“the best way to predict the future is to create it”
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
NeSSI* – An Enabling Platform for the NeSSI* – An Enabling Platform for the Reduction in TCO** of Process Reduction in TCO** of Process
Analytical SystemsAnalytical Systems(* New Sampling/Sensor Initiative
** Total Cost of Ownership)
“the best way to predict the future is to create it”
IFPAC2008 NeSSI Day29 January 2008
Peter van VuurenPeter van VuurenApplication and Technical Consultant
SpectraSensors Inc.
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
+
TCO$Measurement
value$“Analyzer Credits”
$Bottom-line Value$
TCO
PA/NeSSI Value Proposition
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
NumberK USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
To Build/Install
To Own
Cost to Build/Install/Own – Major Greenfield Project
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
What to DO?
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensors
• Phase IIIPhase IIIPromote/Apply Micro-Analytical Sensors onPromote/Apply Micro-Analytical Sensors onNeSSI Sampling PlatformNeSSI Sampling Platform
A Three Phase Proposed TCO Optimization Strategy
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pictures Courtesy ExxonMobil Chemical
Intrinsically Safe NeSSI: Modular Smart Sampling System
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Benefits of Smart NeSSI
TCO Benefits of Smart NeSSI:• Push Validation down to Sampling System level • More reliable operation• Improves EQA of analyzer
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Simplified Topographical Diagram of a Process Analytics installation
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Implementation Today)Utilize NeSSI as a Platform for Spectroscopic Sensorspreferably at the Sampling Point (By-line Mode)
• Phase IIIPhase IIIPromote/Apply Micro-Analytical Sensors in By-Promote/Apply Micro-Analytical Sensors in By-Line ModeLine Mode
A Three Phase Proposed TCO Optimization Strategy
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
VO2
Micro- Climate enclosure
The NeSSI Platform = Sampling & Communications Platform
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
VO2
R
Micro- Climate enclosure
TDL
RAMAN
Spectroscopic Sensors with NeSSI as Enabler
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
NeSSI: Enabling Topographical Changes
AN
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
Optograph
TDL
NeSSI: Enabling Topographical Changes
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
Optograph
Other
AN
TDL
NeSSI: Enabling Topographical Changes
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
XX
X
XX
Cost Benefits of TOPOGRAPHICAL Changes
X
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensorspreferably at the Sampling Point (By-line Mode)
• Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode
A Three Phase Proposed TCO Optimization Strategy
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
V
Micro- Climate enclosure
Micro- GasAnalyzer(UV, MIR, MS, GC, …
NeSSI & Next Generation Micro Analyzers
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
P
Optograph
TDL
NeSSI Enabled Spectroscopy/Micro-Analytics Topography
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Understand the NeSSI Platform Concept (Enabler)* Provides a Standardized Micro-Infrastructure Environment
for Deploying micro-analytical sensors/Analyzers* At the same time, allows for IP protection
• IS has to be designed in up front * NeSSI platform can be installed anywhere (Zone 0/1/2 GP) – no costly purge systems
• Design for temperature accommodation/correction
•Design for validation of results (Good Housekeeping Seal)* Use all the analytical process information for validation
•Design for no or little consumables
•Design for mechanical simplicity – no or few moving parts
•Design for extensive but smart diagnostics
Spectroscopic/Micro-Analytics Design Requirements
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of Smart NeSSI:• Push Validation down to Sampling System level • More reliable operation• Improves EQA of analyzer
TCO: The BIG PICTURE of Cost Savings
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of Spectroscopic Analyzers: :• Inherent reliability, low EQA index• No consumables
TCO: The BIG PICTURE of Cost Savings
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Cost to Build/Install Benefits of Spectroscopic Sensors:• Integrate Probe with NeSSI and Move to Sampling Point• Separate Probe and Analyzer Locations (Fiber-coupled)• No Consumables
TCO: The BIG PICTURE of Cost Savings
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Cost to Build/Install Benefits of Spectroscopic Sensors:• Integrate Probe with NeSSI and Move to Sampling Point• Separate Probe and Analyzer Locations (Fiber-coupled)• No Consumables
TCO: The BIG PICTURE of Cost Savings
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
+
TCO$Measurement
value$“Analyzer Credits”
$Bottom-line Value$
TCO
PA/NeSSI Value Proposition Revisited
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Acknowledgements
• All the Believers (all of you and many others)
• My ex-colleagues at ExxonMobil
• CPAC (adopted NeSSI as a new IURC “business model”)
• Special Thank You to Rob Dubois
NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Thank You
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