NeSSI  connectivity: progress on SAM and Smarts Jeff Gunnell ExxonMobil Chemical Limited

Domain architecture

The NeSSI rail concept

Objectives for CPAC fall 05 Selection / finalization of the NeSSI™-bus or buses. Articulate the need for both an embedded and a standalone SAM. Prioritize the SAM applet software needed by end users to drive reliability. Clearly describe what component makers need to do to produce NeSSI™ products.

User wants NeSSI (TM) -bus that is certified for both IS and non-IS. Open architecture, non-proprietary NeSSI (TM) -bus communication - anyone's component can talk to anyone's analyzer. Open connectivity to the process control and maintenance domains, using OPC. Open transferable applets - across all analyser manufacturer's platforms for both the embedded and stand-alone SAM. Plug and play sample systems.

NeSSI  Bus options

SAM: hardware options Explained in the Gen II spec updated for clarity in May 05 see Section 10.3 see Figure 10

Figure 10 Stand-alone SAM Embedded SAM

SAM has its own enclosure The NeSSI-bus provides intrinsically safe, bi- directional communication with sensors and actuators Heating for the substrate, enclosure or other devices is controlled by SAM SAM communicates to the DCS and operations and maintenance domains via Ethernet. Stand-alone SAM

Embedded SAM The sensor or analyzer has its own controller and is directly connected to the controller, eg: –spectrometer with a sample cell on the substrate connected by fiber optic cable –GC with the sample delivered by NeSSI –pH sensor connected with electrode cable SAM is embedded into the analyzer controller The NeSSI-bus provides intrinsically safe, bi-directional communication with sensors and actuators Heating for the substrate, enclosure or other devices is controlled by SAM Analyzer controller communicates to the DCS and operations and maintenance domains via Ethernet.

SAM software applets Michelle Kohn (UOP) survey to identify priorities for elements in each major class of functionality: –Analyser / sample handling system monitoring and control –Validation routines –Asset management –Utility management –System health –User interface Responses according to: –Customer viewpoint: importance 1 = Nice to have 2 = Important 3 = Critical –Supplier viewpoint: ease of implementation 1 = Difficult > 6 months 2 = Easy < 6 months 3 = Doable now < 1 month –Priority = Importance x Ease Participants –Customers Dow ExxonMobil UOP/HW CPAC –Suppliers Parker Swagelok Circor ABB Emerson Siemens Infometrix

Analyser / sample handling system monitoring and control RequirementRanking Stream switching – multiple process sample streams 8.6 Temperature monitor/control of sample system (substrate) heater 6.8 Stream switching – zero, linearity, span checks 6.4 Data Validity/quality Flag 6.3 Temperature monitor/control of vaporizing regulator 6.1 Barometric pressure sensing for use with compensation algorithm with analytical results 5.9 Pressure control by means of a pressure sensor / modulating valve 5.5 Temperature monitor/control of enclosure heater 5.4 Temperature monitor/control of selected external heating zones (e.g. methanizer) 5.1 Flow control by means of a flow sensor / modulating valve (sample and bypass) 4.7 Heat tracer – temperature monitoring and control 4.6 Backpressure monitoring and control 4.5 Control of sampling pumping and aspiration systems ( spent process back to the source) 4.5 Temperature monitor/control of instrument air purifiers, etc. (clean up) 4.1 Pressure control around a fluctuating process control valve - constant flow 4.0 Provides safety trips – based on pressure, temperature, flow (leak), etc. 4.0 Using differential pressure sensor to swing sample filters or change / loss of flow 3.8 Leak detection by pressure lock-in/isolation monitoring pressure fixed time 3.8 Deviation alarm between redundant analyzers 3.8 Interaction with process events for startup and shutdown of sampling and analysis 3.5 Cooling of substrate 3.0 Analytical interaction modules - ranges, optical filter selection, path length selection 2.6 Moisture/condensation sensing and remedial action (as part of filter for example) 2.6 Calculates mass flow/density of process (vapour) sample flows and uses with analyzer concentration to give a mass concentration 2.4 Self-purges / cleans a dirty system on an as need or regular basis 1.7

Validation RequirementRanking Introduction of zero and span fluids (e.g. valve commands) or other checks for benchmarking/calibration 7.3 Alarms on failed validation check 6.1 Validate analytical sensor operation 4.6 Programmable ability to introduce checks at various times and durations (e.g. every day for x minutes) common to all 4.6 Control charts to determine the need for calibration and track performance above and below the control limits 4.5 Validate flow accuracy 4.0 Validate temperature accuracy 3.8 Validate pressure sensor accuracy–e.g. timing routine from calibration fluids 3.0 Long term storage and history of SQC results on board 3.0 Calculation of deviation from benchmark values common to all routine USD 2.9 Supports the use of permeation devices (flow and temperature control) 2.8 Calculate analyzer system uptime 2.8 Ability to stagger validation routines when redundant devices are used 1.6 Full survey available on CPAC web-site:

Legacy connectivity

A way forward to develop SAM? Start off with embedded systems in GCs –hardware (computing power) already there –networking to DCS/maint. domains already there –control of sample systems already part of design  Opportunity to develop and test functionality in fastest time and at lowest cost  Starts out with a natural deployment mechanism Follow on by deploying the software into a stand-alone package –what ready made devices are already available?

Reminder Open discussion session this evening As usual – should be lot’s of fun