modular sampling system initiative background and status

Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000

Modular Sampling System Modular Sampling System InitiativeInitiative

Background and Status

2000 Fall Sponsor Meeting

Center for Process Analytical Chemistry


AgendaAgenda

• Status and UpdateStatus and Update

• Preview of Swagelok ProposalPreview of Swagelok Proposal


CPAC as a Multi-Purpose PA ForumCPAC as a Multi-Purpose PA Forum

• Legal Umbrella for Sponsors to MeetLegal Umbrella for Sponsors to Meet

R&D: Long Range / Short RangeR&D: Long Range / Short Range

Information Clearing HouseInformation Clearing House

Enabling Mechanism to Address Other Common Enabling Mechanism to Address Other Common NeedsNeeds

• Focus Groups: Forum toFocus Groups: Forum to

Review R&D ProgramsReview R&D Programs

Present Industry Present Industry CommonCommon Needs - RFP Needs - RFP

Address Industry Common NeedsAddress Industry Common Needs

Fieldbus Datalink Specification - DoneFieldbus Datalink Specification - Done

NeSSI - In progressNeSSI - In progress

MatLab On-line/Connectivity - Future?MatLab On-line/Connectivity - Future?


Background and Chronology of NeSSI Background and Chronology of NeSSI ActivitiesActivities

• O&P Focus Group May 1999O&P Focus Group May 1999

Identified Sampling Systems as Common Area Of Identified Sampling Systems as Common Area Of InterestInterest

Sponsored Tutorial for Nov99 Sponsor MeetingSponsored Tutorial for Nov99 Sponsor Meeting

• Tutorial Nov99 CPAC MeetingTutorial Nov99 CPAC Meeting

Background/Reasons for InterestBackground/Reasons for Interest

Presentations by Suppliers/ End UsersPresentations by Suppliers/ End Users

• Participation in IFPAC2000 MeetingParticipation in IFPAC2000 Meeting

Plenary/General Papers (SS Enjoyed High Profile)Plenary/General Papers (SS Enjoyed High Profile)

WorkshopWorkshop


FLAN (Optical Fiber)

Sensor/Signal Bus

IA

Controller

(ASIC)A

TP

F

Sensor = Moisture Probe

Sampling System VisionSampling System Vision


Process Analyzer VisionProcess Analyzer Vision


Background and Chronology of NeSSI Activities Background and Chronology of NeSSI Activities (cnt’d)(cnt’d)

• Ad-hoc O&P Meeting @ Pittcon2000Ad-hoc O&P Meeting @ Pittcon2000

End-users Discuss Initial Target DesignsEnd-users Discuss Initial Target Designs

• CPAC2000 Spring MeetingCPAC2000 Spring Meeting

Formed SS Focus GroupFormed SS Focus Group

Defined Information Package (basis of RFP)Defined Information Package (basis of RFP)

• Distributed RFP (July 2000)Distributed RFP (July 2000)

Clarification Meeting at ISAEXPO2000 (40 Clarification Meeting at ISAEXPO2000 (40 attendees)attendees)

Received Proposals from Swagelok, ParkerReceived Proposals from Swagelok, Parker

Expect Additional Proposals/Comments from Expect Additional Proposals/Comments from Autoflow,Autoflow,

ABB Analytical, SAAI, Rosemount AnalyticalABB Analytical, SAAI, Rosemount Analytical


Background and Chronology of NeSSI Activities Background and Chronology of NeSSI Activities (cnt’d)(cnt’d)

• CPAC2000 Fall MeetingCPAC2000 Fall Meeting

Preview of Swagelok ProposalPreview of Swagelok Proposal

Other Feedback Other Feedback

Micro-Reactor Proposal (MicroAnalytics)Micro-Reactor Proposal (MicroAnalytics)

• What is Next?What is Next?

