• 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
• 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?
• 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
• 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
• 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
Gen III
Gen II
Gen I Mechanical (mostly)
Electrical/Smart (Diagnostic)
MicroAnalytical & WirelessValue
• Concept “Borrowed” from the semiconductor industry
• LEGO® like design• ISA Standard
– rugged
Courtesy of CIRCOR
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.
...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
FeatureSignalProtection 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
- 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
AC PowerAC Power
Conduction Heating- cartridge heater(s)
- over-temperature cut-off
Furn. by
substrate mfg.
Heating Fluids
(alternative)
• 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
Process Cavity- no unswept voids
- low volume
BARRIER- Process Seal- Electrical Isolation- Thermal
Insulation Skirt- engineered
A/D
Comm.
SensorBase
- 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
• 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 andProportional
A
Actuator
Instrument Air
ValveVent
Vent
Comm.
D/ASolenoid
Conventional pneumatic valve
“TopHat” Comm. Chip
3-way “pilot” solenoidvalve - Intrinsically Safe
Actuator- NO or NC
Engineered InsulationSkirt
Port- standard size/pin
- daisy chain
Digital On-Board
Thermal Barrier
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
Wired Sensor/Actuator Bus
SensorAnalyticalManager(SAM)
Analyzer System Ethernet LAN
PLegend:
Pressure Sensor Temp SensorValve/Actuator Analytical Sensor
VA
T
PC or Analyzer Controller
VTP
A
?☺
- Wired Sensor/Actuator Bus
Analyzer System Ethernet LAN
PLegend:
Pressure Sensor Temp SensorValve/Actuator Analytical Sensor
VA
T
VTP
A
?Analyzer Controller
w/ Embedded SAM Functionality
☺
4Zero & span validation4Pressure regulation4Temperature monitoring3Stream switching4Maintenance diagnostics• Interoperability
– talk to all analytical systemsSAM
Enabling Technology
for microAnalytical
(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
• CANbus– DeviceNet, SDS, etc.– Intrinsically Safe
• Engineering units on board sensors
• Reduces wiring load– multi-drop
• Eliminates I/O• Rugged, low cost
VTP
A
“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 forGlobal Use
Analyzer 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.
Plug & Play µAnalytical
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 µAnalytical - GC-on-a-chip
- micro MS
- chem. sensors
• Make use of existing connectivity and communication...
• Ethernet• OPC• CANbus• wireless e.g. Bluetooth™ • WEB servers/Internet
Personal Digital Assistant (PDA)
• International– Europe, Japan, Canada,
USA
• Consortia– CPAC, CPACT
• Conferences– ISA, Pittcon, IFPAC,
etc.
• 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
“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
• 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
FSupply
Shut-Off
NC
NO
NC
NC
NC
Atmos.Vent
Calib.Shut-Off
FE
PI
F
Analyzer FlowController
FE
PE
PressureTransmitter
• 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)
New System in an Old Box
Assembly Test of Smaller System (76 Pieces)
Example of Mechanic’s Previous Work
The “Mechanic”, Age 9
Comparison of “Old” and “New” Sample Systems
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.
– Porter Inst. (Div. 2)– Others…Gen Purpose
• Unit Instruments• Brooks
Undergoing
Certification
Courtesy of Applied Analytics
MIR ATR
– Miniature physicalsensors
– Flow– Temperature– Pressure
– Miniature chemicalsensors
• “lab-on-a-chip”
– Component Mfgs.• Calibrators, pumps &• dryers, etc.
Courtesy of Mass-Sensors Inc.
Coutesy of a
gulf coast
petrochemical facility
Courtesy of an east coast petrochemical facility
and Parker-Hannifin
• Draft version now compete• Global Review Teams in Progress
– X-team (hazardous areas)– C-team (connectivity issues)– A-team (simple applets)
• 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
µAnalytical & WirelessGen. III
01 0605
Rev. 1, Dec. 2001
µ Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)
...a few references you may want tolook over.z The NeSSI portion of the CPAC web site at
www.cpac.washington.eduz The ISA Draft Standard - ISA Draft 76.00.02 , “Modular
Component Interfaces for Surface-Mount FluidDistribution Components--Part 2: Elastomeric Seals”
z "The New Sampling/Sensor Initiative", Terence K.McMahon, Control, August/2001, Vol XIV, No. 8, page158
z "Molding the Future of Process Analytical Sampling",Ellen Fussell, InTech, August/2001, page 32
• 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
– 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
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
• 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?
Ethernet LAN
Analyzer or PC Controller
VTP
A
CANbus
• Foundation like organization?• Applet creator?• Analyzer Vendors?
• 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?