Siemens Applied Automation Process Gas Chromatography Siemens Update.pptSlide 1; CPAC; May 11, 2006 NeSSI Update Siemens Activities CPAC; NeSSI: May 2006

Siemens Applied Automation

Process Gas Chromatography

Siemens Update.ppt Slide 1; CPAC; May 11, 2006

NeSSI Update

Siemens Activities

CPAC; NeSSI: May 2006




Topics

Summary of Siemens activities

Review of requirements

More detail on Siemens approach




Action and Inaction – Benefits and None

The NeSSI concept is intended to bring benefits to users by doing a common thing better

► Reduced cost• Size, utilities, material, labor

► Higher availability• Intrinsic reliability, MTBF, MTTR, skill set, parts

► Better performance• Volumes, flow paths, design

On any project intended to result in the benefits of doing a thing better:

► The costs continue to occur even if you do nothing;► The benefits NEVER occur if you do nothing!

Sometimes, you need to do something – maybe ANYTHING – even if it’s not perfect – in order to get things going.

► This can be true EVEN if you’re dealing with possible rework later on.




Summary of Siemens Activities Working with a major user to meet the requirements of a

specific large analyzer project► Strong time lines and “field-proven” requirements

Committed to development of a Generation 2 approach to “smart sampling system” design

► Use of Generation 1 mechanical components and design► Development of Generation 2, intrinsically safe serial bus for

component interconnection► Implementation of Generation 2 SAM functionality; both virtual

and physical► Creation of a Sampling-System-specific human interface

Working cooperatively with 3 major substrate and component vendors to interface components to the Generation 2 bus

Continuing to work actively with NeSSI work groups on review and establishment of broader standards




Requirements Review

The NeSSI Vision

The needs of a practical sampling system

Some details




The Analyzer System Today

HMI

DumbAnalyzer

Air

PowerSmart

Analyzer

HMIAir

Power

System Communication Network

AirPow

er

Process

AirPow

er

Process




The NeSSI Vision

SAM HMI SAM HMI

System Communication Network

SmartAnalyzer

HMIAir

Power

DumbAnalyzer

Air

Power

AirPow

er

Process

AirPow

er

Process




Pieces Of the NeSSI Idea

New mechanical components► Modular

► Standardized mounting platform

► Interchangeable function

New electrical interconnection► Serial connection – plug in

► Intrinsically safe

► Self-identifying components

New smart design features (SAM)► Helpful HMI

► Programmability

► Standardized, transportable user programming




Requirements

Certain key requirements► Bus length

► Active device count

► Power consumption and distribution issues

Operational issues► Field repair and replacement considerations

► Component identification issues

► Support for interchangeability

Other requirements




Bus Length

An “obvious” statement:Sampling systems are associated with analyzers

Bus length is the amount of cable required to go from a SAM to the sampling system and to continue linking to each of the components in the system

So, the key question is, where is the SAM relative to the sampling system?

SAM HMISAM HMISmart

Analyzer

HMIAir

Power

SmartAnalyzer

HMI

SmartAnalyzer

HMIAirAir

PowerPower

AirPow

er

Process

AirAirPow

er

Power

ProcessProcess




Local Sample Conditioning Summary

► Sample is extracted from process and transported to the sampling system with only minimal modification

► A relatively small portion of sample is cleaned and conditioned and provided to the analyzer

► Distance between the analyzer and the sampling system is limited by sample transport considerations

Most typical situation that we think of and experience in the field – for both “smart” and “dumb” analyzers

Typically – a few feet; a reasonable maximum 10-20 meters

Sample Conditioning

SystemAnalyzer

(and SAM)

10’s to 100’s m

1 to 20 m

Ax

Ax

Analyzer House

SS

SS




Remote sample conditioning Summary

► Sample is extracted from the process and immediately cleaned and conditioned► Relatively small quantities of conditioned sample are transported to the analyzer► Distance between the analyzer and sample conditioning system is limited by

transport considerations

Not (today) a common configuration. However, some systems have some remote devices

SAM associated with the system might be located adjacent to it

Remote Sample

Conditioning System

Analyzer (and SAM)

Sample Delivery

10’s to 100’s m

SAMClose

coupled;1 meter

System Network




In situ analysis

Sample is not removed from the process

No sample conditioning exists




Component Count

How many active devices must be supported by the NeSSI bus?

There are differences between older, conventional construction techniques and NeSSI construction techniques. In NeSSI, the count will be larger!




