1. NeSSI II - A Platform for Micro-Analytical Devices
CPAC Spring Meeting – May 2003 by
John Mosher, Bob Nickels – Honeywell Sensing & Control
and
Ulrich Bonne – Honeywell Laboratories 2

2. Why NeSSI?
“It's estimated that 70-80% of analyzer outages can be traced to the sample system.”
T. McMahon, Control Magazine, August 2001
Sample systems limit the effectiveness of process analytical technology:
Complex
Expensive
Sparingly deployed
High maintenance
Large, bulky, “dumb” devices
Major cause of unplanned downtime

3. Evolution of the NeSSI Project
MicroAnalytical
(enabled by Technology Advances)
End User
Value
Gen III
Circa 200?
At the Pipe
(enabled by Intrinsic Safety)
Gen II
Circa 2003
Electrical/Smart
(enabled by Communication Standard)
Gen I
2002
Miniature/Modular
(enabled by Mechanical Standard)
Honeywell Proof Of Concept Apparatus
( under development at S&C, Feb. 03)

4. User-Driven, Multi-vendor Supported
NeSSI Objectives
Promote the concept of...
at the pipe field-mounted analytical systems
Facilitate the acceptance/implementation of...
modular & miniature process analytical technology
Lay the groundwork for...
smart technology open connectivity & communications
Provide a technology bridge to the process for...
microanalytical “lab-on-a-chip” - PHASED
U.S. Patent No:
6,393,894
PHASED Multi-Gas Analyzer (Micro Gas Chromatograph) under development at Honeywell Labs
GE-Panametrics Oxygen sensor probe on NeSSI
User-Driven, Multi-vendor Supported

5. Gen I - Miniature/Modular Concept
Traditional Sample System:
NeSSI Sample System:
ANSI/ISA
Modular Component Interfaces for Surface-Mounted Fluid Distribution Components
Part 1: Elastomeric Seals
Approved August 2002

6. Gen II - Smart/Electrical Technology
NeSSI II = ANSI/ISA76 + IS + CAN + SAM
NeSSI Gen II
ENTERPRISE DOMAIN
Level 4 Enterprise LAN
SAM
CANbus
Programmable Substrate Heater V P A F
Auxiliary Heating/Cooling
Substrate T
Level 3 LAN
PROCESS CONTROL DOMAIN
INFORMATION D0MAIN
Level 2 LAN = Field LAN
Open communications protocol standard based on CAN
Intrinsically Safe
SAM = Sensor Actuator Manager – Embedded Controller, Profile Manager Communications Gateway
eSAM  
SAM
Level 1 Sensor Bus (CAN)
MEASUREMENT DOMAIN

7. NeSSI II/III – Platform Development
Communications Interface “Rail” – DeviceNet IS
The Area Between the Enabling “Rails” is Where
Sensor and Instrument Vendors Add Value and
Commercialize Intellectual Property.
Physical Interface “Rail” – ANSI/SP76

8. NeSSI II/III – Product Development
Typical NeSSI Device combines state-of-the-art combi- sensor technology with Intelligence and network interface in one small, surface-mount package.
Mod
Valve
D/A
Network
Press/
Temp
A/D
Network
Other Analytical:
pH,
O2,
Ion,
Conductivity,
NOx,
Turbidity,
???
Substrate
Substrate
Substrate
On/Off and Modulating valves
Flow Sensor w/ Temp, Pressure w/ Temp
PHASED Micro GC
Moisture in Dry Gasses

9. Adaptation of Honeywell Temp, Pressure, Flow Sensors
Microbridge flow sensor interfaced to a typical miniature CAN microcontroller and 8 mm connector.
A similar interfacing
approach will be used in this project to connect existing sensors and actuators to
the CAN network.
8 mm
by Bob Nickels, Honeywell 2

10. Honeywell Proof-of-Concept-Assembly (POCA)
Current Status:
Sensor Design and SP76 housing qualified
Intrinsically Safe (IS).
CAN controller and transceiver chipsets
identified.
DeviceNet protocol selected and pre-tested
in selected chipset.
M8 connector tested for DeviceNet on POCA.
Preliminary CAN IS mode testing done.
First POCA units delivered to Dow and
ExxonMobil.
Next Steps:
Design and build PCBs incorporating selected sensing and communication chipsets/circuits.
Design and build PCBs into SP76 Housings and qualify full product as IS.
Test Assemblies in full DeviceNet network.
Identify DeviceNet IS network restrictions and rules.
Propose establishment of DeviceNet IS Special Interest Group (SIG) to ODVA. 2

