evolving applications that demonstrate the value of the nessitm
TRANSCRIPT
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February 2, 2012
Evolving Applications that Demonstrate the Value of the NeSSITM Platform
Sampling System Development for the Field and Laboratory
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Process Analytical Systems: The Big Picture Sample Conditioning
Sample Disposal Vent Master™
Sample Extraction
Key System Performance
Information To Analyzer Network
Hub
Analyzer
Clean Gas DBB Probe Sample Transport
Heat Trace
R-Max™
Intertec (enclosure & heat)
Honeywell Alliance (pressure & flow sensing)
Gas Generators
Carrier & Cal Gas Delivery
Control
Sensor Monitoring
DCS/Unit Control
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The Conventional Approach
3 Picture Courtesy ExxonMobil Chemical
Sample Conditioning Systems: * Custom designed, engineered and built * Lots of tubing/fittings * Many man-hours designing/building it * Lots of discrete components Cost Issue – Irritates the Bean Counters
* Typically not Smart (Smart = knowing if p,t,f of sample are normal, i.e. validating representative sample)
“Quality of Measurement Issue” - Credibility of analysis
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• Simple “Lego-like” assembly • Easy to re-configure • No special tools or skills required
• Standardized flow components • “Mix-and-match” compatibility between vendors • Growing list of components
• Standardized electrical and communication (Gen II) • “Plug-and-play” integration of multiple devices • Simplified interface for programmatic I/O and control
• Advanced analytics (Gen III) • Micro-analyzers • Integrated analysis or “smart” systems
What Is NeSSI? New Sample/Sensor Initiative
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Gen I: Fluid Handling Systems Mostly Mechanical Components
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Gen II: Electrically Networked Systems
IS Serial Bus, miniTransducers, local wireless
Gen III: Microanalytical
Systems Platform for microAnalytical, remote
wireless, advanced gas & liquid sensors
NeSSITM – Modular Sampling System Initiative: Technology Roadmap
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Modular Component Suppliers
6 Parker - IntraflowTM
Swagelok Circor
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Modular Hardware Functionality • Three Suppliers: Parker, Swagelok and Circor • Parker Design Incorporates a Taper connection between substrates • Swagelok Design Utilizes a channeled tube design • Circor Design models Swagelok but uses welded joint connections
Parker Intraflow
Swagelok
Circor
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IntraflowTM Parker Modular (NeSSITM) Systems: Gen I Foundation of Modular Approach
Slip-fit intra-fitting connectors
Same screw size throughout
ISA/ANSI SP76.00.02 Compliant
Mounting “Pegboard”
Field connectors (top or end)
Same plane flowpaths
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•Design Drivers • Simplicity Overcomes Limitations
IntraFlow™ Fitting IntraFlow™ System
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IntraflowTM Substrates/Flowpath Options: The Library is Has Become Much Larger to Accommodate
Laboratory and Process Applications (over 100 flow options)
IntraFlow™ Fitting
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Modular Sampling System “Tool Box”
• Full range of valves (Library) • Full range of pressure control hardware • Flow control – Volumetric and Mass • Flow/Pressure Monitoring (Local/Remote) • Temperature Control – Convective/Conductive • Sample Eductors/Pumps • Sample Cylinders • Analytical Systems (pH, Cond., O2, GC, RAMAN, FTIR, etc.)
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"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
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Modular System vs. Conventional Tubing
Conventional Flow System
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Modular System Applications: Where and How are They Used?
