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Searching for Higher Ground: Unveiling NeSSI* Gen. II
IFPAC - San Diego, CA, USA - Jan. 23, 2002Rob Dubois - Peter van Vuuren - Jim Tatera .
CPC
“the best way to predict the future is to create it”
Tatera and Associates
*New Sampling/Sensor Initiative
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What is NeSSI?- Activities in 2001...
An ad hoc global industry initiative, formed June, 2000 to drive permanent change in how we do Process Analytical.
Sponsored by the Center for Process Analytical Chemistry (CPAC)
2001 Activities… Focus Groups: Pittcon, ISA, IFPAC, CPAC Tutorials: ISA-Houston, INTERMAC-Tokyo Special Teams: X-Team
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NeSSI Objectives
Facilitate the acceptance/implementation of... modular, miniature & smart sample system technology based on ISA SP76 standard substrate (aka footprint)
Promote the concept of... field-mounted smart sampling/analytical systems sample system integration with miniature physical sensors
Lay the groundwork for... open connectivity architecture for sensor communications
(e.g. CANbus, Ethernet, etc.) industry standard communication protocols (e.g. OPC, etc.)
Provide a technology bridge to the process for... “sensor/lab-on-a-chip” micro-analytical devices
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The drivers for change...
Reduce Cost to Build Design and Engineering Manufacturing and Installation
Reduce Cost of Ownership Design Standardization Simpler, less expensive
maintenance
Enhance Reliability Validate sample, data,
communication
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Market AcceptanceLower CostEase of DesignSystem Reliability
Time
So Where In the World Are We?
On the Post
AnalyzerHouse
NeSSI
What’s going on in the world?
• Fast networks; robust electronics
• Lab-on-a-chip; lasers; wireless
What does the Market Need?
• Reliable, rugged, fast analysis
What are the Critical Issues?
• Acceptability by Process Analy.
• Technical challenges
• Reasonable Cost
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NeSSI Generation I
mechanical, passive components on an ISA SP76 standard substrate (SEMI roots)
Courtesy of Swagelok
Manufacturers…
• Parker-Hannifin
• Autoflow
• CIRCOR
• Kinetics
• Swagelok
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NeSSI Generation I
Generation I - Industry Trends… End Users desire the conversion of today’s
proprietary stand-alone modules into a SP76 compliant configuration. (e.g. G.C. block & bleed, bypass loop & filtration, vent control, validation modules, etc.)
There will be a continual introduction of more components as End Users and Manufacturers embrace SP76.
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Introducing the NeSSI Gen. II Specification
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
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NeSSI Generation II
“Electrified” with diagnostic sensorsIntegral substrate heating & temp.
controlSensor & actuator serial communicationElectrical components integrated with
the SAM (Sensor Analytical Manager)Smart (self-diagnostic)
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Gen II - A Global, Hazardous Package
AC Power
Div/Zone 1GP. A-D, T4
NEMA 4 & IP56 RatedEnclosure- insulated
Sensors - Flow, Pressure, Temp.Encapsulated (IEC Ex m)Intrinsically Safe Bus (IEC Ex i)
Heaters: - Substrate & Enclosure- IEC Ex d by Design
AC Power
Under review by multi-functional
X-team
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Gen. II “The Future is Friendly”
AC Power
- Intrinsically Safe electricalsensors and bus allow “hot”Plug & Play capabilities- NO GAS “SNIFF” PERMIT REQ. FOR MAINTENANCE
AC Power
General Enclosure; no costly X-proof bolting or flame-proof enclosure
Flexible All-Climate
Operation
- Typ. No Purge or Pressurization- Low utility req.- No need to S/D for maintenance (X-purge)
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Gen. II - Serial Bus - “Au Revoir 4-20 mA?”
Flashable CANbus DeviceNet, SDS, etc.
Engineering units on board sensors
Reduces wiring loadEliminates I/ORugged, low cost
(tiny) chip
VTP
A
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Gen. II“Get on the substrate (bus)!”
A
Actuator
ValveVent
Vent
Comm.
D/ASolenoid
Flow Sensor
A
A/D
Comm.