Distribute Proposals to All Interested PartiesDistribute Proposals to All Interested Parties

Follow-up by ReportFollow-up by Report

Sampling System Session at IFPAC2001Sampling System Session at IFPAC2001

Review and Summary of NeSSI EffortReview and Summary of NeSSI Effort

Papers by Swagelok, Parker, Autoflow, ABB, Papers by Swagelok, Parker, Autoflow, ABB, RosemountRosemount


AcknowledgementsAcknowledgements

• Dow Rob Dubois/Ron O’Reily/Brian Worthington

• Dow Corning Jim Tatera/Gary Bokerman

• DuPont Bob Bucher

• Rohm&Haas Joe Sung

• Honeywell Ken Creasy

• Akzo Nobel Foad Mozayeni

• ExxonMobil Dan Podkulski/Rajko Puzic/John Cumbus/Jeff Gunnell

• Swagelok Dave Simko

• CPAC Lloyd Burgess/Larry Ricker


The EndThe End


O&P Focus Group Meeting May 99O&P Focus Group Meeting May 99

• Recognized Modular Sampling System Efforts in Semi Conductor Industry (Standard)

• Vendors like Autoflow, A+, Swagelok etc. promoted modular designs

• Recognized that current implementations of sample systems designs have not changed for many years

• CPAC has promoted Versatile Micro Analytical Systems (VMAS) as a basis for future micro-analytical techniques

• O&P decided to sponsor a SSISSS (Small Smart Integrated Sensor and Sampling System) Tutorial at CPAC Nov Meeting


Nov99 CPAC SSISSS TutorialNov99 CPAC SSISSS Tutorial

• ExxonMobil/DuPont Provided Introduction to Tutorial

Validation of Sample System Performance

Integration of Sensor with Sampling System

• Four Suppliers of Sampling/Analyzer Systems Participated in Tutorial:

A+, Autoflow, Swagelok, Rosemount

Many components commercially Available

GCX example of self-contained miniaturized GC (GC on a pole)

• Recognition

Modular Sampling System can be a platform to integrate VMAS

Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers


Driving Forces for Driving Forces for ChangeChange

• Reduce Cost of Ownership

Non Recurring Costs = Cost to Build

Operating Cost

• Data Validation (Fit for Use)


A

F

T

P

Analyzer Analyzer

ControlleControllerr

Fie

ld

Fie

ld

LA

NLA

N

Integration of Sample System and Integration of Sample System and SensorsSensors

Sam

ple

Con

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S

am

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Level 0Level 0 Level 1Level 1

Pro

cess

Pro

cess

Str

eam

Str

eam All System All System

ComponentComponents in Contact s in Contact with Sample with Sample including including the Sensorsthe Sensors

All Additional All Additional Electronic and Electronic and Computing Computing Components Components Required to Required to Generate Analytical Generate Analytical ResultResult

Mainly a Trust ConfigurationMainly a Trust ConfigurationNow a Trust & Verify ConfigurationNow a Trust & Verify Configuration


Inte

gra

ted

Sam

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g/S

en

sor

Inte

gra

ted

Sam

plin

g/S

en

sor

Syste

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A

F

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Level 0 Subsystem IntegrationLevel 0 Subsystem Integration

Sam

ple

Con

dit

ion

ing

S

am

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Con

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S

yste

mS

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Level 0Level 0

Pro

cess

Pro

cess

Str

eam

Str

eam

Purpose:

Prepare and Verify a Representative Sample

(Compatible with Analyzer Sensor)

Opportunity:

Packaging as an Integrated Sensor and Sampling System

• Size

• Cost

Issues:

• Size

• Standardization

• VMAS


A

F

T

P

Analyzer Analyzer


Fie

ld

Fie

ld

LA

NLA

N

Separation or Integration of Level 0/1 Separation or Integration of Level 0/1 SubsystemsSubsystems


Pro

cess

Pro

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Str

eam

Str

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Inte

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Sam

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en

sor

Inte

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Sam

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Objective:Objective:

Close to Close to Sample Sample TapTap

Options:Options:

• RemoteRemote

• Separate but Separate but CloseClose•IntegratedIntegrated


Integrated Sampling/Sensor/Controller Integrated Sampling/Sensor/Controller SystemSystem

A

F

T

P

Analyzer Analyzer


Fie

ld

Fie

ld

LA

NLA

N

Integration of Level 0/1 SubsystemsIntegration of Level 0/1 Subsystems


Pro

cess

Pro

cess

Str

eam

Str

eam $$$$










• Recognition


Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers


Nov99 CPAC SSISSS Tutorial (Vendor Presentations)Nov99 CPAC SSISSS Tutorial (Vendor Presentations)