• Typical process analyzer sample conditioning applications – liquids and gases (HF non-SP76 standard system to accommodate higher viscosity liquids)
• Fluidic control for laboratory and R&D reaction systems • Mixing/blending of standard gases for supplying variable
concentration ranges • Platform for supplying controlled sample to on-board
analytical systems – Gen. III • Implementation of gas purifying hardware • Sample conditioning upstream of bench-top analytical
systems
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IntraflowTM Process Sample Conditioning
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Complete smart sample system integration
• Mono-ethylene glycol liquid service • Flow & pressure sensing • Conductive heating • Conventional grab sample & system functionalities
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10-Stream Natural Gas BTU Analysis System
• Coalescing & Membrane Separator Drain Header • Restricted Orifice Header Pressure Control • Freeze Protection Heating • Sample pressure 1,500 – 3,000psig
High Pressure Applications
Common Drain
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NeSSI™ and Raman Probe Reactor Application
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NeSSI™ Sampling System for Reactor
Raman Probe
monitor
bypass
clean
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NeSSITM and MicroReactor Performance Analysis
19 U.S. Food and Drug Administration
0 500 1000 1500 2000 2500 3000 35000
0.2
0.4
0.6
0.8
1
1.2
Raman Shift (cm-1)
No
rmal
ized
Inte
nsi
ty (
Arb
. Un
its)
Normalized Standard Spectra
Courtesy of Brian Marquardt
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NeSSITM :Reactor Monitoring and Control
Upstream reactor control and monitoring
Product monitoring
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Micro Reactor Fluid Control with IntraflowTM
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Courtesy of Brian Marquardt – UW APL
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Sampling, Vaporization and Injection Integrated
6-port VICI Valve and Actuator
Parker Vaporizing Regulator
Remote Stream Isolation
Pre-heated carrier gas
To GC
Advantage of NeSSI:
Helium
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Reactor Feed 1
Reactor Feed 2
Product Stream
Real-time Calibration
waste
prod
Analyzer Suite
Pump 1
Pump 2
NeSSITM Reactor Sampling/Calibration
• Application of sampling systems and analytics to optimize and control reactor
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Small-Scale Lab Fermenter Applications
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1 Liter Fermentation Vessel
Pump for liquid recirculation
Parker IntraflowTM for Fluidic Control and Sensor Interface
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BioTech Applications: On-line Fermenter Monitoring
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• Hardware used to transport, control and manage fluidic delivery to the analytical system • Calibration media also mounted to hardware and engineered to deliver calibration gas to GC
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Integration of Sophisticated Analytics to Modular Sampling Systems
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RAMAN Probe
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Analytical Probe-Based Measurement on ISA SP76 Platforms
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H2 Measurement
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Parker IntraflowTM – A Platform for Experimentation
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• R&D Sensors for Experimentation • Simple fluid control hardware implemented easily • Complete flexibility for changing flow and pressure
Custom R&D Sensor
Courtesy of Brian Marquardt – UW APL
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NeSSITM SP76 and Transportable Analytical Applications
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Courtesy of Carl Rechsteiner - Chevron
MicroGC (Falcon Analytical) with IntraflowTM Sample Conditioning System Mobile Unit with Support Equipment Mounted
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NeSSITM Lab Calibration/Dilution System with On-board Analytics
30 Real-time monitoring of pressure, flow and component concentration
Courtesy of Brian Marquardt – UW APL
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• Easy removal of heat exchanger
Patent Pending
Conventional Sample Extraction Modularized
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Intraflow™ Vaporizing Regulator • CFD modeling of the
vaporizer indicates that room temp water vaporizes at around 80% through the heat exchanger
°C
Number of Tetrahedral Elements = .42 million Pressure Inlet: 25 psi Pressure outlet : 5 psi Temperature input to aluminum block: 190 oC All other external walls are considered as adiabatic walls Fluid: Water Solver: Segregated 3D steady solver with SIMPLE pressure-velocity coupling with standard k-e turbulence model.
Location of Post
Processing Plane
°C°C
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Calibration from NeSSITM -Permeation Tube System
Conceptual Design
Alternative Prototype Testing
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4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000-5
0
5
10
15
20x 10-3
Wavenumber (cm-1)
Ab
sorb
ance
(A
rbit
rary
Un
its)
Flow Rate Results: Ethanol Permeation Tube Trial
H2O
Ethanol CO2
As Flow Rate Increases the Signal Decrease
10 mL/min
60 mL/min
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4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000-2
-1
0
1
2
3
4
5x 10-3
Wavenumber (cm-1)
Ab
sorb
ance
(A
rbit
rary
Un
its)
H2O Ethanol
CO2
As Temp Decreases the Signal Decreases
85˚C
65˚C
Temperature Range Test: Ethanol Permeation Tube Trial
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Sample Introduction Flexibility for microAnalytics is Available
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Inject valves for GC or LC
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Dilution/Mixing Systems
Expensive Blended Gas Cylinder (H2S, CH4, CO, CO2, etc.) $$$$
Pure gas cylinders $
Gas Calibration System – Yields blended gas cylinder results
Analytics – GC, FTIR, O2, etc.
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The NeSSITM Platform Accommodates Sampling ‘At The Process Extraction Point’
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Astute System with C2V Micro GC and H2Scan hydrogen analyzer
Courtesy of E.I.F (www.eif-filters.com)
microGC H2 Sensor
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NeSSITM: ‘Clean’ Sampling?
