NeSSI – The “New Sampling Sensor Initiative” - An Enabling Technology A CPAC Sponsored Open Initiative Prepared by: –Rob Dubois – Dow Chemical –Peter van Vuuren – ExxonMobil Chemical –Jim Tatera – Tatera & Associates, Inc. ISA AD2002 April 16, 2002

Presentation Outline Introduction, Drivers & History NeSSI Generation I and II comparison Elements of a NeSSI Generation II System What will a Generation II prototype look like? Status Update and New Developments NeSSI Roadmap & Summary How do I get involved with NeSSI?

NeSSI Initiative An ad hoc global industry initiative, formed in June, 2000 to drive permanent change in Process Analysis. –NeSSI mail-out has now grown to 250+ subscribers –Composed of End Users, Manufacturing Companies, Integrators Sponsored by the Center for Process Analytical Chemistry (CPAC) - legal umbrella

Originated from various CPAC focus sessions IFPAC 2000 plenary paper presented NeSSI vision Focus Groups and Workshops –Pittcon 2000; ISA Expo 2000; IFPAC 2001, Pittcon 2001, CPACT Edinburgh, ISA Analytical Division, ISA 2001, IFPAC 2002 Tutorials: – ISA2001 Houston, INTERMAC 2001 Tokyo, Pittcon2002 A Brief History of

NeSSI Objectives Facilitate the acceptance/implementation of... –modular, miniature & smart process analytical technology Promote the concept of... –at the pipe/field-mounted (“byline”) analytical systems Lay the groundwork for... –open connectivity communication architecture Provide a technology bridge to the process for... –“sensor/lab-on-a-chip” microanalytical devices

The drivers for change... Reduce Cost to Build –Design and Engineering –Manufacturing and Installation Reduce Cost of Ownership –Design Standardization –Simpler, less expensive maintenance Enhance Reliability –Validate sample, data, communication

Project Segmentation Gen III Gen II Gen I Mechanical (mostly) Electrical/Smart (Diagnostic) MicroAnalytical & Wireless Value

Gen I - Standardize on a miniature, modular system Concept “Borrowed” from the semiconductor industry LEGO ® like design ISA Standard –rugged Courtesy of CIRCOR

Elastomer Seals are desired in HP Industries Courtesy of the Swagelok Co Manufacturers… Parker-Hannifin Autoflow CIRCOR Kinetics Swagelok Fujikin

What is ISA SP76? Copyright 2001 ISA. All rights reserved. Reproduced and distributed with permission of ISA. Note: Draft provided for promotion only. Refer to ISA SP76.

A Future Analytical System...Will Look More Like Us! Single Processor - Overall Control –Sensor Analytical Manager (SAM) System will be Multifunctional –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

Gen. I versus Gen. II

Generation II Dimensions - 7 Elements 1. Heated Substrate 2. Physical t-Sensors 3. Combi Valves 4. SAM 5. PC with HMI 6. IS Multi-drop bus 7. Enclosure

1. Heated, Programmable Substrate AC Power Conduction Heating - cartridge heater(s) - over-temperature cut-off Furn. by substrate mfg. Heating Fluids (alternative)

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

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

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

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

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

4b. Standalone “SAM” - Wired Sensor/Actuator Bus Sensor Analytical Manager (SAM) Analyzer System Ethernet LAN P Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor V A T PC or Analyzer Controller V T P A ?

4c. Embedded SAM - Wired Sensor/Actuator Bus Analyzer System Ethernet LAN P Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor V A T V T P A ? Analyzer Controller w/ Embedded SAM Functionality

4d. SAM “Pick-list” for Common Sampling Tasks 4Zero & span validation 4Pressure regulation 4Temperature monitoring 3Stream switching 4Maintenance diagnostics Interoperability –talk to all analytical systems SAM Enabling Technology for microAnalytical

5. PC/PDA Graphical HMI (Human Machine Interface) FVvTP FVv A HMI Personal digital assistant PC Hello? Vv=automatic valve; P=pressure sensor; F=Flow Sensor; A=Analytical Sensor;T=Temp. Sensor HMI

6. Serial Multi-drop Bus - “Au Revoir 4-20 mA?” CANbus –DeviceNet, SDS, etc. –Intrinsically Safe Engineering units on board sensors Reduces wiring load –multi-drop Eliminates I/O Rugged, low cost V T P A

7. Enclosure “X-team” Haz. Review Process AC Power Div/Zone 1 GP. A-D, T4 Enclosure - NEMA 4/IP56 Rated - all climate operation - no purges - no X-proof tubs - low cost of operation Sensor Bus Intrinsically Safe (IEC Ex ia) - no gas “sniff” tests req.. - allows hot disconnects - plug & play Heaters - Substrate & Enclosure - IEC Ex d - programmable temp. AC Power Designed for Global Use

Gen III Wireless Signal Analyzer System Ethernet LAN V T P A Eg Bluetooth , Plug and Play! Power Supplied by... –X-proof or IS miniature power bus Sensor Analytical Manager (SAM) P.S.

Generation III Plug & Play  Analytical FVvT A SAM Fiber Optic AT One sensor per component “lab on a chip” One Sensor and Multiple Analytes A Ethernet Transducer Bus Enabling Technology for  Analytical - GC-on-a-chip - micro MS - chem. sensors

Keys to speedy development

Don’t (re)invent…leverage existing standards Make use of existing connectivity and communication... Ethernet OPC CANbus wireless e.g. Bluetooth™ WEB servers/Internet

Communicate…globally! International –Europe, Japan, Canada, USA Consortia –CPAC, CPACT Conferences –ISA, Pittcon, IFPAC, etc.

