exxonmobil progress with generation ii nessi systems dan podkulski and jeff gunnell testing of the...
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ExxonMobil Progress with Generation II NeSSI Systems
Dan Podkulski and Jeff Gunnell
Testing of the modular sample system concept is complete at ExxonMobil: NeSSI is a success
Current work is focused on migration to NeSSI Generation II systems
November 2006 CPAC Meeting - Seattle, WA
Use of NeSSI systems at sites and on projects
• Characteristics of sites– Purchases in small quantities– Can accept some risk by maintaining existing sample system as backup– Able to test ideas, components
• Characteristics of projects– Large quantities purchased – Risk averse / use proven designs only– Can take most advantage of standard designs
• Engineering cost savings– for standard designs, first duplicate design saves more than 50% of the engineering cost
• Manufacturing cost savings – for standard designs, first duplicate construction saves 10-20% of labor due to repetitive tasks
November 2006 CPAC Meeting - Seattle, WA
Projects
• Project in Asia Pacific will have modular systems specified along with proven Gen. II technology components– Will use modular technology on all streams where it has been shown to work
at our plant sites (>95% of applications)
– Will use Gen. II components and connectivity, assuming testing is successful
• Gen. II components will be proven during side-by-side evaluations– Siemens has provided leadership on development of GC-based Gen. II
systems
– Gen. II systems from three substrate suppliers will be ready to test in 4Q06• Moisture will be measured by the three systems
– Evaluation period will run for 4-6 months• Continuous switching of samples between sample systems and into analyzer • Remove and test of one company’s product onto another company’s “stick”
(interoperability)• Results to be used as a component in selection process for project suppliers • Might end up with mix of component suppliers on one selected substrate
November 2006 CPAC Meeting - Seattle, WA
Sample in
Fil
DPT
FT
FI
PI
Filter
PI
PT FT
FI
Stream Select
Sample Shut off
Sample from GC
RTD
Atm
Atm
Sample out
Backplane (SS Plate)
PlateTemperature
Val
Std
Cal
Std
Sample to GC
NeSSI Gen IIBuss
Siemens Applied AutomationNAU
(Siemens Maxum II GC Simulation)
With HMI or via Laptop PC
Bus Buffer& IS Barriers
IS BusPWR Supplies
OPC Server
NeSSI Gen. 2 Sample Conditioning System for Test & Evaluation
The test set system shall be connected to a Siemens NAU running Maxum II GC Software. The NAU is connected to an OPC Server. HMI functionality is required. The test shall simulate as close as possible an actual field installation. Valve actuation shall be via pneumatic output from a Siemens SVCM. The NeSSI Gen 2 single wire bus shall be compatible with I2C bus amplified by a Siemens Bus Buffer and IS barrier powered from a Siemens I.S. Power supply to simulate an actual connection to a Siemens Maxum II GC. Siemens Media Access Controller chips or an equivalent interface shall be provided for the local single wire NeSSI Bus to insure compatibility between the hardware and the Siemens Maxum II GC.
Test Sample data:Compressed Air28.965 g/molePressure: 30 psiG, 206.8 kpaGTemp: approx. 95 F, 35 C
Bypass Flow: 0.06 Cu Ft /min, 1.5 LPM
Sample Flow: 0.00353 Cu Ft/ min., 0.100 LPM
(P2)
(P1)
(BPF)
(FL1)
(FL2)
(DPT1)
(FT1)(FT2)(PT1)
(GF1)
(V1)
Test system
November 2006 CPAC Meeting - Seattle, WA
Sites
• Multiple sites using modular componentry today– Most have been Chemical plant sites to date– Research sites are discovering and using this technology
• Faster reconfiguration to new processes (see work by UOP)
• Smaller surface area, less absorption effects
• Additional testing of Siemens Gen. II systems to be done at plant sites– Tests to be run on process streams, important applications– Siemens supplying these systems in support of project work – Tests will be witnessed by ExxonMobil and suppliers
• Liquid and vapor streams
• Low ppm adsorbing compound in one application, challenging application
– Equipment to be installed by year’s end for continuing evaluation, field toughness
• Generation II design and testing– System developed jointly by a vendor and ExxonMobil– System being readied for field installation with direct support from the vendor– First truly Gen. II system being installed in the field
November 2006 CPAC Meeting - Seattle, WA
November 2006 CPAC Meeting - Seattle, WA
Gen 2 Human Machine Interface
Photo ©2006 Swagelok Company used with permission
November 2006 CPAC Meeting - Seattle, WA
Gen. 2 Human Machine Interface
• Three Modes of Operation– Automatic– Manual– Maintenance
• States of Operation– Measure– Zero – Analyzer– Span – Analyzer– Zero – Stack– Span – Stack
Photo ©2006 Swagelok Company used with permission
November 2006 CPAC Meeting - Seattle, WA
HMI System Configuration Screen
• Custom screen built for time sequences
• Totalizer is somewhat inferential
• SAM?
• Very system specific
Photo ©2006 Swagelok Company used with permission
November 2006 CPAC Meeting - Seattle, WA
Status
• Testing of the modular sample system concept is complete at ExxonMobil
• Current work is focused on migration to NeSSI Generation II systems
• Future projects will use smart, modular technology
• Sites will upgrade as opportunity allows