Courtesy of Brian Marquardt – UW APL
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Sterilization Method Sterilized Sterile Water Rinse ~ 500mL 120 °C for 15 min
Filled Sterile growth media is pumped by head pressure of compressed gas
Incubated 37°C for 72 hours
Swabbed Substrates sampled onto bacterial streak plates
Courtesy of Brian Marquardt – UW APL
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Growth Study
1. End piece (Start Flow) 2. Valve substrate 1 3. Substrate 3 4. Top mount 3 5. Substrate 4 6. Substrate 5 7. Valve substrate 6 8. End piece (End Flow)
1
2 3 5 7 4 6
8
contaminated
Note: Contamination only found in starting and ending components. Most likely due to insufficient sterilization of the sealing caps placed during incubation.
Courtesy of Brian Marquardt – UW APL
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• Demonstrated sterilization of NeSSI components • Possibly contaminated by residual cells trapped in threads of end
caps • Steam sterilization is a valid method of sterilization for NeSSI
components • O-rings and tubing are compatible with autoclave conditions • Ensures a sterile flow path without exposing external parts to hot
and humid conditions • Next step – Top mount components
• Sterilization of top mount components will be dependent on the materials and flow path of the components themselves
• Next step – Full integration to NeSSI System • Integrate rinse stream and boiler system to NeSSI fast loop
sampling system • Create digital control system for automatic sterilization
What may be Concluded?
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Gen I: Fluid Handling Systems Mostly Mechanical Components
Gen II: Electrically Networked Systems
IS Serial Bus, miniTransducers, local wireless
Gen III: Microanalytical
Systems Platform for microAnalytical, remote
wireless, advanced gas & liquid sensors
NeSSITM – Modular Sampling System Initiative
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Sensors for NeSSI
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Pressure Transmitters: • Dwyer (Series 626) • Ashcroft (Series A2X, A4) • GE Sensing (PTX1200,DPS4000) • Brooks Instruments (SS2 series) • SensorsONE (PD33X,DMP331i) • Mensor (series 6000) • StellarTech (GTX2511)
Flow Controllers: • Porter Instruments (3261) • Brooks model (SLA5850) • Horiba (STEC) (SEC-G100) • Sierra Instruments • MKS Instruments • Alicat Scientific (316L MCS/MCRS)
Area Classification: • Intrinsically Safe • Intrinsically safe, Class I Div. II • Class I Div. II, Class I Div. I, IS, GP • Class I Div. II • GP and IS • GP • Class I Div I & II
Area Classification: • Class I Div. II • Class I Div. II • GP • GP • GP • Class I Div. II, ATEX
Signal Output: • 4-20mA • 4-20mA • 4-20mA, RS485, CanBus • 4-20mA • 4-20mA, RS-485, USB • RS-485 • RS-232, RS485, CanBus
Signal Output: • 0-10vdc, 4-20mA • 0-5vdc,4-20mA, RS485, DeviceNet, Profibus • 0-5vdc, DeviceNet •0-5vdc, DeviceNet •0-5vdc, DeviceNet • 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus
Flow Meters: • Porter Instruments (3261) • Brooks (SLA5850) • FCI (FS10A (FM, FS)) • Sierra Instruments • MKS Instruments • Alicat Scientific (M Series)
Signal Output: • 4-20mA • 0-5vdc,4-20mA, RS485, DeviceNet, Profibus • 4-20mA • 4-20mA • 4-20mA • 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus
Area Classification: • Class I Div. II • Class I Div. II • Class I Div. II • GP • GP • Class I Div. II, ATEX
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Parker: Sensor, Analyzer, Valve Actuation Management
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SAM Valve Control Valve “On/Off” Indication
Ethernet Comm.
Gen II Model Architecture
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Future Modular Sampling Hardware Developments for the Lab and Process Markets?
• Mixing Systems – Liquid and Gas Dynamic/Static
• Permeation/Calibration Hardware • Inject Valve Integration for Microanalytics • Solvent Delivery System • Modified Interface Hardware for RAMAN,
FTIR, pH and other probe-based analytics • Alternative Material Applications - PEEK
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Acknowledgments
• Brian Marquadt, Charlie Branham, Wes Thompson, Michael Roberto, Lauren Hughs and Thomas Dearing– Applied Physics Laboratory University of Washington
• Kin – Tek Laboratories • CPAC –University of Washington
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Thank You!!