11. NeSSI II/III Cost Comparison
System Configuration:
Above Average Complexity, 4 Gas Streams: 2 Process, 1 Span, 1 Calibration.
Extra, Blank Locations for Additional Instrumentation, including PHASED GC.
Traditional SS NeSSI Gen 1 w/Control NeSSI Gen 2/3
$20, $36, $40,000 est.
Traditional Sampling System:
Gauges, Manual Valves, Rotometers, Gas-Purged Enclosure, No
Information, Process Variable Disconnect, Custom One-of-a-Kind
NeSSI Gen 1 w/Control:
Smaller Footprint, Modular Gas Path, Gauges, 4-20mA Input/Output Devices
PLC Control, Process Variables Connected, Huge Gas Purged Enclosure,
Custom One-of-a-Kind.
NeSSI Gen 2/3:
Much Smaller Footprint, Networked I/O Devices, Local & Remote Control,
Process Variables Integrated, Intrinsically Safe, Software Menu Designed,
SAM Controlled, GC Onboard, PDA Enabled, Standard Enclosure Located Near Flow. 2

12. Intelligence + Communications = Improved Productivity
The Value of Good, Fast Information:
Monitoring of key parameters
Verify constant flow of analyte
Control pressure, temperature
Self-validation, both continuous and periodic (embedded control, integrated diagnostics, self-calibration)
Intelligent statistical tools identify abnormal events
Operators notified when trouble is anticipated (predictive diagnostics)
Data presented in a user-friendly way to the right person, anywhere
Self-correcting systems to avoid downtime
                                                   
                                            
                                                           
Wireless enablers for operator productivity

13. Preliminary Investigation of SAM Controller Choices
Honeywell Experion PKS C200 Controller 
DeviceNet in/Ethernet or ControlNet out
Direct Connectivity to Honeywell Architectures
|CPU|Enet|Dnet| I/O|
 SAM Design A:
DeviceNet in/Ethernet out
4” x 4” x 2”
USB and Serial Ports
Linux OS w/ JavaVirtual Machine
SAM Design B: 
DeviceNet in/Ethernet out
3” x 4” x 6”
Expandable local I/O, Serial Ports
Windows CE OS
Webserver OPC Connectivity 2

14. NeSSI Integration into Information Systems
Control & Information - Level 3 LAN (Ethernet)
OPC
Gateway
Control Room
                                                                                                                                   
Field
Class 1 Div 1
At-Line
Sample Point
Field - Level 2 LAN (Wired or Wireless)
Analyzer Shed
Field - Level 2 LAN (Ethernet)
Sensor Actuator Manager
Local
HMI
Station
Gas Analyzer
Sensor Actuator Manager V T P A
Sample System I/O Subsystem
Sample System
Class 1 Div 2
Wireless
Handheld
HMI
DeviceNet
Class 1 Div 2
Sensor - Level 1 LAN (DeviceNet) V
Gas
Analyzer P T A
Sample System
NeSSI Generation 2/3
Class 1 Div 1
NeSSI Generation 1

15. NeSSI II – Market Development
Industry Organizations:
Honeywell Products and Services:
Sensing & Control
- Pressure, Temperature, Flow
Moisture, Turbitity, ???
Industrial Measurement & Control
- pH, O2, H20, Conductivity
NOx, Ion, Moisture, ???
Honeywell Labs
- PHASED, Microanalyzers
Industry Solutions
- Sales, Service, and Support
NeSSI - New Sampling Sensor Initiative
Center for Process and Analytical Chemistry
Open DeviceNet Vendors Association 2

16. Sophisticated End Users & Application-Specific OEMs
NeSSI II/III – Commercialization Strategy
Unsophisticated
End Users
Sophisticated End Users &
Application-Specific OEMs
Customers
Analyzer OEMs
Honeywell Services &
Industrial Solutions
Solutions
ABB, Siemens,
Many Others
Other Integrators/Installers Also
ABB, Siemens,
Many Others
Analyzer OEMs
Gas Box Assemble,
Test Companies
Celerity, UCT,
Others
Products
Components
Other Analytical
Device
Manufacturers
Substrate/Valve
Manufacturers
Honeywell Indust.
Measure & Control
Honeywell
Sensing & Control
DeviceNet &
Controller
Manufacturers
GE Panametrics,
Circor, Rosemount,
Others
Parker, Swagelok,
Celerity, Others
pH, O2, H2O,
PHASED, More
Pressure, Temp,
Flow, Moisture
Many

17. NeSSI II - A Platform for Micro-Analytical Devices
Thank You!
NeSSI II - A Platform for
Micro-Analytical Devices
CPAC Spring Meeting – May 2003
(209)
(815)
(763) 2