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Citius, Fortius, Altius:A New Sampling/Sensor Initiative (NeSSI)

Rob Dubois

&

Peter van Vuuren CPC

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Process analyzer systems have been accused of being...

• complex• expensive• proprietary• “big box”

(battleship)• hi maintenance• suspect

regarding data integrity

• slow to change

Edvard Munch “The Scream” Photo Credit: Erich Lessing/Art Resource, NYNational Gallery, Oslo, Norway.© 2000 The Munch Museum, The Munch-Ellingsen Group, Artists Rights Society, New York

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Citius (Faster)

• Faster to design & build– modular design– at the pipe: field mounted– “analytical transmitter”– engineering tool kit

• Faster to modify– plug and play sample sys.

• Faster sensor to analyzer development cycle

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Fortius (Stronger)

• Rugged and compact• Reduced maintenance

– predictive model• Sample system as a science rather than art• Standard components• Standard sampling systems for industry wide

“common” applications

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Altius (Higher)

• How can we reduce cost to build -35%*?• How can we reduce cost of ownership -40%*?• How can we obtain higher reliability?• How can we achieve higher data confidence?• How do obtain common validation protocols?

*Ref. To Gunnell/van Vuuren IFPAC2000 Presentation

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A Brief History - NeSSI• Operates under the umbrella of the Center for

Process Analytical Chemistry (CPAC)• Originated from various CPAC focus sessions • IFPAC 2000 plenary paper: J. Gunnell/P. van

Vuuren• Focus groups: Pittcon 2000; ISA Expo2000• NeSSI: ad hoc group interested in new sample

systems • NeSSI: supportive of the ISA SP76 standard• NeSSI: no affiliations; sponsored by CPAC

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NeSSI objectives...• Facilitate the acceptance/implementation of...

– modular, miniature & smart sample system technology• based on semiconductor (SEMI) standards & ISA SP76 work

• Promote the concept of...– field-mounted analytical systems– integration of sample systems with physical/chemical sensors

• Lay the groundwork for...– open connectivity architecture (e.g. Ethernet, wireless)– industry standard protocols (e.g. OPC, Hart, Fieldbus, Profibus)– web enabled technology (e.g. browser, HMI, I/O Servers)

• Provide a technology bridge to the process for...– “lab-on-a-chip” analytical sensors

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“Request for Proposals” (RFP’s)

1 Paper designs requested for six “typical” petrochemical industry sampling scenarios– Measurement of PPM H2O and O2 in a high Purity

Hydrocarbon– Measurement of pH in an Aqueous Acid/Base Stream– O2 Measurement in a Stack Gas (low pressure)– Sampling System for Toxic Gas Measurement– Two stream sampling system (includes Liquid

Vaporization)– Eight (8) Stream Sampling System

• INTENT: DIVERSE SAMPLING SCENARIOS

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2 Provide electrical layout and interface drawings3 Provide a functional description of the design4 Propose a “sampling system/electrical bus”5 Propose ideas to standardize the software

protocol interface6 Describe compliance/non-compliance and

barriers to the use of ISA standard SP76 (modular component interface draft standard)

• INTENT: ESTABLISH ISSUES, BARRIERS & SYNERGIES

“Request for Proposals” (RFP’s)

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Response to “RFP’s”SwagelokSwagelok

• Complies with SP76– Metallic ‘C’ seal design

now• Elastomer seals later

– 3 channels– 1.5” blocks;

