evolving applications that demonstrate the value of the nessitm
TRANSCRIPT
February 2, 2012
Evolving Applications that Demonstrate the Value of the NeSSITM Platform
Sampling System Development for the Field and Laboratory
Process Analytical Systems: The Big Picture Sample Conditioning
Sample Disposal Vent Master™
Sample Extraction
Key System Performance
Information To Analyzer Network
Hub
Analyzer
Clean Gas DBB Probe Sample Transport
Heat Trace
R-Max™
Intertec (enclosure & heat)
Honeywell Alliance (pressure & flow sensing)
Gas Generators
Carrier & Cal Gas Delivery
Control
Sensor Monitoring
DCS/Unit Control
The Conventional Approach
3 Picture Courtesy ExxonMobil Chemical
Sample Conditioning Systems: * Custom designed, engineered and built * Lots of tubing/fittings * Many man-hours designing/building it * Lots of discrete components Cost Issue – Irritates the Bean Counters
* Typically not Smart (Smart = knowing if p,t,f of sample are normal, i.e. validating representative sample)
“Quality of Measurement Issue” - Credibility of analysis
• Simple “Lego-like” assembly • Easy to re-configure • No special tools or skills required
• Standardized flow components • “Mix-and-match” compatibility between vendors • Growing list of components
• Standardized electrical and communication (Gen II) • “Plug-and-play” integration of multiple devices • Simplified interface for programmatic I/O and control
• Advanced analytics (Gen III) • Micro-analyzers • Integrated analysis or “smart” systems
What Is NeSSI? New Sample/Sensor Initiative
Gen I: Fluid Handling Systems Mostly Mechanical Components
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Gen II: Electrically Networked Systems
IS Serial Bus, miniTransducers, local wireless
Gen III: Microanalytical
Systems Platform for microAnalytical, remote
wireless, advanced gas & liquid sensors
NeSSITM – Modular Sampling System Initiative: Technology Roadmap
Modular Component Suppliers
6 Parker - IntraflowTM
Swagelok Circor
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Modular Hardware Functionality • Three Suppliers: Parker, Swagelok and Circor • Parker Design Incorporates a Taper connection between substrates • Swagelok Design Utilizes a channeled tube design • Circor Design models Swagelok but uses welded joint connections
Parker Intraflow
Swagelok
Circor
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IntraflowTM Parker Modular (NeSSITM) Systems: Gen I Foundation of Modular Approach
Slip-fit intra-fitting connectors
Same screw size throughout
ISA/ANSI SP76.00.02 Compliant
Mounting “Pegboard”
Field connectors (top or end)
Same plane flowpaths
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•Design Drivers • Simplicity Overcomes Limitations
IntraFlow™ Fitting IntraFlow™ System
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IntraflowTM Substrates/Flowpath Options: The Library is Has Become Much Larger to Accommodate
Laboratory and Process Applications (over 100 flow options)
IntraFlow™ Fitting
Modular Sampling System “Tool Box”
• Full range of valves (Library) • Full range of pressure control hardware • Flow control – Volumetric and Mass • Flow/Pressure Monitoring (Local/Remote) • Temperature Control – Convective/Conductive • Sample Eductors/Pumps • Sample Cylinders • Analytical Systems (pH, Cond., O2, GC, RAMAN, FTIR, etc.)
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"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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Modular System vs. Conventional Tubing
Conventional Flow System
Modular System Applications: Where and How are They Used?