µP
Mem
ory
Pneu-trinsic “combi” valve
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Gen. II“Flexible PID control”
Pressure Regulator
- spring & diaphragm
VP
Substrate
PID Control
- also temperature and flow control
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Gen. II - SAM* does the repetitive jobs
Gateway to an Ethernet LAN
- OPC
Host to a…
Sensor/Actuator Bus
PDA Field Interface
- Graphical
- Wireless
-Bluetooth™
- 802.11 Wi-Fi
Software Applets for Sample System Repetitive Tasks (Appl-I)
Provides “Open” Development Space for Custom Software
SAM
*SAM = Sensor Analytical Mgr.The Bluetooth and the Bluetooth trademark are owned by Bluetooth SIG, Inc.
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Gen. II - Standalone and/or Embedded SAM
Ethernet LAN
Analyzer Controller
VTP
A
CANbus
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Programmable Substrate Heater
What will a Gen II system look like?
VP
A
F
Ethernet LAN
Analyzer
Controller
SAM
CANbus
PDA
Auxiliary Heating/Cooling
SubstrateT
T
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Gen III - Enabling Technology for Analysis
F Vv T
A
SAM
Fiber Optic
ATOne sensor
per component“lab on a chip”
One Sensor and Multiple Analytes
A
Courtesy of CPAC
(Mass-Sensors Inc.)
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Gen. III“Beam Me Up, Scotty”
Ethernet LAN
VFP
A
Sensor signal is wireless... 802.11 Wi-Fi Bluetooth
Power Supplied by... X-proof mini power bus …or IS power bus
PowerSupply Universal AC Power
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Today’s NeSSI Compliant Analytical Systems
Courtesy of Panametrics & Swagelok Courtesy of Rosemount Analytical
Courtesy of Applied AnalyticsCourtesy of Panametrics & Swagelok
OXYGEN
H2O
pH
UV, VIS
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Announced at IFPAC 2002...
Courtesy of Rosemount Analytical and CD Feng
Conductivity
HOT
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Courtesy of Porter Instruments and the Swagelok Co.
Today’s Mass Flow Controllers
Porter (Div. 2) Unit Instruments Brooks
New
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Petrochemical Plant installations...
Courtesy of a major
gulf coast petrochemical facility
Courtesy of another petrochemical facility
and Parker-Hannifin
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Time (years)
03 04
NeSSI Roadmap
02
Mechanical Components e.g. filters, valves, etc.
Mechanical FieldInstallations
SP76 Substrate Available
NeSSI/CPAC Vision & Roadmap
2000
Prototype - Gen II Smart/Heating/SAM
Smart Field Installations
MechanicalGen. I
Smart/”Electrified”Gen. II
Analytical & WirelessGen. III
01 0605
Rev. 1, Dec. 2001
Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)
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Summary: “Higher Ground is in Sight”
Roadmap & 3 Generations OutlinedImpending Release of Gen II Spec to
NeSSI Mail-out ListGen. II prototype Spin-offs: ConnI, Appl-I, analytical, t
- sensors
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Acknowledgements I
The X-Team [Team Lead] Jim Tatera Peter Pergande (ExxonMobil) Dave Lewko (Bantrel) S. Leach (Shell) A. Allen (Conoco) D. Chadwick (TotalElfFina) R. Ales (Swagelok) R Eddleman
(Measurementation) Don Long (MTL) Glen Schmidt (SAAI)
ISA SP76 Members
ExxonMobil Chemical Dan Podkulski (SP76) Jeff Gunnell John Cumbus Rajko Puzic
Dow Chemical Craig Snook Walt Henslee Bac Vu (SP76)/John Leach III C. Kleimeier/S. Bach Debbie Mack/Naim Akmal K. Elliot/D. Ponthieu
CPAC Mel Koch/Dave Veltkamp
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Acknowledgements II
Doug Mitchell - Panametrics
John Wawrowski - Swagelok
Yoav Barshad - Applied Analytics
Nick van Bruggen - Porter
CD Feng - Rosemount Steve Doe - Parker-
Hannifin
Kelley Bell - ABB Bob Nickels - Honeywell Bob Farmer - Siemens Jonathan Bradford -
Rockwell Automation Gary Frank - Kinetics Rick Ales - Swagelok
Chris Towle - MTL
NeSSI Components Connectivity
Instrinsic Safety
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Aurora Borealis
Yellowknife,
Northwest Territories,
Canada
NO BOUNDARIES!
Courtesy of Yellowknife Tourism