Koch Lloyd Burgess Brian Marquardt Acknowledgements I

  50. Doug Mitchell - Panametrics John Wawrowski - Swagelok Rick Ales - Swagelok Yoav Barshad - Applied Analytics Trevor Knittel - Analytical Specialties Mike Marsceill - Porter Carl Jones - Rosemount Analytical CD Feng - Rosemount Analytical Bob Nickels - Honeywell Ron Eddleman - Measurementation Chris Towle & David Blisset - MTL Acknowledgements II

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