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Citius, Fortius, Altius:A New Sampling/Sensor Initiative (NeSSI)

Rob Dubois

&

Peter van Vuuren

CPΛΛΛΛC

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Process analyzer systems have been accused of being...

• complex• expensive• proprietary• “big box”

(battleship)• hi maintenance• suspect regarding

data integrity• slow to change

Edvard Munch “The Scream”Photo Credit: Erich Lessing/Art Resource, NYNational Gallery, Oslo, Norway.© 2000 The Munch Museum, The Munch-Ellingsen Group, Artists Rights Society, New York

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Citius (Faster)

• Faster to design & build– modular design– at the pipe: field mounted– “analytical transmitter”– engineering tool kit

• Faster to modify– plug and play sample sys.

• Faster sensor to analyzer development cycle

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Fortius (Stronger)

• Rugged and compact• Reduced maintenance

– predictive model• Sample system as a science rather than art• Standard components• Standard sampling systems for industry wide

“common” applications

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Altius (Higher)

• How can we reduce cost to build -35%*?• How can we reduce cost of ownership -40%*?• How can we obtain higher reliability?• How can we achieve higher data confidence?• How do obtain common validation protocols?

*Ref. To Gunnell/van Vuuren IFPAC2000 Presentation

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A Brief History - NeSSI• Operates under the umbrella of the Center for

Process Analytical Chemistry (CPAC)• Originated from various CPAC focus sessions • IFPAC 2000 plenary paper: J. Gunnell/P. van

Vuuren• Focus groups: Pittcon 2000; ISA Expo2000• NeSSI: ad hoc group interested in new sample

systems • NeSSI: supportive of the ISA SP76 standard• NeSSI: no affiliations; sponsored by CPAC

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NeSSI objectives...• Facilitate the acceptance/implementation of...

– modular, miniature & smart sample system technology• based on semiconductor (SEMI) standards & ISA SP76 work

• Promote the concept of...– field-mounted analytical systems– integration of sample systems with physical/chemical sensors

• Lay the groundwork for...– open connectivity architecture (e.g. Ethernet, wireless)– industry standard protocols (e.g. OPC, Hart, Fieldbus,

Profibus)– web enabled technology (e.g. browser, HMI, I/O Servers)

• Provide a technology bridge to the process for...– “lab-on-a-chip” analytical sensors

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“Request for Proposals” (RFP’s)

1 Paper designs requested for six “typical” petrochemical industry sampling scenarios– Measurement of PPM H2O and O2 in a high Purity

Hydrocarbon– Measurement of pH in an Aqueous Acid/Base Stream– O2 Measurement in a Stack Gas (low pressure)– Sampling System for Toxic Gas Measurement– Two stream sampling system (includes Liquid

Vaporization)– Eight (8) Stream Sampling System

• INTENT: DIVERSE SAMPLING SCENARIOS

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2 Provide electrical layout and interface drawings3 Provide a functional description of the design4 Propose a “sampling system/electrical bus”5 Propose ideas to standardize the software

protocol interface6 Describe compliance/non-compliance and

barriers to the use of ISA standard SP76 (modular component interface draft standard)

• INTENT: ESTABLISH ISSUES, BARRIERS & SYNERGIES

“Request for Proposals” (RFP’s)

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Response to “RFP’s”SwagelokSwagelok

• Complies with SP76– Metallic ‘C’ seal design

now• Elastomer seals later

– 3 channels– 1.5” blocks;

downmounts• Lego like assembly

– IGC II technology– highly engineered

• Investigating flow & X-proofing solutions

DWG.NO. CPAC PANEL #1

TITLE

DRAWN BY

CHECK/APR BYDMW

DWG.NO. CPAC PANEL #1

THIS PRINT IS THE EXCLUSIVE PROPERTY OF SWAGELOK COMPANY. IT MUST BE RETURNED ON REQUEST ALONG WITH ANY DOCUMENTS CONTAINING INFORMATION OBTAINED FROM THIS PRINT. NEITHER THIS PRINT NOR ANY PART OF IT NOR ANY INFORMATION CONCERNING IT MAY BE COPIED, DISCLOSED TO OTHERS OR USED FOR ANY PURPOSE EXCEPT IN FURTHERANCE OF YOUR BUSINESS WITH SWAGELOK. THE PARTS REFERRED TO ON THIS PRINT MAY BE THE SUBJECT OF PATENTS AND/OR PENDING APPLICATIONS AND MAY NOT BE MANUFACTURED WITHOUT PERMISSION FROM SWAGELOK COMPANY.

