nessi*: shiftin’ gearsdepts.washington.edu/cpac/nessi/17_cpac_spring...nessi*: shiftin’ gears...
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NeSSI*: Shiftin’ Gears“Moving to the Project Stage”
CPAC - Seattle, WA - May 6, 2002
Rob Dubois - Peter van Vuuren - Jim Tatera .
C PΛ C
“the best way to predict the future is to create it”
Tatera and Associates
*New Sampling/Sensor Initiative
2
Presentation Outline
z Summary of NeSSI Objectives & Driversz Activities Updatez [Quick] Gen I, II, III Comparisonz Project Plansz Progress Rating of Gen II Elementsz Installs & Late Breaking Developmentsz Summary and Acknowledgements
Courtesy of Owen Beattie,
University of Alberta, Canada
Question:
Is Process Analytical frozen in time?
Answer:
No! A renaissance is in progress.
John Torrington Chief Petty Officer on the HMS Terror - preserved in the permafrost. Victim of lead poisoning.
”The Franklin Expedition” d. 1846 (age 20)
4
NeSSI Structure
zAn ad hoc global industry initiative, formed in June, 2000 to drive permanent change in how we do Process Analysis.yNeSSI mail-out has now grown to 300+ subscribers⌧Represents over 31 End Users from Oil and Petrochemical as
wells as Manufacturing Companies, Academia, National Labs, etc.
zCenter for Process Analytical Chemistry(CPAC) is our sponsor and legal umbrella
5
NeSSI Objectives
z Facilitate the acceptance/implementation of...ymodular, miniature & smart process analytical
technologyz Promote the concept of...yat the pipe/field-mounted (“byline”) analytical
systems z Lay the groundwork for...yopen connectivity communication architecture
z Provide a technology bridge to the process for...y“sensor/lab-on-a-chip” microanalytical devices
6* Posted on CPAC website
Activities Update
zActivities since Fall CPAC, 2001yTutorial - INTERMAC November, 2001 [Tokyo]yPlenary Paper, Session & Roundtable - IFPAC Jan2002 [San
Diego]*yTalk - IEC SC65D Maintenance Mtg, Feb. 2002 [Frankfurt]y“UMIX” & Workshop Pittcon March, 2002 [New Orleans]*yTalk: IEC SC65D Full Committee Mtg, April, 2002 [Beijing]yTutorial & Session - ISA Analytical Div. April, 2002 [Denver]yX-team (hazardous area focus group) activities completedyNeSSI Marketing Survey - Included in AD newsletter
7
NeSSI Generation Segmentation Pyramid
Gen III
Gen II
Gen IMechanical (mostly)
Electrical/Smart (Diagnostic)
MicroAnalytical & WirelessValue
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Gen I - Mechanicalminiature, modular footprint
zAdapted from the semicon industryzLEGO® like designzISA SP76 Standard
Courtesy of Swagelok
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Gen II SystemPlug and Play Electrical
Programmable Substrate Heater
VP
A
F
Ethernet LAN
Analyzer
Controller or PC
SAM
CANbus
PDA
Auxiliary Heating/Cooling
SubstrateT
T
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Gen III SystemPlug & Play µAnalytical
SAM
Fiber Optic
AT
One sensorper component“lab on a chip”
One Sensor and Multiple Analytes
Ethernet LANEnabling Technology
for µAnalytical
VTA
A
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Gen IIIPlug & Play Wireless Signal
Ethernet LAN
VTP
A
z Bluetooth , 802.11 Wi-Fiz Power Supplied by...yX-proof MINI busy...or IS miniature power bus
P.S.
SAM
12
Gen I Installs & Tests in progress...
Coutesy of a
gulf coast
petrochemical facility
Courtesy of an east coast petrochemical facility
and Parker-Hannifin
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Gen II Development CampaignLead - Honeywell Labs/Ulrich Bonne
1. Finalize NeSSI Gen II spec2. Fabricate an alpha unit. Lab evaluate. 3. Fabricate 10-20 beta units. Field tests
years 20044. 2005 Commercial Product available
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Gen II DevelopmentInvolvement and Funding
z$1-2M funding request to DoE-OITySubmit White Paper (June 2002)
z50% of funding to be borne by “prototype testers” as “work in kind”ycommitment of $50K/participantyExxonMobil Chemical, Air Products,
ChevronTexaco, Honeywell, DowyWe would like 10-20 participants!
zPossibly other funding sources (eg ATP)
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Generation II DimensionsProgress to Date...