downmounts• Lego like assembly

– IGC II technology– highly engineered

• Investigating flow & X-

proofing solutions

D W G .N O . CPAC PANEL #1

T IT L E

D R A W N B Y

C H E C K /A P R B YDMW

D W G .N O . CPAC PANEL #1

T H IS P R IN T IS T H E E X C L U S IV E P R O P E R T Y O F S W A G E L O K C O M P A N Y. IT M U S T B E R E T U R N E D O N R E Q U E S T A L O N G W IT H A N Y D O C U M E N T S C O N T A IN IN G IN F O R M A T IO N O B T A IN E D F R O M T H IS P R IN T. N E IT H E R T H IS P R IN T N O R A N Y P A R T O F IT N O R A N Y IN F O R M A T IO N C O N C E R N IN G IT M A Y B E C O P IE D , D IS C L O S E D T O O T H E R S O R U S E D F O R A N Y P U R P O S E E X C E P T IN F U R T H E R A N C E O F Y O U R B U S IN E S S W IT H S W A G E L O K . T H E P A R T S R E F E R R E D T O O N T H IS P R IN T M A Y B E T H E S U B JE C T O F P A T E N T S A N D /O R P E N D IN G A P P L IC A T IO N S A N D M A Y N O T B E M A N U FA C T U R E D W IT H O U T P E R M IS S IO N F R O M S W A G E L O K C O M P A N Y.

M A T E R IA L S C A L E

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M F C V A LV E

SURFACE M O UNT KEY

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R E G U L A T O RP R E S S U R E T R A N S D U C E R

S U B S T R A T E C A P

S U B S T R A T EB L IN D

F ILT E R

S U B S T R A T E T U B E P O R T

M A N U A L V A LV E

Courtesy of Swagelok

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Response to “RFP’s”Parker-HannifinParker-Hannifin

• Compliant with SP76, but...– 5 channels– 1.5 & 2.25” block available– ability to isolate sections– elastomer seals

• Hybrid design– manifold and tube &

block

• Heating– fluid heating “channel”

• Investigating flow & X-proofing solutions

Courtesy of Parker-Hannifin

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Response to “RFP’s”AutoflowAutoflow

• Fully compliant with SP76– TFE loaded elastomer seals– 3 channels– 1.5” blocks

• Division 1 cartridge heating

• Div. 2 thermal flow meter, flow switches

• Utilizing current electrical X-proofing concepts

Courtesy of Autoflow

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Response to “RFP’s”Rosemount-SwagelokRosemount-Swagelok

• Example of synergy that can drive NeSSI

• Field mounted chromatograph with a miniature/modular sample system

• THESE COLLABORATIONS AND ALLIANCES ARE CRUCIAL

Courtesy of Rosemount & Swagelok

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Response to “RFP’s”ABB Analytical ABB Analytical At-LineAt-Line

• Demonstrates intuitive Human Machine Interface (HMI) Graphical User Interface (GUI) for a sample system

• Demonstrates digital comm. to a sample system(Profibus, Ethernet, VistaNET)

• Autoflow miniature, modular system– 5x reduction in volume!

Courtesy of ABB Analytical

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Response to RFP’sElectrical IssuesElectrical Issues

• Electrical codes do not support simple, safe wiring methods– NIS Methods: bulky x-proof conduit, MI, metal sheath – IS Methods: simple braided cable not yet approved– Physical separation required between IS and NIS

• Simple sensors such as temperature, proximity flow & strain gauge pressure do support Intrinsic Safe wiring methods

• Conventional pressure/flow controllers need high energy and are unsuitable for IS Safety methods

• Enclosure mounted components should be rated Div/Zone 1

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Comments versus “RFP’s”Viable and Practical?Viable and Practical?

• We may be “trading labour to build for labour to engineer”• Programmed substrates require detailed design

engineering– possible loss of flexibility offered by tube & block

• Costs, at least for initial systems, will not be any cheaper • Need vendors who can provide novel X-proof wiring

solutions and association with Fieldbus style agencies• A linear, singular substrate is not feasible• Small ports may have problems with liquid streams• Need a base plate or substrate port for signal air• Viable & Practical: YES, with limitations

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So what are the barriers/issues?

• Lack of Div. 1 explosion proof components• Need for new, miniature flow devices• Need for new IS/NIS Div. 1 miniature wiring

methods• Std. communication methods• Need for integral heating• Cost & flexibility?• “Brute force” legacy

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Clever Sample Systems Needed!