MATERIAL SCALE

1 : 3REV. -

SHEET OF1 1

REVISIONS

UNLESS OTHERWISE SPECIFIED

7 6 5 4 3 2 1

D

C

B

A

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8 7 6 5 4 3 2 1

A

B

C

D

CPAC PANEL #1 - CUSTOMER DRAWING DIMENSIONS ARE IN INCHES .XX .01 .XXX .005 .XXXX .0015 ANGLES 30 MINUTESINTERPRET DIM. AND TOL. PER ASME Y14.5M-1994

DCN REV.

09-27-00

DATE

DATEDAN 09-27-00

2.02

2.02

12.68

33.65

1.50

1.50

TYP1.60

.84 TYP

1.53 TYP

1.36

1.36

4.607.64

9.18

12.24

3.06

7.51

.38

TYP1.56TYP

2.99

MFC VALVE

SURFACE MOUNT KEY

PRESSURE GAGE

REGULATOR PRESSURE TRANSDUCER

SUBSTRATE CAP

SUBSTRATEBLIND

FILTER

SUBSTRATE TUBE PORT

MANUAL VALVE

Courtesy of Swagelok

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Response to “RFP’s”ParkerParker--HannifinHannifin

• Compliant with SP76, but...– 5 channels– 1.5 & 2.25” block available– ability to isolate sections– elastomer seals

• Hybrid design– manifold and tube &

block• Heating

– fluid heating “channel”• Investigating flow & X-

proofing solutionsCourtesy of Parker-Hannifin

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Response to “RFP’s”AutoflowAutoflow

• Fully compliant with SP76– TFE loaded elastomer

seals– 3 channels– 1.5” blocks

• Division 1 cartridge heating

• Div. 2 thermal flow meter, flow switches

• Utilizing current electrical X-proofing concepts

Courtesy of Autoflow

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Response to “RFP’s”RosemountRosemount--SwagelokSwagelok

• Example of synergy that can drive NeSSI

• Field mounted chromatograph with a miniature/modular sample system

• THESE COLLABORATIONS AND ALLIANCES ARE CRUCIAL

Courtesy of Rosemount & Swagelok

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Response to “RFP’s”ABB Analytical ABB Analytical AtAt--LineLine

• Demonstrates intuitive Human Machine Interface (HMI) Graphical User Interface (GUI) for a sample system

• Demonstrates digital comm. to a sample system(Profibus, Ethernet, VistaNET)

• Autoflow miniature, modular system– 5x reduction in volume!Courtesy of ABB Analytical

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Response to RFP’sElectrical IssuesElectrical Issues

• Electrical codes do not support simple, safe wiring methods– NIS Methods: bulky x-proof conduit, MI, metal sheath – IS Methods: simple braided cable not yet approved– Physical separation required between IS and NIS

• Simple sensors such as temperature, proximity flow & strain gauge pressure do support Intrinsic Safe wiring methods

• Conventional pressure/flow controllers need high energy and are unsuitable for IS Safety methods

• Enclosure mounted components should be rated Div/Zone 1

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Comments versus “RFP’s”Viable and Practical?Viable and Practical?

• We may be “trading labour to build for labour to engineer”

• Programmed substrates require detailed design engineering– possible loss of flexibility offered by tube & block

• Costs, at least for initial systems, will not be any cheaper • Need vendors who can provide novel X-proof wiring

solutions and association with Fieldbus style agencies• A linear, singular substrate is not feasible• Small ports may have problems with liquid streams• Need a base plate or substrate port for signal air• Viable & Practical: YES, with limitations

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So what are the barriers/issues?

• Lack of Div. 1 explosion proof components• Need for new, miniature flow devices• Need for new IS/NIS Div. 1 miniature wiring methods• Std. communication methods• Need for integral heating• Cost & flexibility?• “Brute force” legacy

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Clever Sample Systems Needed!

