1 Citius, Fortius, Altius: A New Sampling/Sensor Initiative (NeSSI) Rob Dubois & Peter van Vuuren

2 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” Photo Credit: Erich Lessing/Art Resource, NY National Gallery, Oslo, Norway. © 2000 The Munch Museum, The Munch-Ellingsen Group, Artists Rights Society, New York

3 Citius (Faster) Faster to design & build –modular design –at the pipe: field mounted –“analytical transmitter” –engineering tool kit Faster to modify –plug and play sample sys. Faster sensor to analyzer development cycle

4 Fortius (Stronger) Rugged and compact Reduced maintenance –predictive model Sample system as a science rather than art Standard components Standard sampling systems for industry wide “common” applications

5 Altius (Higher) How can we reduce cost to build -35%*? How can we reduce cost of ownership -40%*? How can we obtain higher reliability? How can we achieve higher data confidence? How do obtain common validation protocols? *Ref. To Gunnell/van Vuuren IFPAC2000 Presentation

6 A Brief History - NeSSI Operates under the umbrella of the Center for Process Analytical Chemistry (CPAC) Originated from various CPAC focus sessions IFPAC 2000 plenary paper: J. Gunnell/P. van Vuuren Focus groups: Pittcon 2000; ISA Expo2000 NeSSI: ad hoc group interested in new sample systems NeSSI: supportive of the ISA SP76 standard NeSSI: no affiliations; sponsored by CPAC

7 NeSSI objectives... Facilitate the acceptance/implementation of... – modular, miniature & smart sample system technology based on semiconductor (SEMI) standards & ISA SP76 work Promote the concept of... –field-mounted analytical systems –integration of sample systems with physical/chemical sensors Lay the groundwork for... –open connectivity architecture (e.g. Ethernet, wireless) –industry standard protocols (e.g. OPC, Hart, Fieldbus, Profibus) –web enabled technology (e.g. browser, HMI, I/O Servers) Provide a technology bridge to the process for... –“lab-on-a-chip” analytical sensors

8 “Request for Proposals” (RFP’s) 1Paper designs requested for six “typical” petrochemical industry sampling scenarios –Measurement of PPM H2O and O2 in a high Purity Hydrocarbon –Measurement of pH in an Aqueous Acid/Base Stream –O2 Measurement in a Stack Gas (low pressure) –Sampling System for Toxic Gas Measurement –Two stream sampling system (includes Liquid Vaporization) –Eight (8) Stream Sampling System INTENT: DIVERSE SAMPLING SCENARIOS

9 2Provide electrical layout and interface drawings 3Provide a functional description of the design 4Propose a “sampling system/electrical bus” 5Propose ideas to standardize the software protocol interface 6Describe compliance/non-compliance and barriers to the use of ISA standard SP76 (modular component interface draft standard) INTENT: ESTABLISH ISSUES, BARRIERS & SYNERGIES “Request for Proposals” (RFP’s)

10 Swagelok Response to “RFP’s” Swagelok Complies with SP76 –Metallic ‘C’ seal design now Elastomer seals later –3 channels –1.5” blocks; downmounts Lego  like assembly –IGC II technology –highly engineered Investigating flow & X- proofing solutions Courtesy of Swagelok

11 Parker-Hannifin Response to “RFP’s” Parker-Hannifin Compliant with SP76, but... –5 channels –1.5 & 2.25” block available –ability to isolate sections –elastomer seals Hybrid design –manifold and tube & block Heating –fluid heating “channel” Investigating flow & X- proofing solutions Courtesy of Parker-Hannifin

12 Autoflow Response to “RFP’s” Autoflow Fully compliant with SP76 –TFE loaded elastomer seals –3 channels –1.5” blocks Division 1 cartridge heating Div. 2 thermal flow meter, flow switches Utilizing current electrical X-proofing concepts Courtesy of Autoflow

13 Rosemount-Swagelok Response to “RFP’s” Rosemount-Swagelok Example of synergy that can drive NeSSI Field mounted chromatograph with a miniature/modular sample system THESE COLLABORATIONS AND ALLIANCES ARE CRUCIAL Courtesy of Rosemount & Swagelok

14 ABB Analytical At-Line Response to “RFP’s” ABB Analytical At-Line Demonstrates intuitive Human Machine Interface (HMI) Graphical User Interface (GUI) for a sample system Demonstrates digital comm. to a sample system(Profibus, Ethernet, VistaNET) Autoflow miniature, modular system –5x reduction in volume! Courtesy of ABB Analytical

15 Electrical Issues Response to RFP’s Electrical Issues Electrical codes do not support simple, safe wiring methods –NIS Methods: bulky x-proof conduit, MI, metal sheath –IS Methods: simple braided cable not yet approved –Physical separation required between IS and NIS Simple sensors such as temperature, proximity flow & strain gauge pressure do support Intrinsic Safe wiring methods Conventional pressure/flow controllers need high energy and are unsuitable for IS Safety methods Enclosure mounted components should be rated Div/Zone 1

