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NeSSI – The “New Sampling Sensor Initiative” - An Enabling Technology
• A CPAC Sponsored Open Initiative
• Prepared by: – Rob Dubois – Dow Chemical– Peter van Vuuren – ExxonMobil Chemical– Jim Tatera – Tatera & Associates, Inc.
• ISA AD2002 April 16, 2002
Presentation Outline
• Introduction, Drivers & History
• NeSSI Generation I and II comparison
• Elements of a NeSSI Generation II System
• What will a Generation II prototype look like?
• Status Update and New Developments
• NeSSI Roadmap & Summary
• How do I get involved with NeSSI?
NeSSI Initiative
• An ad hoc global industry initiative, formed in June, 2000 to drive permanent change in Process Analysis.– NeSSI mail-out has now grown to 250+ subscribers
– Composed of End Users, Manufacturing Companies, Integrators
• Sponsored by the Center for Process Analytical Chemistry (CPAC) - legal umbrella
• Originated from various CPAC focus sessions • IFPAC 2000 plenary paper presented NeSSI vision• Focus Groups and Workshops
– Pittcon 2000; ISA Expo 2000; IFPAC 2001, Pittcon 2001, CPACT Edinburgh, ISA Analytical Division, ISA 2001, IFPAC 2002
• Tutorials:– ISA2001 Houston, INTERMAC 2001 Tokyo, Pittcon2002
A Brief History of
NeSSI Objectives
• Facilitate the acceptance/implementation of...– modular, miniature & smart process analytical
technology• Promote the concept of...
– at the pipe/field-mounted (“byline”) analytical systems
• Lay the groundwork for...– open connectivity communication architecture
• Provide a technology bridge to the process for...– “sensor/lab-on-a-chip” microanalytical devices
The drivers for change...
• Reduce Cost to Build– Design and Engineering
– Manufacturing and Installation
• Reduce Cost of Ownership– Design Standardization
– Simpler, less expensive maintenance
• Enhance Reliability– Validate sample, data, communication
Project Segmentation
Gen III
Gen II
Gen I Mechanical (mostly)
Electrical/Smart (Diagnostic)
MicroAnalytical & Wireless
Value
Gen I - Standardize on a miniature, modular system
• Concept “Borrowed” from the semiconductor industry
• LEGO® like design• ISA Standard
– rugged
Courtesy of CIRCOR
Elastomer Seals are desired in HP Industries
Courtesy of the Swagelok Co
Manufacturers…
• Parker-Hannifin
• Autoflow
• CIRCOR
• Kinetics
• Swagelok
• Fujikin
What is ISA SP76?
Copyright 2001 ISA. All rights reserved.
Reproduced and distributed with permission of ISA.
Note: Draft provided for promotion
only.
Refer to ISA SP76.
A Future Analytical SystemA Future Analytical System...Will Look More Like Us!
• Single Processor - Overall Control– Sensor Analytical Manager (SAM)
• System will be Multifunctional– Emphasis on all sensors
• System will be Adaptable– Predictive maintenance; self-healing
• Capable of Multivariate Analysis– Use many sensors for analysis
Courtesy of Ken Creasy, Honeywell. IFPAC 2001
Gen. I versus Gen. IIFeatureSignalProtection MethodsClassificationSensorsIntelligenceControl PhilosophyRegulating Comp.Passive Comp.ActuatorsHeatingWiring
Generation I4-20 mAPurgeDiv 2Non-substrateLimitedCentralizedSelf-containedMechanicalStand-aloneExternalConduit/Cable
Generation IISerial BusISDiv 1SubstrateSmartDistributed (SAM)PID control loopsElectro-mechanicalSubstrate MountSubstrate integratedIS Wiring
Generation II Dimensions- 7 Elements
• 1. Heated Substrate• 2. Physical t-Sensors• 3. Combi Valves
• 4. SAM • 5. PC with HMI
• 6. IS Multi-drop bus• 7. Enclosure
1. Heated, Programmable Substrate
AC PowerAC Power
Conduction Heating- cartridge heater(s)
- over-temperature cut-off
Furn. by
substrate mfg.
