networked sampling system development (nessi generation ii/iii) progress and challenges john mosher,...
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Networked Sampling System Development Networked Sampling System Development (NeSSI Generation II/III)(NeSSI Generation II/III)
Progress and ChallengesProgress and Challenges
John Mosher, Bob Nickels, Ulrich BonneJohn Mosher, Bob Nickels, Ulrich BonneHoneywell InternationalHoneywell International
IFPAC 2004, January 13, 2004, Arlington, VAIFPAC 2004, January 13, 2004, Arlington, VA
NeSSI ObjectivesNeSSI Objectives
• Promote the concept of...– at the pipe field-mounted analytical systems
• Facilitate the acceptance/implementation of...– modular & miniature process analytical technology
• Lay the groundwork for...
– smart technology open connectivity & communications
• Provide a technology bridge to the process for...– microanalytical “lab-on-a-chip” - PHASED
GE-Panametrics Oxygensensor probe on NeSSI
User-Driven, Multi-vendor Supported
PHASED Multi-Gas Analyzer(Micro Gas Chromatograph) under development at Honeywell Labs
U.S. Patent No:
6,393,894
Gen II - Smart/Electrical TechnologyGen II - Smart/Electrical Technology
• Open communications protocol standard.
• Intrinsically Safe
• SAM = Sensor Actuator Manager – Embedded Controller, Profile Manager Communications Gateway
NeSSI Gen II
Level 2 LAN = Field LAN
Level 3 LAN
INFORMATION D0MAINPROCESS CONTROL
DOMAIN
ENTERPRISE DOMAIN
MEASUREMENT DOMAIN
SAM
eSAM
Level 1 Sensor Bus
Level 4 Enterprise LAN
SAM
Network
Programmable Substrate Heater
VP
A
F
Auxiliary Heating/Cooling
SubstrateT
T
NeSSI II = SP76 + IS + NET + SAMNeSSI II = SP76 + IS + NET + SAM(Physical Connection + Intrinsic Safety + Network + Controller)
Physical Interface “Rail” – ANSI/SP76Physical Interface “Rail” – ANSI/SP76
Communications Interface “Rail” – ProfiBus PACommunications Interface “Rail” – ProfiBus PA
The Area Between the Enabling “Rails” is WhereThe Area Between the Enabling “Rails” is WhereSensor and Instrument Vendors Add Value andSensor and Instrument Vendors Add Value andCommercialize Intellectual Property.Commercialize Intellectual Property.
NeSSI II/III – Platform DevelopmentNeSSI II/III – Platform Development
Substrate Substrate
Typical NeSSI Device combines state-of-the-art combi- sensor technology with Intelligence and network interface in one small, surface-mount package.
On/Off and On/Off and Modulating valvesModulating valves
Flow Sensor w/ Flow Sensor w/ Temp, Pressure Temp, Pressure w/ Tempw/ Temp
NeSSI II/III – Product DevelopmentNeSSI II/III – Product Development
Substrate
Moisture in Moisture in Dry GassesDry Gasses
PHASED PHASED Micro Micro GCGC
(Future)(Future)
Other Analytical:Other Analytical:Ion, Nox. OIon, Nox. O2, 2, pHpHConductivity, Conductivity, NOx, Turbidity,NOx, Turbidity,Density, OpacityDensity, OpacityRefractive Index,Refractive Index,OthersOthers
ChemometricChemometricSensors for Sensors for Complex AnalyticalComplex AnalyticalMeasurements.Measurements.
ModValve
D/A
Network
Press/Temp
A/D
Network
POCA 1 – Proof of Concept AssemblyPOCA 1 – Proof of Concept Assembly
POCA 1 – The Intent:
• Designed by Dow, ExxonMobil Chemical and Honeywell to prove that the NeSSI II concept was workable by:• Deploying Combi-Sensors: Temperature/ Pressure and Temp/Flow in the same device.• Deploying the Combi-Sensor with an integral Network Interface (DeviceNet)• Deploying additional NeSSI I devices to Emulate NeSSI II such as valves.• Provide SAM functionality through a PC Interface and graphical software.• Provide a platform for future device testing control functions for Dow and EMC.
POCA 1 – Proof of Concept AssemblyPOCA 1 – Proof of Concept Assembly
POCA 1 – The Outcome:
• The Network Interface allows the multiple Measurands of a Combi-Sensor to exist in a single device.• 8mm network cables robust and small enough.• Pressure/Temp sensors very robust• Flow sensor easily damaged by fast pressure pressure changes. Temp was not included.• One Heater short circuit damaged Substrate.• Single network cable allowed for easy control connection.• PC-based emulation of SAM controller very useful in testing devices and system.
POCA 2 – A Working System in a Lab Environment at UOPPOCA 2 – A Working System in a Lab Environment at UOP
Outcome:• SAM Software to Hardware configuration must be foolproof and reliable.• Size and power reduction of actuators will be critical.• In use today in real system.• Exceptional diagnostic, control, and data collection capabilities.• Remote monitoring and control is possible.
