1. NeSSI* - Generation II “Revolution or Evolution?”
*New Sampling/Sensor Initiative
ISA Houston, TX - September 10, 2001
INTERMAC - Tokyo, Japan - Nov. 8, 2001
Rob Dubois - Peter van Vuuren - Jim Tatera .
Tatera and Associates
“the best way to predict the future is to create it”

2. Tutorial Outline Introduction, Drivers & History
A Vision and the Market Trends
NeSSI Generation I, II, III Comparisons
10 Dimensions of a NeSSI Generation II System
What will a Generation II prototype look like?
Some recent developments…
NeSSI Roadmap & Summary
CPAC (Center for Process Analytical Chemistry) Review
9/17/2018

3. Process analyzer systems have been accused of being...
complex
expensive
proprietary
“big box” (battleship)
hi maintenance
suspect regarding data integrity
slow to change
9/17/2018
Edvard Munch “The Scream”

4. Originated from various CPAC focus sessions
A Brief History of
Operates under the umbrella of the Center for Process Analytical Chemistry (CPAC)
Originated from various CPAC focus sessions
IFPAC 2000 plenary paper presented NeSSI vision
Focus groups: Pittcon 2000; ISA Expo2000; IFPCA2001, Pittcon2001
ISA2001 Houston: Kick-off of NeSSI Generation II

5. Facilitate the acceptance/implementation of...
Major Goals of
Facilitate the acceptance/implementation of...
modular, miniature & smart sample system technology
based on ISA SP76 standardization work
Promote the concept of...
field-mounted smart sampling/analytical systems
integration of sample systems with physical/chemical sensors
Lay the groundwork for...
open connectivity architecture for sensor communications (e.g. Ethernet, DeviceNet, etc.)
industry standard communication protocols (e.g. OPC, DeviceNet, CAN, etc.)
web enabled technologies (e.g. Browser based HMI)
Provide a technology bridge to the process for...
“sensor/lab-on-a-chip” micro-analytical devices

6. A Modular Picture of
Picture Courtesy John Thomas, Parker Hannifin Corp

7. Imagine the Future after the

8. Design, Engineering, Manufacturing, Installation, Etc.
What is Driving
Reduce Cost to Build
Design, Engineering, Manufacturing, Installation, Etc.
Reduce Cost of Ownership
Maximize Sustained “Fit for Use” Data Generation
System Validation
Representative Sample Validation
Measurement (Data) Validation
Communication Validation

9. Where In the World Are We?
Market Acceptance
Cost
Ease of Design
System Reliability
Where In the World Are We?
Critical Issues
acceptability by Process Analytical community
technical challenges
cost
NeSSI
Analyzer
House
Value
Reduce capital costs by 35% ; 40% LTCO
On the Post
Time
Vision
Plug and Play - modular
At line/near line
A platform for microAnalytical
What’s going on in the world?.
Fast networks; robust electronics
“Lab on a chip”; lasers; wireless
Market Needs
Fast, reliable, rugged, reasonable cost

10. Vision: The End of the Analyzer House System
9/17/2018

11. An Analytical System Single Processor - Overall Control
...Will Look More Like Us!
Single Processor - Overall Control
Sensor Analytical Manager (SAM)
System will be Multifunctional
Equal 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

12. Intent…of the Gen II Spec
“The NeSSI Generation II specification is intended as a vehicle for alerting the marketplace to the need for these types of products.”
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged
9/17/2018

13. NeSSI Generations NeSSI Generation I (circa 2000)
an “arranged marriage”
NeSSI Generation II (circa )
a “courtship” - reengineering solution
NeSSI Generation III (circa 2005+)
wireless, analytical sensors
9/17/2018

14. Gen. I versus Gen. II

15. The Penitent - We’ve come a long way!
9/17/2018
Courtesy of Health and Safety Executive, Sheffield, England

16. Generation II Dimensions - Shopping List for NeSSI
1. Heated Substrate
2. Physical Sensors
3. Actuators
4. SAM 
5. HMI (Graphical)
6. Wired Bus
7. Wireless Bus
8. X Mini Power Bus
9. Packaging
10. Analytical Sensor
9/17/2018

17. - over-temperature cut-off
1. Heated Substrate
Div/Zone 1
GP. A-D
Div/Zone 1 or 2
GP. A-D
Conduction Heating
- cartridge heater(s)
- over-temperature cut-off
AC Power
Furn. by
substrate mfg.
AC Power
Heating Fluids
(alternative)
9/17/2018