Heating Fluids
(alternative)
2a. Physical Sensors for System Diagnostics
• Doing analytical is not good enough!• Miniature Flow, Pressure, Temperature
– Gas and/or liquid service– Rugged construction– Intrinsically Safe (IEC Ex ia)– Div/Zone 1 Gp A-D; T4 (135 C)
A/D
COM
FLOW:
P, coriollis,
thermal, other?
Substrate
2b. Conceptual Sensor for NeSSI
Process Cavity- no unswept voids
- low volume
BARRIER- Process Seal- Electrical Isolation- Thermal
Insulation Skirt- engineered
A/D
Comm.
Sensor
Base - pressure rated
µP
Mem
ory
Body- encapsulated
“Top Hat” Comm. Chip
A
Port- standard size/pin
- daisy chain
1.50”
Digital “Smart” Sensor- engineering units
- memory
3a. Electrical Actuators on the Substrate - COMBO
• Miniature substrate mount– Gas and/or liquid service
– Wide P & T service
– Intrinsically Safe (IEC Ex ia)
– Div/Zone 1 Gp A-D; T4 (135 C)
COMBO Valve /w integral solenoid
SV
Comm.
Act.
AIR
On/Off and Proportional
3b. Conceptual “Combo” Valve A
Actuator
Instrument Air
Valve
Vent
Vent
Comm.
D/A
Solenoid
Conventional pneumatic valve
“TopHat” Comm. Chip
3-way “pilot” solenoid valve - Intrinsically Safe
Actuator- NO or NC
Engineered InsulationSkirt
Port- standard size/pin
- daisy chain
Digital On-Board
Thermal Barrier
4a. Introducing SAM “I do 5 jobs!”
Gateway to an Ethernet LAN
- OPC perhaps
Host to a
Sensor/Actuator Bus
Field Interface
- Graphical
- Wireless
- e.g. Bluetooth™, 802.11
Software Applets for
Sample System
Repetitive Tasks
(Industry Common)
“Open” Development Space for Custom Software
4b. Standalone “SAM” - Wired Sensor/Actuator Bus
SensorAnalyticalManager
(SAM)
Analyzer System Ethernet LAN
PLegend: Pressure Sensor Temp Sensor Valve/Actuator Analytical SensorVA
T
PC or Analyzer Controller
VTP
A
?
4c. Embedded SAM - Wired Sensor/Actuator Bus
Analyzer System Ethernet LAN
PLegend: Pressure Sensor Temp Sensor Valve/Actuator Analytical SensorVA
T
VTP
A
?Analyzer Controller
w/ Embedded SAM Functionality
4d. SAM “Pick-list” for Common Sampling Tasks
Zero & span validation Pressure regulation Temperature monitoringStream switching Maintenance diagnostics
• Interoperability– talk to all analytical systems
SAM
Enabling Technology
for microAnalytical
5. PC/PDA Graphical HMI (Human Machine Interface)
F Vv T P
FVvA
HMIPersonal digital
assistant
PC
Hello?
Vv=automatic valve; P=pressure sensor; F=Flow Sensor; A=Analytical Sensor;T=Temp. Sensor
HMI
6. Serial Multi-drop Bus - “Au Revoir 4-20 mA?”
• CANbus– DeviceNet, SDS, etc.– Intrinsically Safe
• Engineering units on board sensors
• Reduces wiring load– multi-drop
• Eliminates I/O• Rugged, low cost
VTP
A
7. Enclosure “X-team” Haz. Review Process
AC Power
Div/Zone 1GP. A-D, T4
Enclosure- NEMA 4/IP56 Rated- all climate operation- no purges- no X-proof tubs- low cost of operation
Sensor Bus
Intrinsically Safe (IEC Ex ia)- no gas “sniff” tests req..- allows hot disconnects- plug & play
Heaters- Substrate & Enclosure- IEC Ex d- programmable temp.
