1. Heated, Smart & Modular Sample Handling System: Enabler for Closed Loop Process Control

2. Topics Introduction & Background Elements of Analyzer Reliability
New Tools for Sample Handling System Reliability
Field Results
Conclusions

3. Introduction & 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) problems

4. “How to Trust Your Process Analyzer"
Perhaps this Paper should be entitled:
“How to Trust Your Process Analyzer"

5. Elements of Analyzer Reliability
Adopt a “Mini-Process” mindset and methodology to definition of the analyzer sample handling system (SHS)
Focus on 4 Key Elements:
Training
Preventative Maintenance
Automation
Performance Monitoring

6. Process Control Information
Training
Analyzer Technicians should have intimate knowledge of the entire analyzer system:
Carrier & Cal Gas Delivery
Sample Transport
Sample Return
Sample Extraction
Sample Conditioning
Analyzer
Including: what the analysis does, why it is important to the plant, and its role in the DCS
Process Control Information
INTERNAL CUSTOMER!

7. Preventative Maintenance
Analyzer MTBF must exceed unit shutdown schedules
Perform PM On The Plant Shutdown Schedule…
…Not On The Analyzer’s or SHS’s Schedule!

8. Preventative Maintenance
Case Study: Early 2004
Analyzer PM had been properly completed
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!
Stage was set for deployment of new SHS tools

9. Automation
Engage Process Engineering & Plant Operations (the internal customer) on “mini-process” SHS needs
Monthly ISO driven manual validations/calibrations proved to be major source of variability
Secondary standard integrity found to be inconsistent
Technician val/cal performance also inconsistent
Enablers for remote val/cal:
Modular, remote actuation double block & bleed stream switching valve
Modular flow indication

10. Performance Monitoring
Scrape DCS for “mini-process” data; fed into networked Process Information (PI) system
Correlations predict validation requirements
Eliminating ISO validations- takes time to validate
Benefits
Reduced variations resulting from unnecessary P.M. and validations
Parameters constantly monitored- deviations show up prior to problems being found

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

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

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

14. Field Results
System Commissioned June 24, 2005

15. Field Results Remote validation available to Operators via DCS
DBB Stream Switch
Reference Gas Dryer

16. 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

17. 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

18. Next Steps Incorporate Human Machine Interface (HMI) in field
Provides local host for “Smart Shelters”

19. Conclusions
Process Engineering & Operations early involvement created a team atmosphere for a win-win conclusion
Team wins are very fulfilling
Breaking free form “the way we’ve always done it” requires open-mindedness to determine the vision
And single-mindedness to work through the inevitable hurdles

20. Thank You!