• Self-adjusting for optimal performance under varying conditions– On board delta/Pressure,

Flow, Temp. Measure & Control

• Tracks reliability and operation metrics – tally valve cycles, gas

usage– maintenance log, operation

manuals

• Self-diagnostic Graphical User Interface (GUI)– show Sample System

operation• Embedded processors• Decentralized control• “Since the oft quoted 80-

90% of the problems with analyzers are sample system related then perhaps our efforts should be focussed in this area!”

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Tower of Babel or Open Standards?

• Opportunity for standard sample system software “applets”. Examples...– stream selection protocols– validation protocols– monitoring packages– sample system diagnostics, etc.

• Opportunity for…– common communication protocols– hard wire, wireless & fiber optic connectivity buses

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Ι - A Call to Action…

• Component manufacturers we need new, miniature Div./Zone I manifold mounted components– flow measurement devices– pressure/temp. transducers– motorized valves; solenoids– mini-purged components!

• We need an effort to define Div/Zone 1 signal & power ‘bus’...– IS (signal) and NIS (power)– wireless; fiber optic signals?

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Ι Ι - A Call to Action…

• We need a task force to define...– stand alone sample system controllers– standard communication protocols– interoperable software “applets” to make sample systems

“clever”• Analyzer manufacturers, universities we need:

– simple/small analytical devices– substrate mounted; X-proof– “lab on a chip” devices

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Ι Ι Ι - A Call to Action…

• Substrate manufacturers…– we need Div. 1 integral electrical/fluid heated bases– “design guides” for 3rd parties

• We need to...– Promote; synergize– Publish test results– Harmonize regulatory barriers– Bring in key technical players– Work with groups like Fieldbus, Profibus, OPC…

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NeSSI Next Steps…Sunrise…..Sunset?

• NeSSI deliverable...– Compact Disk (CD)– final report

• Should NeSSI continue?– In what form, membership, etc.

• Is there a need for a Process Analytical Foundation?• YOU ARE CORDIALLY INVITED:

– to an open forum …Tuesday 6:30 - 7:30 PM in the Ossabaw Room.

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Summary…let’s stay on track!

• Three excellent but diverse substrate designs• Good synergies emerging• NeSSI “list” is growing...• Opportunities abound …• Some barriers to overcome (esp. Electrical issues)• Petro-chemical end users desire change!

– Citius, Fortius, Altius!

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Acknowledgements• ISA

– Jim Tatera• Expo2000 forum, etc.

– Dan Podkulski • SP76 Contribution!

• Focus group (Pittcon 2000)

• Focus group (ISA Expo2000)

• IFPAC 2001

• Dow Chemical– David Gay; Reg Hartwig;

Walt Henslee; François Ramond; Ron O’Reilly; Brian Worthington

• ExxonMobil Chemical– Jeff Gunnell; Dan Podkulski;

John Cumbus; PaulHromadka; Rajko Puzic

• CPAC – Mel Koch; Lloyd Burgess;

Larry Ricker

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AcknowledgementsNeSSI contributors

• Kelley Bell (ABB PA)• Richard Hughes

(Autoflow)• John Gajewski (FRCO)• Bud Keyes (FRCO)• Stephen Staphanos

(FRCO)• Steve Doe (Parker)• John Morse (Parker)

• CD Feng (Rosemount-Uniloc)

• Frank Ruiz (Ruiz and Assoc.)

• Dave Simko (Swagelok)• Richard Ales

(Swagelok)• Doug Nordstrom

(Swagelok)• All NeSSI contributors

not acknowledged or mistakenly omitted!

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AcknowledgementsNeSSI contributors

• Kelley Bell (ABB Analytical)

• Richard Hughes (Autoflow)

• John Gajewski (FRCO)• Bud Keyes (FRCO)• Stephen Staphanos

(FRCO)• Steve Doe (Parker)• John Morse (Parker)

• CD Feng (Rosemount-Uniloc)

• Frank Ruiz (Ruiz and Assoc.)

• Dave Simko (Swagelok)• Richard Ales

(Swagelok)• Doug Nordstrom

(Swagelok)• All NeSSI contributors

not acknowledged or mistakenly omitted!