1. Networked Sampling System Development (NeSSI Generation II/III) Progress and Challenges John Mosher, Bob Nickels, Ulrich Bonne Honeywell International IFPAC 2004, January 13, 2004, Arlington, VA

2. 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 GE-Panametrics Oxygen sensor probe on NeSSI User-Driven, Multi-vendor Supported PHASED Multi-Gas Analyzer (Micro Gas Chromatograph) under development at Honeywell Labs U.S. Patent No: 6,393,894

3. Gen II - Smart/Electrical Technology Open communications protocol standard. Intrinsically Safe SAM = Sensor Actuator Manager – Embedded Controller, Profile Manager Communications Gateway NeSSI Gen II Level 2 LAN = Field LAN Level 3 LAN INFORMATION D0MAIN PROCESS CONTROL DOMAIN ENTERPRISE DOMAIN MEASUREMENT DOMAIN SAM eSAM Level 1 Sensor Bus Level 4 Enterprise LAN SAM Network Programmable Substrate Heater V P A F Auxiliary Heating/Cooling Substrate T T NeSSI II = SP76 + IS + NET + SAM (Physical Connection + Intrinsic Safety + Network + Controller)

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

5. Substrate Typical NeSSI Device combines state-of-the-art combi- sensor technology with Intelligence and network interface in one small, surface-mount package. On/Off and Modulating valves Flow Sensor w/ Temp, Pressure w/ Temp NeSSI II/III – Product Development Substrate Moisture in Dry Gasses PHASED Micro GC (Future) Other Analytical: Ion, Nox. O 2, pH Conductivity, NOx, Turbidity, Density, Opacity Refractive Index, OthersChemometric Sensors for Complex Analytical Measurements. Mod Valve D/A Network Press/ Temp A/D Network

6. POCA 1 – Proof of Concept Assembly POCA 1 – The Intent: Designed by Dow, ExxonMobil Chemical and Honeywell to prove that the NeSSI II concept was workable by: Deploying Combi-Sensors: Temperature/ Pressure and Temp/Flow in the same device. Deploying the Combi-Sensor with an integral Network Interface (DeviceNet) Deploying additional NeSSI I devices to Emulate NeSSI II such as valves. Provide SAM functionality through a PC Interface and graphical software. Provide a platform for future device testing control functions for Dow and EMC.

7. POCA 1 – Proof of Concept Assembly POCA 1 – The Outcome: The Network Interface allows the multiple Measurands of a Combi-Sensor to exist in a single device. 8mm network cables robust and small enough. Pressure/Temp sensors very robust Flow sensor easily damaged by fast pressure pressure changes. Temp was not included. One Heater short circuit damaged Substrate. Single network cable allowed for easy control connection. PC-based emulation of SAM controller very useful in testing devices and system.

8. POCA 2 – A Working System in a Lab Environment at UOP Outcome: SAM Software to Hardware configuration must be foolproof and reliable. Size and power reduction of actuators will be critical. In use today in real system. Exceptional diagnostic, control, and data collection capabilities. Remote monitoring and control is possible. UOP – The Intent: Adapt NeSSI II concepts to a real system. Used Ethernet and DeviceNet as networks. Used commercially available products throughout. Use LabView software on PC for configuration, control, data and diagnostics.

9. Adaptation of Honeywell Sensors to NeSSI standards Current Status: Sensor Design and SP76 housing qualified Intrinsically Safe (IS). ProfiBus controller and transceiver chipsets identified. ProfiBus protocol selected and pretested in selected chipset.. First POCA units delivered to Dow and ExxonMobil Chemical LAMIMS NeSSI I/II system delivered to UOP. 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. Establish and incorporate ProfiBus connector architecture for NeSSI applications. Test Assemblies in full ProfiBus network. Build and deliver DoE project NeSSI systems to participating companies. Identify and build additional prototype, cluster application systems for select partners.