• Typical process analyzer sample conditioning applications – liquids and gases (HF non-SP76 standard system to accommodate higher viscosity liquids)
• Fluidic control for laboratory and R&D reaction systems • Mixing/blending of standard gases for supplying variable
concentration ranges • Platform for supplying controlled sample to on-board
analytical systems – Gen. III • Implementation of gas purifying hardware • Sample conditioning upstream of bench-top analytical
systems
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IntraflowTM Process Sample Conditioning
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Complete smart sample system integration
• Mono-ethylene glycol liquid service • Flow & pressure sensing • Conductive heating • Conventional grab sample & system functionalities
10-Stream Natural Gas BTU Analysis System
• Coalescing & Membrane Separator Drain Header • Restricted Orifice Header Pressure Control • Freeze Protection Heating • Sample pressure 1,500 – 3,000psig
High Pressure Applications
Common Drain
NeSSI™ and Raman Probe Reactor Application
NeSSI™ Sampling System for Reactor
Raman Probe
monitor
bypass
clean
NeSSITM and MicroReactor Performance Analysis
19 U.S. Food and Drug Administration
0 500 1000 1500 2000 2500 3000 35000
0.2
0.4
0.6
0.8
1
1.2
Raman Shift (cm-1)
No
rmal
ized
Inte
nsi
ty (
Arb
. Un
its)
Normalized Standard Spectra
Courtesy of Brian Marquardt
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NeSSITM :Reactor Monitoring and Control
Upstream reactor control and monitoring
Product monitoring
Micro Reactor Fluid Control with IntraflowTM
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Courtesy of Brian Marquardt – UW APL
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Sampling, Vaporization and Injection Integrated
6-port VICI Valve and Actuator
Parker Vaporizing Regulator
Remote Stream Isolation
Pre-heated carrier gas
To GC
Advantage of NeSSI:
Helium
Reactor Feed 1
Reactor Feed 2
Product Stream
Real-time Calibration
waste
prod
Analyzer Suite
Pump 1
Pump 2
NeSSITM Reactor Sampling/Calibration
• Application of sampling systems and analytics to optimize and control reactor
Small-Scale Lab Fermenter Applications
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1 Liter Fermentation Vessel
Pump for liquid recirculation
Parker IntraflowTM for Fluidic Control and Sensor Interface
BioTech Applications: On-line Fermenter Monitoring
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• Hardware used to transport, control and manage fluidic delivery to the analytical system • Calibration media also mounted to hardware and engineered to deliver calibration gas to GC
Integration of Sophisticated Analytics to Modular Sampling Systems
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RAMAN Probe
Analytical Probe-Based Measurement on ISA SP76 Platforms
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H2 Measurement
Parker IntraflowTM – A Platform for Experimentation
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• R&D Sensors for Experimentation • Simple fluid control hardware implemented easily • Complete flexibility for changing flow and pressure
Custom R&D Sensor
Courtesy of Brian Marquardt – UW APL
NeSSITM SP76 and Transportable Analytical Applications
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Courtesy of Carl Rechsteiner - Chevron
MicroGC (Falcon Analytical) with IntraflowTM Sample Conditioning System Mobile Unit with Support Equipment Mounted
NeSSITM Lab Calibration/Dilution System with On-board Analytics
30 Real-time monitoring of pressure, flow and component concentration
Courtesy of Brian Marquardt – UW APL
• Easy removal of heat exchanger
Patent Pending
Conventional Sample Extraction Modularized
Intraflow™ Vaporizing Regulator • CFD modeling of the
vaporizer indicates that room temp water vaporizes at around 80% through the heat exchanger
°C
Number of Tetrahedral Elements = .42 million Pressure Inlet: 25 psi Pressure outlet : 5 psi Temperature input to aluminum block: 190 oC All other external walls are considered as adiabatic walls Fluid: Water Solver: Segregated 3D steady solver with SIMPLE pressure-velocity coupling with standard k-e turbulence model.
Location of Post
Processing Plane
°C°C
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Calibration from NeSSITM -Permeation Tube System
Conceptual Design
Alternative Prototype Testing
4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000-5
0
5
10
15
20x 10-3
Wavenumber (cm-1)
Ab
sorb
ance
(A
rbit
rary
Un
its)
Flow Rate Results: Ethanol Permeation Tube Trial
H2O
Ethanol CO2
As Flow Rate Increases the Signal Decrease
10 mL/min
60 mL/min
4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000-2
-1
0
1
2
3
4
5x 10-3
Wavenumber (cm-1)
Ab
sorb
ance
(A
rbit
rary
Un
its)
H2O Ethanol
CO2
As Temp Decreases the Signal Decreases
85˚C
65˚C
Temperature Range Test: Ethanol Permeation Tube Trial
Sample Introduction Flexibility for microAnalytics is Available
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Inject valves for GC or LC
Dilution/Mixing Systems
Expensive Blended Gas Cylinder (H2S, CH4, CO, CO2, etc.) $$$$
Pure gas cylinders $
Gas Calibration System – Yields blended gas cylinder results
Analytics – GC, FTIR, O2, etc.
The NeSSITM Platform Accommodates Sampling ‘At The Process Extraction Point’
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Astute System with C2V Micro GC and H2Scan hydrogen analyzer
Courtesy of E.I.F (www.eif-filters.com)
microGC H2 Sensor
NeSSITM: ‘Clean’ Sampling?