AC Power
Designed for Global Use
Gen III Wireless SignalAnalyzer System Ethernet LAN
VTP
A
• Eg Bluetooth , 802.11• Plug and Play!• Power Supplied by...
– X-proof or IS miniature power bus
SensorAnalyticalManager
(SAM)
P.S.
Generation IIIPlug & Play Analytical
F Vv T
A
SAM
Fiber Optic
ATOne sensor
per component“lab on a chip”
One Sensor and Multiple Analytes
A
Ethernet
Transducer Bus
Enabling Technologyfor Analytical
- GC-on-a-chip
- micro MS
- chem. sensors
Keys to speedy development
Don’t (re)invent…leverage existing standards
• Make use of existing connectivity and communication...
• Ethernet
• OPC
• CANbus
• wireless e.g. Bluetooth™
• WEB servers/Internet
Personal Digital Assistant (PDA)
Communicate…globally!
• International– Europe, Japan, Canada,
USA
• Consortia– CPAC, CPACT
• Conferences– ISA, Pittcon, IFPAC,
etc.
Design & certify to global requirements...
• NEC, UL, FM (USA)• CEC, CSA (Canada)• CENELEC (Europe)• ATEX Directive
(Europe)• CE Mark• JAPAN, ASIA…
Around the Loop: The New Sampling/Sensor Initiative
CONTROL MAGAZINE
Great publicity...
“It's estimated that 70-80%
of analyzer outages can
be traced to the sample system”Terrence McMahon
August 01, 2001
Also ISA InTech Magazine; Chem. & Eng. News
How difficult are these substrates to work with ?
The following section (compliments of John Cumbus of ExxonMobil) should give you an idea.
Expected Advantages
• Minimum Engineering /Drafting Effort
• Simplicity of Construction
• Ease of Maintenance
• Leverage Technicians for Higher Priority Activity
• Higher Service Factors
SupplyFilter
Bypass FlowController
SampleSupply
SampleBypass
SupplyPressure
ToAnalyzer
CalibrationSupply Stream
Valve(config-1)
GuardFilter
StreamValve
(config-2)
FromAnalyzerAnalyzer
Return
F
SupplyShut-Off
NC
NO
NC
NC
NC
Atmos.Vent
Calib.Shut-Off
FE
PI
F
Analyzer FlowController
FE
PE
PressureTransmitter
Engineering Package
• Provided by Configurator
• Pressure Indicator left for Technicians
• Eight Single Stream and One Dual Stream
• Three Analog Outputs, Two Inputs
Modular Sample System (minus MFMs)
Modular System Connections Inside Enclosure
New System in an Old Box
Assembly Test of Smaller System (76 Pieces)
Assembly Test Configuration
Assembly Drawings Provided
Completed Assembly
Example of Mechanic’s Previous Work
The “Mechanic”, Age 9
Comparison of “Old” and “New” Sample Systems
New Developments
NeSSI Analyzers - here today
Courtesy of Panametrics & Swagelok Courtesy of Rosemount Analytical
Courtesy of Rosemount AnalyticalCourtesy of Panametrics & Swagelok
Oxygen
H2O
pH
Conductivity
Courtesy of Porter Instruments and the Swagelok Co.
MFC’s here today
– Porter Inst. (Div. 2)
– Others…Gen Purpose• Unit Instruments
• Brooks
Undergoing
Certification
Just announced...
Courtesy of Applied Analytics
MIR ATR
Enabling technology for...
– Miniature physical sensors
– Flow– Temperature– Pressure
– Miniature chemical sensors
• “lab-on-a-chip”
– Component Mfgs.• Calibrators, pumps &• dryers, etc.
Courtesy of Mass-Sensors Inc.
Petrochemical installs...