1. Programmable Substrate2. mini-Sensors3. “Combi” Valve
4. SAM - Sensor/Actuator Manager ☺5. PC/PDA with HMI* [Wireless]6. Multi-Drop IS Bus7. Micro Climate Enclosure
* HMI = Human Machine Interface
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1. Programmable substrate temp.IEC Ex d Div/Zone 1 Haz. Locations
AC PowerAC Power
Purpose
Maintain the substrate/sample at the appropriate temperature to maintain dewpoint and optimize & simplify sample heating. Improve reliability, minimize utility load and reduce LTCO.
Strengths
Available from certain “solid block” substrate mfgs.
Commercial technology avail.
Weaknesses
Difficult to implement in substrate suspended designs
No IS version of control portion4/10
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2. mini-SensorsIEC Ex ia (low power) Haz. Location
FLOW
PRESSURE
TEMP
Substrate
A/D
Comm.
µP
Mem
ory
A
4/10
PurposeProvides measurements for validation and control. Simplify andstandardize. Lower cost implementation. Increase reliability by increased vigilance of the system and reduce maintenance by predictive as opposed to preventive maintenance.
StrengthsExcellent results from Honeywell - thisappears to be the genesis of process readymini instrumentation suitable for use in hazardous locations. Suspect wide applicability in industry as well as analytical. Enables plug and play with extremely low power.
WeaknessesCurrently untried in industry. We need toknow the operating characteristics such asrange, accuracy, robustness, etc.
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3. “COMBI” ValveIEC Ex ia Low Power Haz. Location
A
Actuator
Instrument Air
ValveVent
Vent
Comm.
D/ASolenoid
Pneumatic valve
3/10
Purpose
On/off and/or modulation of sample and validation fluids. Combining a pneumatic valve and solenoid in one package simplifies design. Low power gives plug and play & multi-drop capabilities. Safe design reduces maintenance.
Strengths
Some commercial products for the pilot valve are available. C/w haz. certifications and very low (1.45 mA) power drain.
Weaknesses
No one has integrated this product into a 1.5” substrate.
No modulation product.
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4. Sensor/Actuator ManagerEx d microPC c/w CE operating system
Gateway to an
Ethernet LAN
Host to a
Sensor/Actuator Bus
Wireless Field
Interface to HMI
Software Applets “Open”Development Space
3/10
PurposeStandardizes repetitiveoperating tasks and providesnetworking hardware.
StrengthsSimplify maintenance across all platforms. Reduces design engineering.
Weaknesses- Competes with some product offerings of existing analytical mfgs.- No standards for applets - foundation like organization req. for over-sight. - Cost and size must be minimized. Remains to be seen if this can be accomplished.
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5. Graphical HMI*Intrinsically Safe Field PC/PDA
☺PDA/PC
HMI
VTP
A
* HMI = Human Machine Interface
Purpose
Allows field adjustment and interrogation of an analytical system. (mimics remote PC)
Simplifies and uncomplicates maintenance by standardizing interface.
Strengths
Commercial Intrinsically Safe PC’s, PDA’s available. One unit may service many field devices.
Weaknesses
Haven’t set whether IrDA, Bluetooth or Wi-Fi wireless.
Need standard way to do HMI software. Oversight needed.
SAM
5/10
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6. Serial Multi-drop BusEx ia Intrinsically Safe
VTP
A
CANbus
Purpose
Simplify maintenance. Vendors can sell their product with “value added”software applets on board their devices. Plug and Play with no gas test.
Strengths
Many existing multi-drop buses and software. DeviceNet has critical mass in the industry for a bit bus. Low cost.
Weaknesses
Confusion and lack of thrust on identifying an IS product (and cost) to do this properly.
2/10
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7. MicroClimate Enclosure
Div/Zone 1GP. A-D, T4
PurposeProvides a practical temperature controlled microenvironment tohandle sampling and analyticalequipment in varied climatic conditions “in the field”. Simplifies design.
StrengthsAll technology available to implement.Simplifies design by standardizing onan area classification inside the enclosure which accounts for any hazardous fluid leakage.
WeaknessesCooling not addressed at this time.6/10
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The Race to the PipeWhat will it be? An In-ey or Out-ey? Suggest both...
“Like a thermocouple”
[in situ - inline]
In-ey
“Like a pressure transmitter”
[ex situ - byline]
Out-ey
Analytical sensor (typ.)
tx
tx
SS
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AcknowledgementsEnd Users
zDowyDanny QuevillonyReg HartwigyBac Vu (SP76)yCraig SnookyWalter Henslee
zAir ProductsyFrank Schweighardt
zChevronTexacoyD. Nettles/D. Young
zExxonMobil ChemicalyDan Podkulski (SP76)yJeff GunnellyJohn CumbusyRajko PuzicyKelley Bell
zHoneywellyKenneth CreasyyJohn MosheryUlrich BonneyBob Nickels
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