1. “How to Trust Your Process Analyzer"
Steve Doe
Parker Hannifin
NeSSI™ Workshop May 11, 2006

2. Topics
Case Study
New Tools to Improve Sample Handling System Reliability
Field Results
Next Steps

3. Case Study: Background
Lanxess
Born of Bayer AG strategic realignment in 2004
Produces Performance Chemicals, Chemical Intermediates, Engineering Plastics & Performance Rubber
Sarnia, Ontario Plant: Butyl Rubber producer >60 years
Moisture analysis & control is key
Process Engineers & Plant Operators lacked confidence in analyzer results due to Sample Handling System (SHS) legacy problems
Plant shutdowns resulted – big bucks lost on several occasions!

4. Case Study: Early 2004
Analyzer PM had been properly completed within 48 hours of a moisture increase trend
Midnight callout from operations: “Your Analyzer Isn’t Working!”
Analyzer Engineer twisted operations arm over the phone: “Act On The Analyzer’s Results!!!”
Operations listened- and set a new production record that very day!
“High-fives” for everyone- but Analyzer Engineer reminded the team about the “dodged bullet”
Cross-functional team was created to increase SHS reliability and “customer confidence”

5. New Tools for SHS Reliability
Robust, modular, remote actuation double block & bleed stream (DBB) switching valve

6. New Tools for SHS Reliability
Differential pressure flow indication w/ integral relief function (I.S., 4-20mA output)

7. New Tools for SHS Reliability
Smart, Proportional Heater & Purge Preheater

8. Field Results System Commissioned June 24, 2005
Zero Downtime After Commissioning

9. Field Results
Operations has authority via DCS stream switch reference gas to validate analyzer calibration
DBB Stream Switch
Reference Gas Dryer

10. Field Results
Remote analyzer and bypass flow indication available to operators via DCS
Bypass Flow Indication
Analyzer Flow Indication
Reference Gas Flow (9min 25sec)
Switching valve cycled
Sample Gas Flow (9min 25sec)
Cycles repeated during commissioning

11. Field Results Process Engineers & Operations TRUST THE ANALYZER
Several analyzers in the Sarnia plant are running closed loop control
Plant Shutdowns HAVE BEEN AVERTED
5 additional “smart” systems have since been commissioned in the Sarnia plant- more planned

12. Next Steps
Incorporate Human Machine Interface (HMI) in field; Class 1, Division 2 compliant
Provides local host for “Smart Shelters”

13. Ethernet to Technician Workstation Onboard PLC Ethernet to HMI
Smart Shelter
Ethernet to Technician Workstation
Onboard PLC Ethernet to HMI
4-20 mA to PLC
- For Now!
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