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

Around the Loop: The New Sampling/Sensor Initiative CONTROL MAGAZINE Great publicity... “It's estimated that 70-80% of analyzer outages can be traced to the sample system” Terrence McMahon August 01, 2001 Also ISA InTech Magazine; Chem. & Eng. News

How difficult are these substrates to work with ? The following section (compliments of John Cumbus of ExxonMobil) should give you an idea.

Expected Advantages Minimum Engineering /Drafting Effort Simplicity of Construction Ease of Maintenance Leverage Technicians for Higher Priority Activity Higher Service Factors

Supply Filter Bypass Flow Controller Sample Supply Sample Bypass Supply Pressure To Analyzer Calibration Supply Stream Valve (config-1) Guard Filter Stream Valve (config-2) From Analyzer Return F Supply Shut-Off NC NO NC Atmos. Vent Calib. Shut-Off FE PI F Analyzer Flow Controller FE PE Pressure Transmitter

Engineering Package Provided by Configurator Pressure Indicator left for Technicians Eight Single Stream and One Dual Stream Three Analog Outputs, Two Inputs

Modular Sample System (minus MFMs)

Modular System Connections Inside Enclosure

New System in an Old Box

Assembly Test of Smaller System (76 Pieces)

Assembly Test Configuration

Assembly Drawings Provided

Completed Assembly

Example of Mechanic’s Previous Work

The “Mechanic”, Age 9

Comparison of “Old” and “New” Sample Systems

New Developments

NeSSI Analyzers - here today Courtesy of Panametrics & Swagelok Courtesy of Rosemount Analytical Courtesy of Panametrics & Swagelok Oxygen H2OH2O pH Conductivity

Courtesy of Porter Instruments and the Swagelok Co. MFC’s here today –Porter Inst. (Div. 2) –Others…Gen Purpose Unit Instruments Brooks Undergoing Certification

Just announced... Courtesy of Applied Analytics MIR ATR

Enabling technology for... –Miniature physical sensors –Flow –Temperature –Pressure –Miniature chemical sensors “lab-on-a-chip” –Component Mfgs. Calibrators, pumps & dryers, etc. Courtesy of Mass-Sensors Inc.

Petrochemical installs... Coutesy of a gulf coast petrochemical facility Courtesy of an east coast petrochemical facility and Parker-Hannifin

What’s New - Generation II Specification Draft version now compete Global Review Teams in Progress –X-team (hazardous areas) –C-team (connectivity issues) –A-team (simple applets)

White Paper in Progress Driven by Honeywell Automation Will adapt final NeSSI Gen II spec as criteria for build Expand End Users, Manufacturers –Looking for involvement!! Gen II prototypes will be built DoE being approached for funding in June

Time (years) NeSSI Roadmap 02 Mechanical Components e.g. filters, valves, etc. Mechanical FieldInstallations SP76 Substrate Available NeSSI/CPAC Vision & Roadmap 2000 Design /Prototype - Gen II Smart/Heating/SAM Smart Field Installations Mechanical Gen. I Smart/”Electrified” Gen. II  Analytical & Wireless Gen. III Rev. 1, Dec  Analytics/Sensors (e.g. laser based)/Wireless Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)

References & involvement...

Acknowledgements I Dow –Danny Quevillon –Reg Hartwig –Walt Henslee –Bac Vu (SP76) –John Leach II –Craig Snook ExxonMobil Chemical –Dan Podkulski (SP76) –Jeff Gunnell –John Cumbus –Rajko Puzic CPAC –Mel Koch –Dave Veltkamp

Acknowledgements II –Doug Mitchell - Panametrics –John Wawrowski, Rick Ales, Dave Simko - Swagelok –Yoav Barshad - Applied Analytics –Nick van Bruggen - Porter –Gary Frank, Raj Adani - Kinetics –CD Feng - Rosemount Analytical –Bob Nickels, Ulrich Bonne, Ken Creasy - Honeywell –Chris Towle/Don Long - MTL –Steve Doe - Parker –X-Team

A parting thought... "When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged

MicroAnalytical Do you have any questions regarding the the standard footprint and/or the relevance of your technology to this concept and/or its suitability beyond plant applications (lab, pilot plant, etc)? Do you understand the Process Safety issues and requirements (e.g. I.S. Ex ia)? Would your like to discuss any of them?

Sensor/Actuator Bus Sensor Analytical Manager (SAM) Analyzer System Ethernet LAN Analyzer Controller V T P A Sensor Requirements: Simple Sensor Host Communications Configurable Sensor Attributes Small Footprint of Sensor Engineering Units Inexpensive but reliable Host Requirements: Controls all Sensor/Actuator Functions Support Common SS tasks (Applets) Gateway to Analyzer LAN/Imbedded

Sensor/Actuator Bus Sensor Analytical Manager (SAM) Analyzer System Ethernet LAN Analyzer Controller V T P A CAN-bus: Simple Sensor Host Communications Configurable Sensor Attributes Measurement and Diagnostics Small Footprint of Sensor Engineering Units Inexpensive but reliable (proven technology) Attributes Flashable (DeviceNet/SDS..)

Sensor/Actuator Bus Sensor Analytical Manager (SAM) Analyzer System Ethernet LAN Analyzer Controller V T P A Workgroup Question/Feedback: Is CAN the right answer? Is IS the right answer?

Embedded or Standalone SAM Ethernet LAN Analyzer or PC Controller V T P A CANbus

Q1. Who Should Manage the Applets? Foundation like organization? Applet creator? Analyzer Vendors?

Q2. SAM Concept Would you agree that SAM would be useful device for interfacing and interacting with both the Sensor bus and the larger world of the Ethernet –What do you (or don’t you) like….? –What would you like improved or added?