1. NeSSI*: Key Aspects of the NeSSI Gen II Specification ISA - Houston, Texas, USA October 23, 2003 “the best way to predict the future is to create it” *New Sampling/Sensor Initiative Rob DuboisPeter van Vuuren

2. 2 Presentation Outline Today’s Technology vs. the Vision of Success NeSSI Development Roadmap & Generations Key Aspects of the NeSSI Gen II Specification (from the End User’s Perspective) Summary

3. Explosion Proof Fittings and Conduit Seals Custom each job Skilled electrician Multiple fittings, valves tubed by skilled inst. fitter IS Solenoids Valve and Pneumatic Valves Z-purge assemblies Today’s Technology Armored rotameters and X proof flow switches Manual P, F control

4. 4 Vision of Success - I Move Analysis By-Line Typical Analyzer House - Dow Freeport, TX

5. 5 Vision of Success - II Lego  Like Assembly Reduce Engineering Time –software “configurator” Reliability Centered Maint. –Full Automation Design, assemble & configure an analytical system on the work bench. Courtesy of J. Warwowski/D. Mitchell. Swagelok/Panametrics Courtesy of U. Bonne. Honeywell.

6. 6 NeSSI Generation Segmentation Gen III Gen II Gen I Mechanical Components (with conventional 4-20 mA) Electrical Transducers using IS Multi-Drop Network Wireless, Advanced Gas & Liq. Sensors & Platform for microAnalytical End User Value

7. NeSSI Roadmap Time (years) 0304 02 Mechanical Component Availability e.g. filters, valves, etc. Mechanical Field Installations ANSI/ISA SP76 Standard Approved NeSSI/CPAC Vision & Roadmap 2000 Design /Prototype - Gen II Smart/Heating/SAM Smart Field Installations Mechanical Gen. I Smart/”Electrified” Gen. II  Analytical & Wireless Gen. III 01 06 05 October 2003 uAnalytical Field Installations Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)

8. 8 Key Aspects of the NeSSI Gen II Specification A Conceptual and Functional Specification Describing the Use of Miniature, Modular (and Smart) Electrical Components for adaptation to the ANSI/ISA SP76 Substrate in Electrically Hazardous Environments Please refer to Gen II Spec draft version d6... http://www.cpac.washington.edu/NeSSI/NeSSI.htm

9. 9 Programmable Substrate Heater V P A F SAM CANbus Auxiliary Heating/Cooling Substrate T T Ethernet LAN DCS o&m user microClimate Enclosure NeSSI Gen II Elements Div 1/Zone 1 inside the Enclosure Typ. Div/Zone2

10. 10 NeSSI Gen II Preferred Methods of Protection Apparatus inside a microClimate Enclosure –Electrical Heaters & AC Power Wiring [Ex d] –miniTransducers (sensors & actuators) Ex m** and Ex ia or Ex ib –Multi-drop serial network Ex ia or Ex ib via IS barrier Apparatus outside microClimate Enclosure –SAM [Ex d (condulet), Ex n] –PDA [Ex i] ** encapsulation minimizes surface temperature and allows higher power loads

11. 11 Why a serial, IS network? (Why not 4-20 mA & discrete I/O?) PLC/HMI with 4-20 AI/AO, DI,DO (relay & SSR), RTD inputs, X-purged to be safe. This is costly and complex to design and build and not practical for use with a tightly packed miniature, mod. system. Gen I+ Courtesy of Dow Chemical - Fort Saskatchewan

12. 12 …and therefore the need for a multi-drop, IS, simple network POCA* with 8M DeviceNet  Connector (Honeywell) “Freedom 55” for process analytical practitioners (in electrically hazardous areas) is the ability to connect & disconnect an electrical device - without the need for conduits, electrical seals, cable glands, gas “sniff” tests, purging systems, interlocks or safe work permits. *POCA = Proof of Concept Apparatus

13. 13 Global Certification of the Network - single agency Approved for all Zone and Division geographies. (Europe and NA) Why Intrinsically Safe? –Best safety for high risk areas (eg. inside an enclosure handling hazardous, flowing fluids such as ethylene.) –A globally approved method of protection great for companies who are multi-national –However, the most compelling reason for IS is the ability to use plug and play miniature, modular sensors using “normal” wiring.