16 Viable and Practical? Comments versus “RFP’s” Viable and Practical? We may be “trading labour to build for labour to engineer” Programmed substrates require detailed design engineering –possible loss of flexibility offered by tube & block Costs, at least for initial systems, will not be any cheaper Need vendors who can provide novel X-proof wiring solutions and association with Fieldbus style agencies A linear, singular substrate is not feasible Small ports may have problems with liquid streams Need a base plate or substrate port for signal air Viable & Practical: YES, with limitations

17 So what are the barriers/issues? Lack of Div. 1 explosion proof components Need for new, miniature flow devices Need for new IS/NIS Div. 1 miniature wiring methods Std. communication methods Need for integral heating Cost & flexibility? “Brute force” legacy

18 Clever Sample Systems Needed! Self-adjusting for optimal performance under varying conditions –On board delta/Pressure, Flow, Temp. Measure & Control Tracks reliability and operation metrics –tally valve cycles, gas usage –maintenance log, operation manuals Self-diagnostic Graphical User Interface (GUI) –show Sample System operation Embedded processors Decentralized control “Since the oft quoted % of the problems with analyzers are sample system related then perhaps our efforts should be focussed in this area!”

19 Tower of Babel or Open Standards? Opportunity for standard sample system software “applets”. Examples... –stream selection protocols –validation protocols –monitoring packages –sample system diagnostics, etc. Opportunity for… –common communication protocols –hard wire, wireless & fiber optic connectivity buses

20  - A Call to Action… Component manufacturers we need new, miniature Div./Zone I manifold mounted components –flow measurement devices –pressure/temp. transducers –motorized valves; solenoids –mini-purged components! We need an effort to define Div/Zone 1 signal & power ‘bus’... –IS (signal) and NIS (power) – wireless; fiber optic signals?

21   - A Call to Action… We need a task force to define... –stand alone sample system controllers –standard communication protocols –interoperable software “applets” to make sample systems “clever” Analyzer manufacturers, universities we need: –simple/small analytical devices –substrate mounted; X-proof –“lab on a chip” devices

22    - A Call to Action… Substrate manufacturers… –we need Div. 1 integral electrical/fluid heated bases –“design guides” for 3rd parties We need to... –Promote; synergize –Publish test results –Harmonize regulatory barriers –Bring in key technical players –Work with groups like Fieldbus, Profibus, OPC…

23 NeSSI Next Steps… Sunrise…..Sunset? NeSSI deliverable... –Compact Disk (CD) –final report Should NeSSI continue? –In what form, membership, etc. Is there a need for a Process Analytical Foundation? YOU ARE CORDIALLY INVITED: –to an open forum … Tuesday 6:30 - 7:30 PM in the Ossabaw Room.

24 Summary…let’s stay on track! Three excellent but diverse substrate designs Good synergies emerging NeSSI “list” is growing... Opportunities abound … Some barriers to overcome (esp. Electrical issues) Petro-chemical end users desire change! –Citius, Fortius, Altius!

25 Acknowledgements ISA – Jim Tatera Expo2000 forum, etc. –Dan Podkulski SP76 Contribution! Focus group (Pittcon 2000) Focus group (ISA Expo2000) IFPAC 2001 Dow Chemical –David Gay; Reg Hartwig; Walt Henslee; François Ramond; Ron O’Reilly; Brian Worthington ExxonMobil Chemical –Jeff Gunnell; Dan Podkulski; John Cumbus; Paul Hromadka; Rajko Puzic CPAC –Mel Koch; Lloyd Burgess; Larry Ricker

26 Acknowledgements NeSSI contributors Kelley Bell (ABB PA) Richard Hughes (Autoflow) John Gajewski (FRCO) Bud Keyes (FRCO) Stephen Staphanos (FRCO) Steve Doe (Parker) John Morse (Parker) CD Feng (Rosemount- Uniloc) Frank Ruiz (Ruiz and Assoc.) Dave Simko (Swagelok) Richard Ales (Swagelok) Doug Nordstrom (Swagelok) All NeSSI contributors not acknowledged or mistakenly omitted!

27 Acknowledgements NeSSI contributors Kelley Bell (ABB Analytical) Richard Hughes (Autoflow) John Gajewski (FRCO) Bud Keyes (FRCO) Stephen Staphanos (FRCO) Steve Doe (Parker) John Morse (Parker) CD Feng (Rosemount- Uniloc) Frank Ruiz (Ruiz and Assoc.) Dave Simko (Swagelok) Richard Ales (Swagelok) Doug Nordstrom (Swagelok) All NeSSI contributors not acknowledged or mistakenly omitted!