UOP – The Intent:• Adapt NeSSI II concepts to a real system.• Used Ethernet and DeviceNet as networks.• Used commercially available products throughout.• Use LabView software on PC for configuration, control, data and diagnostics.
Adaptation of Honeywell Sensors to NeSSI standardsAdaptation of Honeywell Sensors to NeSSI standards
Current Status:• Sensor Design and SP76 housing qualified Intrinsically Safe (IS).• ProfiBus controller and transceiver chipsets identified.• ProfiBus protocol selected and pretested in selected chipset..• First POCA units delivered to Dow and ExxonMobil Chemical• LAMIMS NeSSI I/II system delivered to UOP.
Next Steps:• Design and build PCBs incorporating selected sensing and communication chipsets/circuits. • Design and build PCBs into SP76 Housings and qualify full product as IS.• Establish and incorporate ProfiBus connector architecture for NeSSI applications.• Test Assemblies in full ProfiBus network.• Build and deliver DoE project NeSSI systems to participating companies.• Identify and build additional prototype, cluster application systems for select partners.
NeSSI II/III – The DoE Project ParticipantsNeSSI II/III – The DoE Project Participants
Wireless and Sensing Solutions Advancing Industrial Efficiency.Honeywell International is leading a collaborative R&D project involving the University of Illinois at Urbana-Champaign, Caviton, Inc., Axonn, Ember Corporation, EPRI, and iAculum. The partners will create and field test an affordable and easy-to-use wireless network technology for industrial environments and will develop and will develop and demonstrate innovative sensor technologies for sampling and demonstrate innovative sensor technologies for sampling and analyzing gaseous and liquid process streamsanalyzing gaseous and liquid process streams. These technologies will reduce process upsets, lower energy consumption, reduce emissions, and enhance competitiveness. DOE and the partnership will each contribute $5,168,713 over the life of the project.
Department of Energy press release, November 2003:
NeSSI II/III – The DoE Project ParticipantsNeSSI II/III – The DoE Project Participants
Participant Role Expertise
Honeywell Laboratory & Sensing & Control Business
Develop PHASED gas composition microanalyzer
World class MEMS & microsystem integration
Honeywell Laboratory & Industrial Measurement Business
Develop solid state reference electrode (SSRE)
Above plus leader in industrial electrochemical measurement
Honeywell Sensing & Control Develop and integrate NeSSI-IIIsystems
Industrial temperature, pressure, flow, and embedded products
Caviton / U of Illinois Develop micro discharge detectors Leaders gaseous electronics
ExxonMobil Chemical Field test GC w/ NeSSI in an ethylene plant
World leader in petrochemical and chemical processing
DowChemical Field test NeSSI w/GC, PHASED& pH in ethylene distillation /trace contam., and boiler feedwater
Leading chemical processor
DuPont Field test humidity sensor on NeSSI for titanium oxide drying
Leading chemical processor
Air Products Field test PHASED and Raman spec. in gas processing plants
Leading gas products supplier
Honeywell Specialty Materials Field test NeSSI w/GC for refrigerant distillation control
Specialty materials supplier
UOP LLC Field test O2 for heater control Ind. process design and control
NeSSI II/III – The DoE Project ParticipantsNeSSI II/III – The DoE Project Participants
NeSSI II/III Developments 2003NeSSI II/III Developments 2003
Progress!• Increased adoption and endorsement of NeSSI as a platform.• Extensive learning from prototype systems delivered to Dow, ExxonMobil and UOP.• Identification of Intrinsically Safe, commercially viable Network for use with NeSSI.• Better understanding of user requirements.• Dept of Energy NeSSI project won.• Expansion of NeSSI II and III platform applications:
• Analyzer Sampling Systems.• ‘Cluster Applications’ of stand-alone components to provide specific data.• Chemometric applications to provide new methods of analysis.• Stand-alone Microanalytical Systems.
Challenges!• DeviceNet too costly and time consuming to become Intrinsically Safe.• There is still a lack of market size data for vendors to base development decisions on.• Must deliver Dept of Energy NeSSI project.• NeSSI II Specification needs to be solidified
CONTACT INFORMATION:CONTACT INFORMATION: John Mosher, NeSSI Customer Development, John Mosher, NeSSI Customer Development,
Honeywell Sensing & Control, (209) 339-4004Honeywell Sensing & Control, (209) [email protected]@honeywell.com
Ulrich Bonne, Research Fellow, Ulrich Bonne, Research Fellow,Honeywell Labs, (763) 954-2758Honeywell Labs, (763) 954-2758
[email protected] [email protected]
Bob Nickels, Industrial Product Development Manager, Bob Nickels, Industrial Product Development Manager,Honeywell Sensing & Control, (815) 235-5735Honeywell Sensing & Control, (815) [email protected] [email protected]
Thank You!