• Self-adjusting for optimal performance under varying conditions– On board delta/Pressure,

Flow, Temp. Measure & Control

• Tracks reliability and operation metrics – tally valve cycles, gas

usage– maintenance log,

operation manuals

• Self-diagnostic Graphical User Interface (GUI)– show Sample System

operation

• Embedded processors• Decentralized control• “Since the oft quoted 80-

90% of the problems with analyzers are sample system related then perhaps our efforts should be focussed in this area!”

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Tower of Babel or Open Standards?

• Opportunity for standard sample system software “applets”. Examples...– stream selection protocols– validation protocols– monitoring packages– sample system diagnostics, etc.

• Opportunity for…– common communication protocols– hard wire, wireless & fiber optic connectivity buses

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- A Call to Action…

• Component manufacturers we need new, miniature Div./Zone I manifold mounted components– flow measurement devices– pressure/temp. transducers– motorized valves; solenoids– mini-purged components!

• We need an effort to define Div/Zone 1 signal & power ‘bus’...– IS (signal) and NIS (power)– wireless; fiber optic signals?

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- A Call to Action…

• We need a task force to define...– stand alone sample system controllers– standard communication protocols– interoperable software “applets” to make sample

systems “clever”

• Analyzer manufacturers, universities we need:– simple/small analytical devices– substrate mounted; X-proof– “lab on a chip” devices

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- A Call to Action…

• Substrate manufacturers…– we need Div. 1 integral electrical/fluid heated bases– “design guides” for 3rd parties

• We need to...– Promote; synergize– Publish test results– Harmonize regulatory barriers– Bring in key technical players– Work with groups like Fieldbus, Profibus, OPC…

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NeSSI Next Steps…Sunrise…..Sunset?

• NeSSI deliverable...– Compact Disk (CD)– final report

• Should NeSSI continue?– In what form, membership, etc.

• Is there a need for a Process Analytical Foundation?

• YOU ARE CORDIALLY INVITED:– to an open forum …

Tuesday 6:30 - 7:30 PM in the Ossabaw Room.

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Summary…let’s stay on track!

• Three excellent but diverse substrate designs• Good synergies emerging• NeSSI “list” is growing...• Opportunities abound …• Some barriers to overcome (esp. Electrical

issues)• Petro-chemical end users desire change!

– Citius, Fortius, Altius!

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Acknowledgements

• ISA– Jim Tatera

• Expo2000 forum, etc.

– Dan Podkulski • SP76 Contribution!

• Focus group (Pittcon 2000)

• Focus group (ISA Expo2000)

• IFPAC 2001

• Dow Chemical– David Gay; Reg Hartwig;

Walt Henslee; François Ramond; Ron O’Reilly; Brian Worthington

• ExxonMobil Chemical– Jeff Gunnell; Dan Podkulski;

John Cumbus; Paul Hromadka; Rajko Puzic

• CPAC – Mel Koch; Lloyd Burgess;

Larry Ricker

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Acknowledgements NeSSI contributors

• Kelley Bell (ABB PA)• Richard Hughes

(Autoflow)• John Gajewski

(FRCO)• Bud Keyes (FRCO)• Stephen Staphanos

(FRCO)• Steve Doe (Parker)• John Morse (Parker)

• CD Feng (Rosemount-Uniloc)

• Frank Ruiz (Ruiz and Assoc.)

• Dave Simko (Swagelok)• Richard Ales (Swagelok)• Doug Nordstrom

(Swagelok)• All NeSSI contributors

not acknowledged or mistakenly omitted!

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Acknowledgements NeSSI contributors

• Kelley Bell (ABB Analytical)

• Richard Hughes (Autoflow)

• John Gajewski (FRCO)• Bud Keyes (FRCO)• Stephen Staphanos

(FRCO)• Steve Doe (Parker)• John Morse (Parker)

• CD Feng (Rosemount-Uniloc)

• Frank Ruiz (Ruiz and Assoc.)

• Dave Simko (Swagelok)• Richard Ales (Swagelok)• Doug Nordstrom

(Swagelok)• All NeSSI contributors

not acknowledged or mistakenly omitted!