18. 2. Physical Sensors for System Diagnostics
Doing analytical is just not good enough!
Miniature Flow, Pressure, Temperature
Gas and/or liquid service
Rugged construction
Encapsulated (IEC Ex m)
Intrinsically Safe (IEC Ex ib)
Div/Zone 1 Gp A-D; T4 (135 C)
FLOW:
 P, coriollis,
thermal, other?
COM
A/D
Substrate
9/17/2018

19. 2. Conceptual Sensor for NeSSI
“Top Hat” Comm. Chip
Parallel Ports
- standard size/pin
- daisy chain A B
Body
- encapsulated
Comm.
Digital “Smart” Sensor
- engineering units
- memory µP
BARRIER
- Process Seal
- Electrical Isolation
- Thermal
Memory
A/D
Process Cavity
- no unswept voids
- low volume
Insulation Skirt
- engineered
1.50”
Base SS
- pressure rated
Sensor
9/17/2018

20. 3. Electrical Actuators on the Substrate - COMBO
COMBO Valve
/w integral solenoid
Miniature substrate mount
Gas and/or liquid service
Wide P & T service
Rugged, encapsulated (IEC Ex m)
Intrinsically Safe (IEC Ex ib)
Div/Zone 1 Gp A-D; T4 (135 C)
Comm. SV
AIR
On/Off and
Proportional
Act.
9/17/2018

21. 3. …or Direct Electrical Actuators on the Substrate
…solenoid valves
…motorized valves
…again suitable for Div/Zone 1
Solenoid or
Motorized Valve
Comm.
On/Off and
Proportional SV
9/17/2018

22. 3. Conceptual “Combo” Valve
Parallel Ports
- standard size/pin
- daisy chain
“TopHat” Comm. Chip A B
Comm.
D/A
3-way “pilot” solenoid
valve - Intrinsically Safe
Vent
Solenoid
Instrument Air
Actuator
Digital On-Board
Actuator
- NO or NC
Vent
Conventional pneumatic valve
Valve
Engineered Insulation
Skirt
Thermal Barrier
9/17/2018

23. 4a. Introducing SAM - Sensor Analytical Manager
Standalone SAM
Analyzer  
Embedded SAM
Analytical
Sensor F Vv T Vv P F A
9/17/2018

24. “Open” Development Space for Custom Software
4b. SAM does 5 jobs!
Gateway to an Ethernet LAN
- OPC perhaps
Field Interface
- Graphical
- Wireless
- e.g. Bluetooth™,
Software Applets for
Sample System
Repetitive Tasks
(Industry Common)
Host to a
Sensor/Actuator Bus
“Open” Development Space for Custom Software
9/17/2018

25. 4. SAM - Provides a “Pick-list” of Common SS Tasks
Zero & span validation
Pressure regulation
Stream switching
Maintenance diagnostics
Temperature control
Interoperability
talk to all analytical systems
Enabling Technology
for microAnalytical 
SAM
9/17/2018

26. 4. SAM - Suggested Package
9/17/2018
Courtesy of Adalet

27. 5. HMI (Human Machine Interface)
PDA    
Hello? PC F Vv T Vv P F A
9/17/2018
Vv=automatic valve; P=pressure sensor; F=Flow Sensor;
A=Analytical Sensor;T=Temp. Sensor

28. 6. Standalone “SAM” with Wired Sensor/Actuator Bus
IEC Ex ib intrinsically safe
Leverage FISCO power concept
Standard Plug & Play Conn.
DeviceNet or SDS
Analyzer System Ethernet LAN
Analyzer Controller
Sensor Analytical Manager (SAM)  ? V P
Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor V A T P T A
9/17/2018

29. 6. Embedded SAM With Wired Sensor/Actuator Bus
IEC Ex ib intrinsically safe
Leverage FISCO power concept
Standard Plug & Play Conn.
DeviceNet or SDS
Analyzer System Ethernet LAN ? 
Analyzer Controller w/ Embedded SAM Functionality V P T A P
Legend: Pressure Sensor Temp Sensor Valve/Actuator Analytical Sensor V A T
9/17/2018

30. 7. Wireless Signal (Gen III?)
Bluetooth or
Plug and Play!
Power & I.S.
X-proof miniature power bus
Analyzer System Ethernet LAN
Analyzer Controller 
Sensor Analytical Manager (SAM)  V P T A
P.S.
9/17/2018

31. 8. What the world need is... …a Miniature wiring method
Sensors (typ)
…a Miniature wiring method
“plug & socket”
Division/Zone 1
MTL (England)
Mini-Power Bus
AC Power
AC/DC
9/17/2018