10. Industry Organizations: Industry Organizations: Honeywell Synergies: Honeywell Synergies: Sensing & Control - Pressure, Temperature, Flow - Pressure, Temperature, Flow Moisture, Condition, Chemometrics Moisture, Condition, Chemometrics Industrial Measurement & Control - pH, O2, H20, Conductivity - pH, O2, H20, Conductivity NOx, Ion, Moisture, ??? NOx, Ion, Moisture, ??? Honeywell Specialty Material - Domain Knowledge, Testing - Domain Knowledge, Testing Honeywell Labs - PHASED, Microanalyzers - PHASED, Microanalyzers Honeywell Process Solutions - Sales, Service, and Support - Sales, Service, and Support NeSSI II/III Development Center for Process and Analytical Chemistry NeSSI - New Sampling Sensor Initiative ProfiBus Trade Organization

11. NeSSI II/III – The DoE Project Participants Wireless and Sensing Solutions Advancing Industrial Efficiency. will develop and demonstrate innovative sensor technologies for sampling and analyzing gaseous and liquid process streams Honeywell International is leading a collaborative R&D project involving the University of Illinois at Urbana-Champaign, Caviton, Inc., Axonn, Ember Corporation, EPRI, and iAculum. The partners will create and field test an affordable and easy-to-use wireless network technology for industrial environments and will develop and demonstrate innovative sensor technologies for sampling and analyzing gaseous and liquid process streams. These technologies will reduce process upsets, lower energy consumption, reduce emissions, and enhance competitiveness. DOE and the partnership will each contribute $5,168,713 over the life of the project. Department of Energy press release, November 2003:

12. NeSSI II/III – The DoE Project Participants

13. ParticipantRoleExpertise Honeywell Laboratory & Sensing & Control Business Develop PHASED gas composition microanalyzer World class MEMS & microsystem integration Honeywell Laboratory & Industrial Measurement Business Develop solid state reference electrode (SSRE) Above plus leader in industrial electrochemical measurement Honeywell Sensing & ControlDevelop and integrate NeSSI-III systems Industrial temperature, pressure, flow, and embedded products Caviton / U of IllinoisDevelop micro discharge detectorsLeaders gaseous electronics ExxonMobil ChemicalField test GC w/ NeSSI in an ethylene plant World leader in petrochemical and chemical processing DowChemicalField test NeSSI w/GC, PHASED & pH in ethylene distillation /trace contam., and boiler feedwater Leading chemical processor DuPontField test humidity sensor on NeSSI for titanium oxide drying Leading chemical processor Air ProductsField test PHASED and Raman spec. in gas processing plants Leading gas products supplier Honeywell Specialty MaterialsField test NeSSI w/GC for refrigerant distillation control Specialty materials supplier UOP LLCField test O2 for heater controlInd. process design and control NeSSI II/III – The DoE Project Participants

14. NeSSI II/III Developments 2003 Progress! Increased adoption and endorsement of NeSSI as a platform. Extensive learning from prototype systems delivered to Dow, ExxonMobil and UOP. Identification of Intrinsically Safe, commercially viable Network for use with NeSSI. Better understanding of user requirements. Dept of Energy NeSSI project won. Expansion of NeSSI II and III platform applications: Analyzer Sampling Systems. ‘Cluster Applications’ of stand-alone components to provide specific data. Chemometric applications to provide new methods of analysis. Stand-alone Microanalytical Systems. Challenges! DeviceNet too costly and time consuming to become Intrinsically Safe. There is still a lack of market size data for vendors to base development decisions on. Must deliver Dept of Energy NeSSI project. NeSSI II Specification needs to be solidified

15. CONTACT INFORMATION: John Mosher, NeSSI Customer Development, Honeywell Sensing & Control, (209) 339-4004 john.mosher@honeywell.com Ulrich Bonne, Research Fellow, Honeywell Labs, (763) 954-2758 ulrich.bonne@honeywell.com Bob Nickels, Industrial Product Development Manager, Honeywell Sensing & Control, (815) 235-5735 bob.nickels@honeywell.com Thank You!