Reference Sampling System Diagram1 stream plus auto-calibrate

Vent

F

Drain

Stream Select Valves

Bypass Flow

Analyzer Flow

Analyzer

Filter

Sample Flow




Device Count

Stream Select

Bypass Flow

Analyzer Flow

Flow / Pressure Adjust

Filters




Device Count Per Stream (5 devices)

► Stream select solenoid► Bypass flow / pressure adjust► Analyzer flow / pressure adjust► Filter pressure drop sense (1 or 2)

Per System► Temperature control / sense► Pressure / air sense

Number of streams► Minimum 1► Typical 2-4► Common 4-5► Maximum 30

Number of devices► Up to 200




Device Power and Connection Issues

Intrinsically safe systems

► I.S. communication bus

► I.S. device Power Source

Small devices

► Connector space

► Separation space for I.S. requirements

Power source

► Preferred: power for communication and device have common source

► Required: power be sourced through I.S.




Operational Issues Repair and replacement must be “in place”. Positive device

identification and physical placement must be provided► Address strapping in hardware

► Address encoding before installation

Field repair needs to be supported under live power

Systems are not ad hoc. An analyzer is controlling the system and it’s needs and programming do not change

► Device recognition during application engineering phases may be useful

Interchangeability requires that the system be able to confirm that a replacement device is of comparable type to device being replaced




NeSSI BusSystem Support Requirements Up to 30 process streams in a sampling system plus 2 calibration streams.

Up to 200 active devices in a NeSSI Sampling System. (Additional “non-active” devices as needed)

Up to 1/2 of the active devices may be of any one type (example, pressure sense”)

Capability for support of standard functions:► pressure, temperature, flow monitoring (absolute measurement and/or binary

alarm level)► pressure and flow absolute control► temperature control of substrate, sample cabinet, flowing stream fluid► automatic valve control to switch on / off or to divert process streams (block or 3-

way)

Capability for the standard functions to be implemented in a variety of ways

All components should be interconnected on as few instances of the NeSSI bus as possible for cost reasons. If more than one instance is required, both shall be capable of being seamlessly controlled by a single analyzer or controller (PLC) operating as a NeSSI “SAM”.




System Bus Requirements (continued) Analyzer may be mounted up to 10 meters away from sampling

system

Opportunity for large number of component manufacturers to participate with large number of component types per manufacturer.

Sampling System HMI / visualization tool shall be capable of identifying an installed component type, manufacturer and model number for purposes of facilitating maintenance or replacement

Any single physical device should be able to represent itself using as multiple device types.

Interruptible while live – user can replace components while system is still operating

Intrinsically Safe for installation in Zone 1 (Type Ib) ; Division 1

Must support power loading and control of power permitted by I.S. bus Start-up, minimum, maximum, abnormal, other power-management issues




Component Specs RequiredEntity Parameters Power profile (for power budgeting)

► Start up

► Maximum

► Steady State

► Minimum

Stored power potential contributed to the system

Capacitive, inductive and resistive loading on the IS system

► Active Load

► Passive Load




Siemens Approach

Utilize existing device bus and protocol

Utilize available commercial methods to achieve I.S. compatibility and establish bus robustness

Provide bus interface method with software to interested component (device) suppliers and support for component interface design

Provide simple method of interface to the bus for other non-Siemens controllers




Siemens GC Electronics




Siemens Implementation of NeSSI Bus

Mechanical component (by others)

Component interface electronics (by component manufacturer)

Bus Access Controller Chip (chip spec and burn image by Siemens; assembly by component manufacturer)

Intrinsically Safe NeSSI Bus

I.S. Power Supply

I.S. Barrier

Bus buffer

Siemens GC




Project Implementation

s

Maxum

edition II

s

WinCCVisualization

WinCCVisualization

Modbus link

Bridge module




Future Plans and the Future Standard

Siemens is planning to implement a large scale NeSSI Generation 2 system using available technology

Other existing buses may still evolve into the long term standard for NeSSI► Fieldbus / Profibus

► CAN Open

► Other

Siemens plans to participate actively in development of standards for the NeSSI bus




Conclusions

Users should implement now► Use “closest available” from their preferred supplier

► Be sure “closest available” is in the same direction as NeSSI is going

► Don’t worry if “closest available” does not exactly match in the future

► Plan to field retrofit IF desirable and needed

Siemens► Plans to support this approach using our available

busses now

► Plans to continue to support the NeSSI efforts toward full standardization

Documents

Siemens Applied Automation Process Gas Chromatography Siemens Update.pptSlide 1; CPAC; May 11, 2006 NeSSI Update Siemens Activities CPAC; NeSSI: May 2006