NeSSI*: Key Aspects of the NeSSI Gen II Specification

ISA - Houston, Texas, USAOctober 23, 2003

CPC

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

*New Sampling/Sensor Initiative

Rob DuboisPeter van Vuuren

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Presentation Outline

• Today’s Technology vs. the Vision of Success• NeSSI Development Roadmap & Generations• Key Aspects of the NeSSI Gen II Specification

(from the End User’s Perspective)• Summary

Explosion Proof Fittings

and Conduit SealsCustom each jobSkilled electrician

Multiple fittings, valves tubed by skilled

inst. fitter

IS Solenoids Valve and

Pneumatic ValvesZ-purge

assemblies

Today’s Technology

Armored rotameters and X proof

flow switches

ManualP, F control

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Vision of Success - I

Move Analysis By-Line

Typical Analyzer House - Dow Freeport, TX

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Vision of Success - II

• Lego Like Assembly• Reduce Engineering

Time– software

“configurator”• Reliability Centered

Maint.– Full Automation

Design, assemble & configure an analytical system on the work bench.

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

Courtesy of U. Bonne. Honeywell.

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NeSSI Generation Segmentation

Gen III

Gen II

Gen IMechanical Components

(with conventional 4-20 mA)

Electrical Transducers using

IS Multi-Drop Network

Wireless, Advanced Gas & Liq. Sensors

& Platform for microAnalytical End User Value

NeSSI Roadmap

Time (years)

03 0402

Mechanical Component Availability e.g. filters, valves, etc.

Mechanical Field Installations

ANSI/ISA SP76 Standard Approved

NeSSI/CPAC Vision & Roadmap

2000

Design /Prototype - Gen II Smart/Heating/SAM

Smart Field Installations

MechanicalGen. I

Smart/”Electrified”Gen. II

Analytical & WirelessGen. III

01 0605

October 2003

uAnalytical Field Installations

Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)

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Key Aspects of the NeSSI Gen II Specification

A Conceptual and Functional Specification Describing the Use of Miniature, Modular (and Smart) Electrical Components for adaptation to the ANSI/ISA SP76 Substratein Electrically Hazardous Environments

Please refer to Gen II Spec draft version d6...http://www.cpac.washington.edu/NeSSI/NeSSI.htm

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Programmable Substrate Heater

VP

A

F SAM

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

Ethernet LANDCS

o&muser

microClimate Enclosure

NeSSI Gen II Elements

Div 1/Zone 1inside the Enclosure

Typ. Div/Zone2

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NeSSI Gen II Preferred Methods of Protection

• Apparatus inside a microClimate Enclosure– Electrical Heaters & AC Power Wiring [Ex d]– miniTransducers (sensors & actuators)

• Ex m** and Ex ia or Ex ib

– Multi-drop serial network • Ex ia or Ex ib via IS barrier

• Apparatus outside microClimate Enclosure– SAM [Ex d (condulet), Ex n]– PDA [Ex i]

** encapsulation minimizes surface temperature and allows higher power loads

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Why a serial, IS network? (Why not 4-20 mA & discrete I/O?)

PLC/HMI with 4-20 AI/AO, DI,DO (relay & SSR), RTD inputs, X-purged to be safe. This is costly and complex to design and build and not practical for use with a tightly packed miniature, mod. system.

Gen I+

Courtesy of Dow Chemical - Fort Saskatchewan

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…and therefore the need for a multi-drop, IS, simple network

POCA* with 8M DeviceNet Connector (Honeywell)

“Freedom 55” for process analytical practitioners (in electrically hazardous areas) is the ability to connect & disconnect an electrical device -without the need for conduits, electrical seals, cable glands, gas “sniff” tests, purging systems, interlocks or safe work permits.

*POCA = Proof of Concept Apparatus

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Global Certification of the Network - single agency

• Approved for all Zone and Division geographies. (Europe and NA)

• Why Intrinsically Safe?– Best safety for high risk areas (eg. inside an

enclosure handling hazardous, flowing fluids such as ethylene.)

