NeSSI*: Full Speed Ahead“Into the Project Stage”

CPAC - Seattle, WA - Nov. 4, 2002

NeSSI End Users Group.

CPC

“the best way to predict the future is to create it”

*New Sampling/Sensor Initiative

“And let it be noted that there is no more delicate matter to take in hand, nor more dangerous to conduct, nor more doubtful in its success, than to set up as the leader in the introduction of changes. For he who innovates will have for his enemies all those who are well off under the existing order of things, and only lukewarm supporters in those who might be better off under the new.'’

Niccolò Machiavelli (from The Prince pub. 1515)

Presentation Outline

• Recap of NeSSI Structure and Objectives• NeSSI Gen I, II, III Overview• Activity Update• Gen II Delivery - POCA/DoE Projects• Acknowledgements• Summary

NeSSI Structure

• An ad hoc global industry initiative, formed in June, 2000 to drive permanent change in the way we do Process Analytical.– NeSSI mail-out has now grown to 330+ subscribers

• Represents over 31 End Users from Oil and Petrochemical as wells as Manufacturing Companies, Academia, National Labs, etc.

• An “Open” Initiative sponsored by CPAC (Center for Process Analytical Chemistry)– provides a legal umbrella

NeSSI Objectives

• Facilitate the acceptance/implementation of...– modular, miniature & smart process analytical

technology• Promote the concept of...

– at the pipe/field-mounted (“by-line”) analytical• Lay the groundwork for...

– open connectivity communication architecture• Provide a technology bridge to the process for...

– “sensor/lab-on-a-chip” microanalytical devices

NeSSI Vision of Success

• Reduce Engineering Time– “configurator tool”– self-documenting

• Reduce Assembly Time– Lego Like Assembly

• Lower Maintenance Costs– diagnostics

Vision Element: To design, assemble and configure an analytical system on one’s kitchen table.

Courtesy of J. Warnowski/D. Mitchell. Swagelok/Panametrics

Courtesy of U. Bonne. Honeywell.

NeSSI Generation Segmentation

Gen III

Gen II

Gen I Mechanical Components (mostly)

Electrical Transducers/IS Network

Wireless, Advanced Gas & Liq. Sensors & Platform for microAnalytical Value

NeSSI Generation IMechanical: Miniature and Modular

• Adapted from SEMI• ANSI/ISA SP76

“Standard” Form Factor• Allows Lego®-like

construction • SP76 compliant vendors

– Autoflow, Celerity, CIRCOR, Parker-Hannifin, Swagelok

Courtesy of Swagelok

Field Installation NeSSI Gen. I

Courtesy of a Gulf Coast Chemical Facility

NeSSI Gen. IINetworked/I.S./ Transducers/Wireless PDA

Programmable Substrate Heater

VP

A

F

Ethernet LAN

Analyzer Controller or PC

SAM

CANbus

PDA

Auxiliary Heating/Cooling

SubstrateT

T

NeSSI Gen III Plug & Play Wireless Signal

Ethernet LAN

VTP

A

• Bluetooth , Wi-Fi, ZigBee, other?• Power Supplied by...

– X-proof MINI bus– ...or IS miniature power bus

P.S.

SAM

PDA

NeSSI Gen III - a platform for Analytical

SAM

Fiber OpticAT

One sensor measures multiple components

Ethernet LANEnabling Technology

for Analytical

VTA

A

One sensormeasures one

componentuanlaytical

Activity Update

• Since Spring CPAC, 2002– May, 2002. DoE supplier/user team formed & White

Paper developed by U. Bonne/Honeywell Labs– June, 2002. White Paper Submitted to DoE– July, 2002. POCA* Project conceived– August, 2002. ISA SP76 footprint approved by ANSI– October, 2002. ISA NeSSI Presentation. Jim Tatera.– November, 2002. POCA prototypes ordered.

*POCA = NeSSI Gen II Proof of Concept Apparatus Project

Introducing POCA Project

• Purpose: Accelerate NeSSI Gen II dev.• Seeded by Dow Chemical, ExxonMobil Chemical,

Air Products (TBA)• Honeywell major supplier/integrator

– B. Nickels (commercialization & networking)– U. Bonne (sensor R&D)

• Impact - introduction of….• first SP76 minisensor (p, T, F)• first SP76 miniactuators (Vo, Vm)• first intrinsically safe, low cost, compact bus

IN PROGRESS

SmartT-Comp.TC SensorSmartT-CompFlow Sensor

17 mm

SmartT-CompFlow Sensor

Courtesy of U. Bonne, Honeywell Labs

Introducing Potential DoE Project

• Purpose– Field test NeSSI Gen II– Develop/source missing components– Certification of electrical products

• ~ $2MM funding (50% “work in kind”)• 2 year duration (1 year lab/1 year field test)

The DoE User/Supplier Team (More folks welcome!!)

• User Team– Peter van Vuuren (ExxonMobil)– Rob Dubois (Dow Chemical)– Joe Andrisani (DuPont)– Steve Wright (Eastman)– Bob Reed (Merck)– Paul Vahey (Honeywell-SM)– D. Young/D. Nettles

(ChevronTexaco)– Frank Scweighardt (Air Products)– George Vickers (BP)– Paul Barnard (EquistarChemicals)– Steve Doherty (Pharmacia)– Alan Eastman (ConocoPhillips)b

• Supplier Team– Ulrich Bonne (Honeywell Labs)*– Bob Nickels (Honeywell ACS)– Dave Simko (Swagelok)– Steve Doe (Parker-Hannifin)

• CPAC– Mel Koch

* Supplier Team Lead PI

DoE Project Deliverables

1. Heated/Temperature Programmed Substrate2. mini-Sensor Transducers (p, T, F)3. “Combi” Actuator Transducers (Vo, Vm)

(on/off & modulating transducers)

4. SAM - Sensor/Actuator Manager 5. PC/PDA with HMI* [Wireless]6. Multi-Drop Digital Intrinsically Safe Bus7. Micro Climate Enclosure

* HMI = Human Machine Interface

Certified CSA, FM, CENELEC

We Need to Better Understand the Process Analytical Market

• Q1. What is the total number of US (and worldwide) sampling points across process industries (Chemical, Petrochem, Pharma, Food & Beverage, Glass, Metals, etc.)?

• Q2. What would be the minimum common denominator of a NeSSI design?

• Q3. Cross-industry, what % is liquid/gas what % of instrumentation is intrinsically safe?

Acknowledgements• Dow

– R. Hartwig/D. Quevillon– Craig Snook– B. Vu/P. Williams/J.Leach– R. O’Reilly– F. Brown

• Air Products– Frank Schweighardt

• Eastman Chemical– Steve Jacobs

• Tatera & Associates– Jim Tatera

• ExxonMobil Chemical– Dan Podkulski (SP76)– Jeff Gunnell– John Cumbus– Rajko Puzic– Kelley Bell

• Honeywell– John Mosher– Bob Nickels

• CPAC– Mel Koch– Dave Veltkamp

Summary...

• Gen I products moving into the field• Gen II Proof of Concept (POCA) in

progress• Gen II White Paper submitted DoE

– Supplier/User Team formed– Looking for more folks– Purpose: Demonstrate & certify full Gen II