Coutesy of a
gulf coast
petrochemical facility
Courtesy of an east coast petrochemical facility
and Parker-Hannifin
What’s New - Generation II Specification
• Draft version now compete
• Global Review Teams in Progress – X-team (hazardous areas)– C-team (connectivity issues)– A-team (simple applets)
White Paper in Progress
• Driven by Honeywell Automation
• Will adapt final NeSSI Gen II spec as criteria for build
• Expand End Users, Manufacturers– Looking for involvement!!
• 10-20 Gen II prototypes will be built
• DoE being approached for funding in June
Time (years)
03 04
NeSSI Roadmap
02
Mechanical Components e.g. filters, valves, etc.
Mechanical FieldInstallations
SP76 Substrate Available
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
Rev. 1, Dec. 2001
Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)
References & involvement...
...a few references you may want tolook over. The NeSSI portion of the CPAC web site at
www.cpac.washington.edu The ISA Draft Standard - ISA Draft 76.00.02 , “Modular
Component Interfaces for Surface-Mount FluidDistribution Components--Part 2: Elastomeric Seals”
"The New Sampling/Sensor Initiative", Terence K.McMahon, Control, August/2001, Vol XIV, No. 8, page158
"Molding the Future of Process Analytical Sampling",Ellen Fussell, InTech, August/2001, page 32
Acknowledgements I
• Dow– Danny Quevillon
– Reg Hartwig
– Walt Henslee
– Bac Vu (SP76)
– John Leach II
– Craig Snook
• ExxonMobil Chemical– Dan Podkulski (SP76)
– Jeff Gunnell
– John Cumbus
– Rajko Puzic
• CPAC– Mel Koch
– Dave Veltkamp
Acknowledgements II
– Doug Mitchell - Panametrics
– John Wawrowski, Rick Ales, Dave Simko - Swagelok
– Yoav Barshad - Applied Analytics
– Nick van Bruggen - Porter
– Gary Frank, Raj Adani - Kinetics
– CD Feng - Rosemount Analytical
– Bob Nickels, Ulrich Bonne, Ken Creasy - Honeywell
– Chris Towle/Don Long - MTL
– Steve Doe - Parker
– X-Team
A parting thought...
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
MicroAnalytical
• Do you have any questions regarding the the standard footprint and/or the relevance of your technology to this concept and/or its suitability beyond plant applications (lab, pilot plant, etc)?
• Do you understand the Process Safety issues and requirements (e.g. I.S. Ex ia)? Would your like to discuss any of them?
Sensor/Actuator Bus
SensorAnalyticalManager
(SAM)
Analyzer System Ethernet LAN
Analyzer Controller
VTP
A
Sensor Requirements:
Simple Sensor Host Communications Configurable Sensor AttributesSmall Footprint of SensorEngineering UnitsInexpensive but reliable
Host Requirements:
Controls all Sensor/Actuator Functions Support Common SS tasks (Applets)Gateway to Analyzer LAN/Imbedded
Sensor/Actuator Bus
SensorAnalyticalManager
(SAM)
Analyzer System Ethernet LAN
Analyzer Controller
VTP
A
CAN-bus:
Simple Sensor Host Communications Configurable Sensor AttributesMeasurement and DiagnosticsSmall Footprint of SensorEngineering UnitsInexpensive but reliable (proventechnology)Attributes Flashable (DeviceNet/SDS..)
Sensor/Actuator Bus
SensorAnalyticalManager
(SAM)
Analyzer System Ethernet LAN
Analyzer Controller
VTP
A
Workgroup Question/Feedback:
Is CAN the right answer?
Is IS the right answer?
Embedded or Standalone SAMEthernet LAN
Analyzer or PC Controller
VTP
A
CANbus
Q1. Who Should Manage the Applets?
• Foundation like organization?
• Applet creator?
• Analyzer Vendors?
Q2. SAM Concept
• Would you agree that SAM would be useful device for interfacing and interacting with both the Sensor bus and the larger world of the Ethernet – What do you (or don’t you) like….?– What would you like improved or added?