32. 8. Mini X-proof connector - Div/Zone 1
Can we make this small?
9/17/2018

33. 9. Enclosure/Package Convection Heater X-Proof (OPTIONAL) Div/Zone 1
GP. A-D
Div/Zone 1 or 2
GP. A-D
Temp. Sensor
Intrinsic Safe
AC Power
No Purge or
Pressurization
NEMA or IP Rated
Enclosure
- insulated
9/17/2018

34. “laser scanning device”
10. Analytical Sensors
Fiber Optic
SAM 
One sensor
per component
“lab on a chip” AT
One Sensor and
Multiple Analytes
“laser scanning device” F Vv T A A
9/17/2018

35. Connectivity! - CPAC “ConnI” Initiative
9/17/2018

36. Elements of a NeSSI Gen II Smart Prototype
Programmable, heated substrate
Digital sensors: F, P & T; serial bus
Division/Zone 1
SAM; control algorithms
Wireless/graphical HMI
Packaged for outdoor installation
9/17/2018

37. Globalize, harmonize... IFPAC CPACT ISA 2001. INTERMAC 2001. USA.
Europe.
ISA 2001.
INTERMAC
2001. Japan.
9/17/2018

38. Design & certify to global requirements...
NEC, UL, FM (USA)
CEC, CSA (Canada)
CENELEC (Europe)
ATEX Directive (Europe)
CE Mark
9/17/2018

39. New Developments!
9/17/2018

40. Courtesy of Panametrics & Swagelok Co.
O2 Measurement
New
9/17/2018
Courtesy of Panametrics & Swagelok Co.

41. Courtesy of Panametrics & Swagelok Co.
First NeSSI H2O Probe
New
Courtesy of Panametrics & Swagelok Co.
9/17/2018

42. Courtesy of Rosemount Analytical
First pH Sensor
New
Courtesy of Rosemount Analytical
9/17/2018

43. Courtesy of Porter Instruments and the Swagelok Co.
Mass Flow Controller
New
9/17/2018
Courtesy of Porter Instruments and the Swagelok Co.

44. Courtesy of Applied Analytics, Inc.
First Optical Cell
New
9/17/2018
Courtesy of Applied Analytics, Inc.

45. IGC-II c/w Elastomer Seals
New
Courtesy of the Swagelok Co
9/17/2018

46. Petrochemical installs...
Courtesy of a majorTexas
gulf coast
petrochemical facility
9/17/2018

47. A 5 year Roadmap A Plan to Achieve the Vision North America Europe
Asia
9/17/2018

48. NeSSI Roadmap Time (years) Analytical & Wireless Gen. III
Definition
Mechanical
Gen. I
Smart/”Electrified”
Gen. II
Analytical
& Wireless
Gen. III
 Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, etc.)
Prototype - Physical Sensors/Heating/SAM
Mechanical Components e.g. filters, valves, etc.
NeSSI/CPAC Vision
Mech. Field Trials
Smart Field Trials
SP76 Substrate Available 01 02 03 04 05 06
2000
Time (years)

49. Acknowledgements I Dow Syncrude ExxonMobil Chemical CPAC
Danny Quevillon
Reg Hartwig
Christoph Kleimeier
Walt Henslee
Bac Vu (SP76)
David Gay
Syncrude
Ian Verhappen
ExxonMobil Chemical
Dan Podkulski (SP76)
Jeff Gunnell
John Cumbus
Rajco Puzic
CPAC
Mel Koch
Lloyd Burgess
Brian Marquardt
9/17/2018

50. Acknowledgements II Doug Mitchell - Panametrics
John Wawrowski - Swagelok
Rick Ales - Swagelok
Yoav Barshad - Applied Analytics
Trevor Knittel - Analytical Specialties
Mike Marsceill - Porter
Carl Jones - Rosemount Analytical
CD Feng - Rosemount Analytical
Bob Nickels - Honeywell
Ron Eddleman - Measurementation
Chris Towle & David Blisset - MTL
9/17/2018

51. Summary Evolution as opposed to revolution Spin-offs….
microAnalytical devices
microReactors
ConnI (connectivity initiative - CPAC)
Release of Generation II Spec
December 2001 (*revised)
To NeSSI Distribution List
9/17/2018

52. ...a few references you may want to look over.
The NeSSI portion of the CPAC web site at
The ISA Draft Standard - ISA Draft , “Modular Component Interfaces for Surface-Mount Fluid Distribution Components--Part 2: Elastomeric Seals”
"The New Sampling/Sensor Initiative", Terence K. McMahon, Control, August/2001, Vol XIV, No. 8, page 158
"Molding the Future of Process Analytical Sampling", Ellen Fussell, InTech, August/2001, page 32