14. 14 Gateway to an Ethernet LAN (DCS/maintenance systems) can use multiple com protocols - OPC/HTTP/FF, etc. - Remote Wireless (Gen III) - 802.11 Wi-Fi Host Port for a… Sensor/Actuator Bus - Two Channels PDA Field Port - Local Wireless -e.g. Bluetooth™ Software Applets for certain Repetitive Tasks (Appl-I) - System Health (P, T, F) - Analyzer Validation - Sample Conditioning/control Provides “Open” Development Space for Custom Software SAM The Bluetooth and the Bluetooth trademark are owned by Bluetooth SIG, Inc. Distributed Control is Essential - Sensor Actuator Manager

15. 15 Maximizing the Number of Network Devices is Essential NeSSI Gen II spec suggests a min. of 25 devices per channel/port for a Class IIC (worst case) hazardous environment –makes a system cost-effective –allows sharing among analytical systems –simplifies installations –justifies the use of multiple sensors –differentiates the “NeSSI-bus” from others

16. 16 A Single, Low Voltage Power Supply opt. Integrated with IS Barrier Minimizes complexity (packaging, wiring, costs) Low voltage assists power budget Single voltage spec gives clear design objective for component makers Larger power supplies (e.g. 24 VDC takes up precious space) NeSSI suggests 12 VDC max.

17. 17 Key Network Attributes Hot Disconnect (w/o shutting down) Distance (typ within 30’ - max. 500’) Approx. 10 updates/second –physical (analogue) transducers (P, T, F, Vo, Vm) - low data throughput –microAnalytical (chromatography, spectroscopy) - high data throughput Mission Critical Performance in a Robust Environment

18. 18 Key Transducer-Network Attributes Industry standard connector Simple diagnostics (traffic light analogy) Simple Configuration –Transducer Ambiguous Low cost - “Open” and Interoperable Encapsulated transducer electronics [Ex m] –no potentiometers (software node ID) Optical isolation [for certain devices which may need to be powered remotely]

19. 19 Superb Power Management - I “Hazardous Intrinsic Power Profile*” * HIPP We envision that each transducer, once certified, will have non-volatile embedded Power, Current, Inductance, Capacitance, T-rating and other parameters associated with its safe operation which helps define its Hazardous Intrinsic Power Profile. (HIPP) Once attached to a network the system manager (SAM) will automatically upload each device’s parameters and accept or reject the device according to built in limits set by the system. For example, SAM is configured for a Class IIC (hydrogen service) with a fixed pool of current/power, etc. and maximum temperature.

20. 20 Superb Power Management - II “Hazardous Intrinsic Power Profile*” Power management is analogous to memory management * HIPP

21. 21 User Friendly Network Adding a component to the network should be a simple & quick task. –Maintenance time is spread thin - a cumbersome or inflexible interface or needing expert assistance, for a simple job, will not be well accepted. Wireless, PDA support

22. 22 Related Applications Pilot Plants/MicroReactors Laboratories Low Power Applications –battery powered systems –wireless –remote systems Auxiliary analytical systems –heat tracing

23. 23 Key Industries which Operate in Electrically Hazardous Locations Petrochemical Fine Chemical Manufacture Refining Oil and Gas Distribution The “Oil Patch” Industrial Gas Producers (e.g. hydrogen)

24. 24 To Summarize - NeSSI Defines an Unmet Networking Need Current practice requires many skilled people and high cost to assemble, install and maintain our analytical systems in various global geographies. The introduction of a low cost IS network meets an unmet need in industry. Providing smart, fully automated systems could fundamentally change how we do process analytics.