Courtesy of Brian Marquardt – UW APL
Sterilization Method Sterilized Sterile Water Rinse ~ 500mL 120 °C for 15 min
Filled Sterile growth media is pumped by head pressure of compressed gas
Incubated 37°C for 72 hours
Swabbed Substrates sampled onto bacterial streak plates
Courtesy of Brian Marquardt – UW APL
Growth Study
1. End piece (Start Flow) 2. Valve substrate 1 3. Substrate 3 4. Top mount 3 5. Substrate 4 6. Substrate 5 7. Valve substrate 6 8. End piece (End Flow)
1
2 3 5 7 4 6
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contaminated
Note: Contamination only found in starting and ending components. Most likely due to insufficient sterilization of the sealing caps placed during incubation.
Courtesy of Brian Marquardt – UW APL
• Demonstrated sterilization of NeSSI components • Possibly contaminated by residual cells trapped in threads of end
caps • Steam sterilization is a valid method of sterilization for NeSSI
components • O-rings and tubing are compatible with autoclave conditions • Ensures a sterile flow path without exposing external parts to hot
and humid conditions • Next step – Top mount components
• Sterilization of top mount components will be dependent on the materials and flow path of the components themselves
• Next step – Full integration to NeSSI System • Integrate rinse stream and boiler system to NeSSI fast loop
sampling system • Create digital control system for automatic sterilization
What may be Concluded?
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Gen I: Fluid Handling Systems Mostly Mechanical Components
Gen II: Electrically Networked Systems
IS Serial Bus, miniTransducers, local wireless
Gen III: Microanalytical
Systems Platform for microAnalytical, remote
wireless, advanced gas & liquid sensors
NeSSITM – Modular Sampling System Initiative
Sensors for NeSSI
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Pressure Transmitters: • Dwyer (Series 626) • Ashcroft (Series A2X, A4) • GE Sensing (PTX1200,DPS4000) • Brooks Instruments (SS2 series) • SensorsONE (PD33X,DMP331i) • Mensor (series 6000) • StellarTech (GTX2511)
Flow Controllers: • Porter Instruments (3261) • Brooks model (SLA5850) • Horiba (STEC) (SEC-G100) • Sierra Instruments • MKS Instruments • Alicat Scientific (316L MCS/MCRS)
Area Classification: • Intrinsically Safe • Intrinsically safe, Class I Div. II • Class I Div. II, Class I Div. I, IS, GP • Class I Div. II • GP and IS • GP • Class I Div I & II
Area Classification: • Class I Div. II • Class I Div. II • GP • GP • GP • Class I Div. II, ATEX
Signal Output: • 4-20mA • 4-20mA • 4-20mA, RS485, CanBus • 4-20mA • 4-20mA, RS-485, USB • RS-485 • RS-232, RS485, CanBus
Signal Output: • 0-10vdc, 4-20mA • 0-5vdc,4-20mA, RS485, DeviceNet, Profibus • 0-5vdc, DeviceNet •0-5vdc, DeviceNet •0-5vdc, DeviceNet • 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus
Flow Meters: • Porter Instruments (3261) • Brooks (SLA5850) • FCI (FS10A (FM, FS)) • Sierra Instruments • MKS Instruments • Alicat Scientific (M Series)
Signal Output: • 4-20mA • 0-5vdc,4-20mA, RS485, DeviceNet, Profibus • 4-20mA • 4-20mA • 4-20mA • 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus
Area Classification: • Class I Div. II • Class I Div. II • Class I Div. II • GP • GP • Class I Div. II, ATEX
Parker: Sensor, Analyzer, Valve Actuation Management
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SAM Valve Control Valve “On/Off” Indication
Ethernet Comm.
Gen II Model Architecture
Future Modular Sampling Hardware Developments for the Lab and Process Markets?
• Mixing Systems – Liquid and Gas Dynamic/Static
• Permeation/Calibration Hardware • Inject Valve Integration for Microanalytics • Solvent Delivery System • Modified Interface Hardware for RAMAN,
FTIR, pH and other probe-based analytics • Alternative Material Applications - PEEK
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Acknowledgments
• Brian Marquadt, Charlie Branham, Wes Thompson, Michael Roberto, Lauren Hughs and Thomas Dearing– Applied Physics Laboratory University of Washington
• Kin – Tek Laboratories • CPAC –University of Washington
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Thank You!!