– A globally approved method of protection• great for companies who are multi-national

– However, the most compelling reason for IS is the ability to use plug and play miniature, modular sensors using “normal” wiring.

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Gateway to an Ethernet LAN(DCS/maintenance systems) can use multiple com protocols

- OPC/HTTP/FF, etc.

- Remote Wireless (Gen III)

- 802.11 Wi-FiHost Port for a…

Sensor/Actuator Bus

- Two Channels

PDA Field Port

- Local Wireless

-e.g. Bluetooth™

Software Applets for certain Repetitive Tasks (Appl-I)

- System Health (P, T, F)

- Analyzer Validation

- Sample Conditioning/control

Provides “Open” Development

Space for Custom Software

SAM

The Bluetooth and the Bluetooth trademark are owned by Bluetooth SIG, Inc.

Distributed Control is Essential- Sensor Actuator Manager

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Maximizing the Number of Network Devices is Essential

• NeSSI Gen II spec suggests a min. of 25 devices per channel/port for a Class IIC (worst case) hazardous environment– makes a system cost-effective– allows sharing among analytical

systems– simplifies installations– justifies the use of multiple sensors– differentiates the “NeSSI-bus” from

others

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A Single, Low Voltage Power Supply opt. Integrated with IS

Barrier• Minimizes complexity (packaging,

wiring, costs)• Low voltage assists power budget• Single voltage spec gives clear design

objective for component makers• Larger power supplies (e.g. 24 VDC

takes up precious space)• NeSSI suggests 12 VDC max.

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Key Network Attributes

• Hot Disconnect (w/o shutting down)• Distance (typ within 30’ - max. 500’)• Approx. 10 updates/second

– physical (analogue) transducers (P, T, F, Vo, Vm) - low data throughput

– microAnalytical (chromatography, spectroscopy) - high data throughput

• Mission Critical Performance in a Robust Environment

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Key Transducer-Network Attributes

• Industry standard connector• Simple diagnostics (traffic light analogy)• Simple Configuration

– Transducer Ambiguous

• Low cost - “Open” and Interoperable• Encapsulated transducer electronics [Ex m]

– no potentiometers (software node ID)• Optical isolation [for certain devices which

may need to be powered remotely]

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Superb Power Management - I“Hazardous Intrinsic Power Profile*”

* HIPP

We envision that each transducer, once certified, will have non-volatile embedded Power, Current, Inductance, Capacitance, T-rating and other parameters associated with its safe operation which helps define its Hazardous Intrinsic Power Profile. (HIPP) Once attached to a network the system manager (SAM) willautomatically upload each device’s parameters and accept or rejectthe device according to built in limits set by the system.

For example, SAM is configured for a Class IIC (hydrogen service)with a fixed pool of current/power, etc. and maximum temperature.

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Superb Power Management - II“Hazardous Intrinsic Power Profile*”

Power management is analogous to memory management

PT- 1

FT- 2

TT- 3

AT- 5

Vm- 6

Free

* HIPP

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User Friendly Network

• Adding a component to the network should be a simple & quick task.– Maintenance time is spread thin - a

cumbersome or inflexible interface or needing expert assistance, for a simple job, will not be well accepted.

• Wireless, PDA support

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Related Applications

• Pilot Plants/MicroReactors• Laboratories• Low Power Applications

– battery powered systems– wireless– remote systems

• Auxiliary analytical systems – heat tracing

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Key Industries which Operate in Electrically Hazardous Locations

• Petrochemical• Fine Chemical Manufacture• Refining• Oil and Gas Distribution• The “Oil Patch”• Industrial Gas Producers (e.g. hydrogen)

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To Summarize - NeSSI Defines an Unmet Networking Need

Current practice requiresmany skilled people and high cost to assemble, install andmaintain our analytical systems invarious global geographies. The introduction of a low cost ISnetwork meets an unmet need in industry. Providing smart, fullyautomated systems couldfundamentally change how we doprocess analytics.