ISAExpo October 2003: Houston, TX NeSSI* - A Sampling and Connectivity Platform Comes of Age (* New Sampling/Sensor Initiative) “the best way to predict the future is to create it” ISAExpo2003 Houston, Texas, USA October 23, 2003 Peter van Vuuren

ISAExpo October 2003: Houston, TX  Why NeSSI? NeSSI as a Sampling/Connectivity Platform Gen II Progress Path Forward Overview Topics

ISAExpo October 2003: Houston, TX NeSSI Objectives Facilitate the acceptance/implementation of...Facilitate the acceptance/implementation of... –modular, miniature & smart sample system technology –based on ISA SP76 standard substrate (aka footprint) Promote the concept of...Promote the concept of... –field-mounted smart sampling/analytical systems –sample system integration with miniature physical sensors Lay the groundwork for...Lay the groundwork for... –open connectivity architecture for sensor communications (e.g. CANbus, Ethernet, etc.) –industry standard communication protocols (e.g. OPC, etc.) Provide a technology bridge to the process for...Provide a technology bridge to the process for... –“sensor/lab-on-a-chip” micro-analytical devices

ISAExpo October 2003: Houston, TX Overview of a Typical Process Analytics InstallationOverview of a Typical Process Analytics Installation What is Wrong with Today's InstallationsWhat is Wrong with Today's Installations Some Cost ConsiderationsSome Cost Considerations NeSSI to the RescueNeSSI to the Rescue Why NeSSI?

ISAExpo October 2003: Houston, TX Today’s Analyzer System Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Inside an Analyzer Shelter Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Sampling Conditioning Systems Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Sampling Conditioning System - Detail Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX What is Wrong with these Pictures Nothing Best we can do with the tools at handNothing Best we can do with the tools at hand And a Lot Considering Cost to Build Cost to Own Data ValidationAnd a Lot Considering Cost to Build Cost to Own Data Validation

ISAExpo October 2003: Houston, TX What is Wrong with these Pictures A Lot of Infrastructure (Brute Forcing the Installation) A/C Sample Conditioning Systems Sample Transport Lines Analyzer Shelter Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Analyzers treated like Prima Donnas We change the environment to meet their needs What is Wrong with these Pictures Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX What is Wrong with these Pictures Sample Conditioning Systems: * Custom designed, engineered and built * Poor standardization Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX What is Wrong with these Pictures Sample Conditioning Systems: * Custom designed, engineered and built * Lots of tubing/fittings * Many man-hours designing/building it * Lots of discrete components * Typically not smart (Smart = knowing if p,t,f of sample are normal, i.e validating sample) Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Today’s Cost to Build For a Major Greenfield Project J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”, Plenary Session Paper, IFPAC2000, Las Vegas, NV

ISAExpo October 2003: Houston, TX Today’s Cost of Ownership J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”, Plenary Session Paper, IFPAC2000, Las Vegas, NV

ISAExpo October 2003: Houston, TX Think outside the Box/ Be Innovative Look across the fence how other industries do things: SEMI - Surface Mount Technology SEMI - Surface Mount Technology What to Do?

ISAExpo October 2003: Houston, TX What to Do? Picture courtesy Swagelok ®

ISAExpo October 2003: Houston, TX Programmable Substrate Heater V P F A Substrate Simple Sampling System Gen 1: Modular Sampling System = NeSSI I Discrete analog signals SP76 Interface Improvements: * Modular (minimum tubing) * Minimal man-hours (design, eng, manufacturing) * Capable of self-validation (p,t,f)

ISAExpo October 2003: Houston, TX Gen 1: Modular Sampling System Picture Courtesy ExxonMobil Chemical

ISAExpo October 2003: Houston, TX Programmable Substrate Heater Ethernet LAN Analyzer Controller V A P F SAM NeSSI bus Auxiliary Heating/Cooling Substrate T T Standard Sampling Interface dcs o&m user Standard Connectivity Interface NeSSI “Sandwich/Rail” Platform Concept next PDA Development Focus can be on Sensors !

ISAExpo October 2003: Houston, TX Programmable Substrate Heater Analytical Cluster Concept: Sensor Arrays with NeSSI as Enabler Ethernet LAN Analyzer Controller V A A A SAM CANbus Auxiliary Heating/Cooling Substrate T T dcs o&m user Cond Multiple Analytical Sensors ! pH DO PDA

ISAExpo October 2003: Houston, TX Analytical Clusters Concept > Going Micro All the Way Pictures Courtesy of Dow Chemical Freeport, TX Analytical Cluster = A Process Stream Requiring Multiple Analyte Measurements Examples: On-line Propylene Certification CEMS (Stack Analysis) Cooling Water Waste Water Treatment/Effluents Byline Analytical Cluster = Multiple Analyte Measurements done on a Single NeSSI Platform Macro-House Micro-House Macro-Analyzers Micro-Analyzers

ISAExpo October 2003: Houston, TX Metal Treatment/Aerospace Applications Bruce Peterson (Boeing) Ethylene, Propylene, Acetylene/MAPD Converters Peter van Vuuren (ExxonMobil) Chlorine, Ethylene Glycol, Ethylene Oxide Boiler Feed Water/Cooling Water Steve McMillan(ABB) Refining including “Sulfur” Applications Don Young (Chevron) CEMS Applications Dave Simko (Swagelok), Bob Sherman (Circor) Gas Plants Frank Schweighardt (Air Products) Potential Cluster Applications - NeSSI Workgroup

ISAExpo October 2003: Houston, TX Concept of Modular Sampling System based on SEMI design conceived at ISA AD Meeting in 1998 Groundwork for NeSSI started at Nov 99 CPAC meeting NeSSI (CPAC Initiative) initiated in June 2000 (Issued RFP)/SP76 Standard developed in parallel (CPAC Legal Umbrella for end-users to work together) NeSSI promoted mainly at ISA and IFPAC meetings Honeywell submitted DoE Proposal in 2002; CPAC forum for coordinating consortium of end-users (e.g. Dow, ExxonMobil, Air Products, Dupont, UOP, Honeywell, Eastman Chemical) Gen II Draft Specification Published; POCA delivered to Dow and ExxonMobil Chronology of events trail at NeSSI Website: Addendum: NeSSI History

ISAExpo October 2003: Houston, TX Gen II Progress Honeywell developed Proof of Concept Assembly (Apparatus) (alpha design) Technical Hi-LitesTechnical Hi-Lites –First “binary” Mini-Sensors (P/T; F/T) –Introduced Absolute Pressure Transmitter GC sample loop compensation, BP control –First “combi-valves” (Enabler for PID control) –Enclosure and Substrate Heater –Early SAM hardware & SAM software (Laptop Implementation) –First Demonstration of IS CANbus communication (Zener-diode based; prefer galvanic isolation)

ISAExpo October 2003: Houston, TX The Path Forward Published Gen II Draft Specification in Collaboration with Dow Available on NeSSI Website; Finalize Working Copy Start on IS NeSSI-bus Design, Certification -Critical path - Finalize selection of NeSSI bus/protocol IS CAN/DeviceNet probably not feasible -Promote at CPAC/IFPAC Meetings, Nov 2003/Jan 2004 Promote Cluster Application Concept - CPAC, ISA, Internally, Vendors, NIST -Identify and Facilitate Development of Sensors * Through CPAC * IFPAC * NIST, Nat Labs etc. Start Gen III Wireless Design/Justification