Autoflow

Rosemount

A+

Swagelok










• Recognition


Bridge between Process Sample (Macro world) and Micro Fluidics Sensors/Analyzers


IFPAC2000IFPAC2000

• ExxonMobil Presented Plenary Paper Promoting SSISSS

Sample System Infrastructure accounts for 50+% Cost to Build

Proposed Conceptual Design for SSISSS

Highlighted sensor and analyzer transmitter configurations

• Sampling System Session

Presentations by A+, Autoflow, etc.

Sampling Systems enjoyed a High Profile

• CPAC/ExxonMobil sponsored Workshop

Confirmed high interest in Modular Sampling System

Provided input for the ISA Standardization effort


TODAY’S COST OF BUILDTODAY’S COST OF BUILD

For a major greenfield projectFor a major greenfield project

NumberK USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000


TODAY’S COST OF OWNERSHIPTODAY’S COST OF OWNERSHIP

Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000


IMAGINE THE FUTUREIMAGINE THE FUTURE

A

T

P

Analyzer Analyzer


Fie

ld

Fie

ld

LA

NLA

N

Level Level 00

Level Level 11

Pro

cess

Pro

cess

Str

eam

Str

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F



FLAN (Optical Fiber)

Sensor/Signal Bus

IA Controller(ASIC) & Interface Module

Original Picture of Gas Delivery System courtesy Valin Corporation;

A

T

PF

Sensor = Moisture Probe



A

T

PF

Sensor = RAMAN Probe

Interface

Module


IFPAC2000IFPAC2000

• ExxonMobil Presented Plenary Paper Promoting SSISSS

Sample System Infrastructure accounts for 50+% Cost to Build

Proposed Conceptual Design fro SSISSS

Highlighted sensor and analyzer transmitter configurations

• Sampling System Session

Presentations by A+, Autoflow, etc.

Sampling Systems enjoyed a High Profile

• CPAC/ExxonMobil sponsored Workshop

Confirmed high interest in Modular Sampling System

Provided input for the ISA Standardization effort


Pittcon2000 (New Orleans)Pittcon2000 (New Orleans)

• O&P Ad-Hoc Meeting of Sponsor End-users

DuPont, Dow, Dow-Corning, CPAC, Rohm&Haas, ExxonMobil

• Main Goal: Identify Typical Sample System Designs as Candidates for Modular Design

Reviewed some typical gas/liquid sample System Designs

Rob DuBois Presented a Modular Component/Service Matrix

• Discussed next steps

Present Sample System Data at May CPAC Meeting

Next Step is to Open Up Discussion (3rd parties)

Leverage ISA Meeting in New Orleans (Aug00)

• Role of CPAC in Facilitating Development/Testing of a Prototype System

Larry Ricker/Lloyd Burgess to Present Proposal


StatusStatus• CPAC Meeting May 1999 Done

O&P Identified Modular Sampling Systems

• CPAC Meeting Nov 1999 Done

O&P Sponsored Tutorial

• IFPAC2000 MeetingDone

Plenary Presentation Promoted SSISS

Session on Modular Sampling Systems

CPAC Sponsored Workshop

• Pittcon2000Done

Ad-hoc O&P Meeting

Propose Candidate Sampling System Descriptions

• CPAC Meeting May 2000 TBD


What is Next?What is Next?

• CPAC Meeting May 2000 (Sampling Focus Group – Wednesday)

Review and Agree on Sample System Information Package

Involvement of 3rd parties

How do we distribute package (Distribution List, Meeting?)

Expectations for proposals from Suppliers (Paper designs?)

Joint Effort with ISA (Meeting in Aug, New Orleans)

Evaluation of Designs - Recommendation

• Prototype design/manufacturing/testing at CPAC

Larry Ricker/Lloyd Burgess proposal

• Program to Evaluate Test Platforms fro Micro Analytical Devices

CPAC Proposal – Lloyd Burgess

modular sampling system initiative background and status

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