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“How to Trust Your Process Analyzer". Steve Doe Parker Hannifin. NeSSI™ Workshop May 11, 2006. Topics. Case Study New Tools to Improve Sample Handling System Reliability Field Results Next Steps. Case Study: Background. Lanxess Born of Bayer AG strategic realignment in 2004 - PowerPoint PPT Presentation
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“How to Trust Your Process Analyzer"
NeSSI™ Workshop May 11, 2006
Steve DoeParker Hannifin
Topics Case Study New Tools to Improve Sample Handling System Reliability Field Results Next Steps
Case Study: Background Lanxess
Born of Bayer AG strategic realignment in 2004 Produces Performance Chemicals, Chemical Intermediates,
Engineering Plastics & Performance Rubber Sarnia, Ontario Plant: Butyl Rubber producer >60 years Moisture analysis & control is key Process Engineers & Plant Operators lacked confidence
in analyzer results due to Sample Handling System (SHS) legacy problems
Plant shutdowns resulted – big bucks lost on several occasions!
Analyzer PM had been properly completed within 48 hours of a moisture increase trend
Midnight callout from operations: “Your Analyzer Isn’t Working!”
Analyzer Engineer twisted operations arm over the phone: “Act On The Analyzer’s Results!!!”
Operations listened- and set a new production record that very day!
“High-fives” for everyone- but Analyzer Engineer reminded the team about the “dodged bullet”
Cross-functional team was created to increase SHS reliability and “customer confidence”
Case Study: Early 2004
New Tools for SHS Reliability Robust, modular, remote actuation double block
& bleed stream (DBB) switching valve
New Tools for SHS Reliability Differential pressure
flow indication w/ integral relief function (I.S., 4-20mA output)
New Tools for SHS Reliability
Smart, Proportional Heater & Purge Preheater
Field Results System Commissioned June 24, 2005 Zero Downtime After Commissioning
Field Results
Operations has authority via DCS stream switch reference gas to validate analyzer calibration
DBB Stream Switch
Reference Gas Dryer
Field Results Remote analyzer and bypass flow indication available
to operators via DCS
Bypass Flow Bypass Flow IndicationIndication
Analyzer Analyzer Flow Flow
IndicationIndication
Reference Gas Reference Gas Flow (9min 25sec)Flow (9min 25sec) Switching Switching
valve cycledvalve cycled Sample Gas Sample Gas Flow (9min Flow (9min
25sec)25sec)
Cycles repeated during Cycles repeated during commissioningcommissioning
Field Results
Process Engineers & Operations TRUST THE ANALYZER
Several analyzers in the Sarnia plant are running closed loop control
Plant Shutdowns HAVE BEEN AVERTED
5 additional “smart” systems have since been commissioned in the Sarnia plant- more planned
Next Steps
Incorporate Human Machine Interface (HMI) in field; Class 1, Division 2 compliant
Provides local host for “Smart Shelters”
>
4-20 mA to PLC- For Now!
Ethernet to Technician Workstation
Smart Shelter
Onboard PLC Ethernet to HMI
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