1. August 23, 2000 R.N. Dubois Dow Chemical
Smart Sample Systems
August 23, 2000
R.N. Dubois
Dow Chemical

2. Design Objectives of a Smart Sampling System
Integrate the sample system with the analytical and other diagnostic sensor(s)
Standardize analytical systems by providing “smart” sample system applets
Increase the reliability of analyzer sample systems
(Q.: Why are % of the analytical problems caused by the sample system?)
Eliminate to an absolute minimum routine maintenance
Provide a representative sample to the analytical sensor(s) and validate under all process conditions
11/13/2018

3. What is a Smart Sampling System?
Provides plug-and-play hardware components and software which…
Self-adjusts for optimal performance under variable process conditions
Tracks Reliability and Operation Metrics
Provides an intuitive Self-Diagnostic GUI
11/13/2018

4. (1) Self-adjusting by means of “smart” applets - some examples
Pressure control by means of a pressure sensor / control valve
Flow control to maintain constant flow by flow sensor / control valve
Pressure control around a fluctuating process control valve to maintain a constant flow
Pressure control to ensure atmospheric pressure or a fixed pressure on the outlet of an analytical sensor
Temperature control of vaporizer, sample system heater, enclosure heater, air purifiers, etc.
Swings sample filters based on DP or change / loss of flow
Cont’d…...
11/13/2018

5. (1) Self-adjusting by means of “smart” applets - some examples
Self-purges / cleans a dirty system on an as need or regular basis
Swings gas cylinders based on pressures
Provides safety trips - pressure, temperature, flow (leak), etc.
Shuts off the sampling system / analysis when the process stream is taken out of service
Analytical interaction modules - ranges, optical filter selection, path length selection
“Soft” startup and shutdown after process events
Suggestions?
11/13/2018

6. (2) Track Reliability and Operation Metrics
(2) Track Reliability and Operation Metrics by means of “smart” applets - some examples
Calculates cycles, for example,
valve operations (millions of ops)
filter in service time (days
Tabulates mass flow of…
sample
utility gases e.g. helium, nitrogen, instrument air
calibration gases
Tabulates power usage
Tracks temperature, pressure, flow cycles or patterns
Provides statistics on percent uptime
Provides drift information on all parameters
Cont’d…...
11/13/2018

7. (2) Track Reliability and Operation Metrics
(2) Track Reliability and Operation Metrics by means of “smart” applets - some examples
Tracks control chart for zero / span benchmark
Tracks control chart for zero / span calibration
Maintenance log
Data storage and recovery (e.g. CEMS applications)
Equipment data e.g. serial number, software version, etc.
Spare parts lists
Equipment parts lists
Auto reorder points for consumable parts, gases, etc.
Suggestions?
11/13/2018

8. (3) Self-diagnostic GUI (the analyzer as a “mini-process”)
Graphical, dynamic user interface (GUI) of all system operation parameters to:
Operations on the plant DCS system
Maintenance PC based
Other Users PC based e.g. via intra / internet
Self-diagnostic providing solutions / fixes to abnormal events
Provides these generic modes…
Condition RED
Out of Service - broke, tripped, “in the weeds”, etc.
Condition AMBER
Standby - undergoing calibration, benchmarking, service request, process shutdown
Condition GREEN
In Service - system running OK
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9. Examples of Some Inputs…..
Sample inlet (upstream) pressure
Sample outlet (downstream) pressure
Sample flow rate
Sample bypass flow rate
Sample temperature
Sample vaporizer temperature
Sample system enclosure temperature
Sample filter differential
Sample pump / aspirator differential
Actuator air pressure
Sample enclosure / housing purge pressure
Cont’d…...
11/13/2018

10. Examples of Some Inputs…..
Valve movement / limit switches
Plant in operation / Process Stream Off-line / In operation
Level monitor in sample collection pots
Condensation sensor
Position of utility gas manifold valving
Pressure of utility gas manifold system
Monitors 120 VAC power
Analyte concentrations
Heat tracer temperature
Pressure / Flow of Utility Gases
Others?
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11. Examples of Some Outputs….
Heater
Thermoelectric cooler
Fan operation
Vortex cooler
Control valve adjustment
Shut-off valve
Pump motor speed
Stream selection
Zero fluid selection
Cal fluid selection
Analyzer range selection
Cont’d….
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12. Examples of Some Outputs….
Optical path length selection
Column selection
Block and bleed
Detector selection
Light source selection
Optical filter selection
Pressure programming
Temperature programming
Ultrasonic Cleaner (on / off)
Others?
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13. Summary - 3 Key Ideas
A need for universal, industry wide “smart applets” for self-adjustment and reliability and operation metric tracking
Tight integration of analytical and physical sensor(s) and sample system
Graphical display of all parameters on remote DCS and / or PC User Interface
11/13/2018