August 23, 2000 R.N. Dubois Dow Chemical Smart Sample Systems August 23, 2000 R.N. Dubois Dow Chemical

Design Objectives of a Smart Sampling System Integrate the sample system with the analytical and other diagnostic sensor(s) Standardize analytical systems by providing “smart” sample system applets Increase the reliability of analyzer sample systems (Q.: Why are 80 - 90% of the analytical problems caused by the sample system?) Eliminate to an absolute minimum routine maintenance Provide a representative sample to the analytical sensor(s) and validate under all process conditions 11/13/2018

What is a Smart Sampling System? Provides plug-and-play hardware components and software which… Self-adjusts for optimal performance under variable process conditions Tracks Reliability and Operation Metrics Provides an intuitive Self-Diagnostic GUI 11/13/2018

(1) Self-adjusting by means of “smart” applets - some examples Pressure control by means of a pressure sensor / control valve Flow control to maintain constant flow by flow sensor / control valve Pressure control around a fluctuating process control valve to maintain a constant flow Pressure control to ensure atmospheric pressure or a fixed pressure on the outlet of an analytical sensor Temperature control of vaporizer, sample system heater, enclosure heater, air purifiers, etc. Swings sample filters based on DP or change / loss of flow Cont’d…... 11/13/2018

(1) Self-adjusting by means of “smart” applets - some examples Self-purges / cleans a dirty system on an as need or regular basis Swings gas cylinders based on pressures Provides safety trips - pressure, temperature, flow (leak), etc. Shuts off the sampling system / analysis when the process stream is taken out of service Analytical interaction modules - ranges, optical filter selection, path length selection “Soft” startup and shutdown after process events Suggestions? 11/13/2018

(2) Track Reliability and Operation Metrics (2) Track Reliability and Operation Metrics by means of “smart” applets - some examples Calculates cycles, for example, valve operations (millions of ops) filter in service time (days Tabulates mass flow of… sample utility gases e.g. helium, nitrogen, instrument air calibration gases Tabulates power usage Tracks temperature, pressure, flow cycles or patterns Provides statistics on percent uptime Provides drift information on all parameters Cont’d…... 11/13/2018

(2) Track Reliability and Operation Metrics (2) Track Reliability and Operation Metrics by means of “smart” applets - some examples Tracks control chart for zero / span benchmark Tracks control chart for zero / span calibration Maintenance log Data storage and recovery (e.g. CEMS applications) Equipment data e.g. serial number, software version, etc. Spare parts lists Equipment parts lists Auto reorder points for consumable parts, gases, etc. Suggestions? 11/13/2018

(3) Self-diagnostic GUI (the analyzer as a “mini-process”) Graphical, dynamic user interface (GUI) of all system operation parameters to: Operations on the plant DCS system Maintenance PC based Other Users PC based e.g. via intra / internet Self-diagnostic providing solutions / fixes to abnormal events Provides these generic modes… Condition RED Out of Service - broke, tripped, “in the weeds”, etc. Condition AMBER Standby - undergoing calibration, benchmarking, service request, process shutdown Condition GREEN In Service - system running OK 11/13/2018

Examples of Some Inputs….. Sample inlet (upstream) pressure Sample outlet (downstream) pressure Sample flow rate Sample bypass flow rate Sample temperature Sample vaporizer temperature Sample system enclosure temperature Sample filter differential Sample pump / aspirator differential Actuator air pressure Sample enclosure / housing purge pressure Cont’d…... 11/13/2018

Examples of Some Inputs….. Valve movement / limit switches Plant in operation / Process Stream Off-line / In operation Level monitor in sample collection pots Condensation sensor Position of utility gas manifold valving Pressure of utility gas manifold system Monitors 120 VAC power Analyte concentrations Heat tracer temperature Pressure / Flow of Utility Gases Others? 11/13/2018

Examples of Some Outputs…. Heater Thermoelectric cooler Fan operation Vortex cooler Control valve adjustment Shut-off valve Pump motor speed Stream selection Zero fluid selection Cal fluid selection Analyzer range selection Cont’d…. 11/13/2018

Examples of Some Outputs…. Optical path length selection Column selection Block and bleed Detector selection Light source selection Optical filter selection Pressure programming Temperature programming Ultrasonic Cleaner (on / off) Others? 11/13/2018

Summary - 3 Key Ideas A need for universal, industry wide “smart applets” for self-adjustment and reliability and operation metric tracking Tight integration of analytical and physical sensor(s) and sample system Graphical display of all parameters on remote DCS and / or PC User Interface 11/13/2018