IFPAC2010

SAM: Functionality Considerations

Peter van Vuuren

Process Analytics Consultant

IFPAC2010

Topics

SAM Incarnations

Connectivity (OPC Considerations)

Remote Access (A New Vehicle?)

IFPAC2010

Programmable Substrate Heater

V

P

F A

Substrate

SimpleSampling

System

Gen 1: Modular Sampling System = NeSSI I

Discrete analog signals

SP76 Interface

Benefits:* Modular (minimum tubing)* Minimal man-hours

(design, eng, manufacturing)* Capable of self-validation (p,t,f)

IFPAC2010

Programmable Substrate Heater

Ethernet LANAnalyzer

Controller

V

A

P F

SAM

NeSSI bus

Auxiliary Heating/Cooling

SubstrateT

T

Standard Sampling Interface

dcs o&muser

Standard Connectivity

Interface

NeSSI “Sandwich/Rail” Platform Concept

PDA

DevelopmentFocus can beon Sensors !

☺

SAM

IFPAC2010

Programmable Substrate Heater

Type 1: Embedded SAM

Ethernet LAN

AnalyzerController

GC, FTIR, MS

V

F

P F

Embedded SAM

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

PDA

☺

IFPAC2010

Programmable Substrate Heater

Type 2A: SAM as Stand-alone Sampling System Front-end Controller

Ethernet LAN

V

A

P F

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

AnalyzerController

SAM

PDA

☺

Note: Analyzer Controller is communications gateway to DCS/O&M User

IFPAC2010

Programmable Substrate Heater

Analytical Cluster Concept: Sensor Arrays with NeSSI as Enabler

Ethernet LAN

V

A

A A

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

1. Multiple Analytical Sensorson NeSSI Substrate

2. May require individual“controller” for each sensor

CondpH DO

IFPAC2010

Programmable Substrate Heater

Ethernet LAN

Analyzer

ControllersV

A

A A

SAMCANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

☺

Type 2B: SAM as Stand-alone Sampling System Front-end Controller (Multiple Analytical Sensors)

IFPAC2010

Programmable Substrate Heater

Ethernet LAN

V

A

A A

SAM

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

Type 3: SAM as Sampling Manager, Controller and Communications Gateway

☺

OPC, Modbus etc.

IFPAC2010

Topics

Connectivity

IFPAC2010

Level 3 an-LANEnterprise IP AddressesSecurity & Controls Rqrments

AnlzrWorkstation

AnlzrWorkstation

e.g. SAAI

Router

GP Area - Control/Analyzer/RIB Room

DesktopWorkstation

DesktopWorkstation

DesktopWorkstationIM/Desktop

Level 4 Enterprise LAN

DesktopWorkstation

L3 PC/ANRouter/Bridge

L4/L3Router

Fibe

r -op

tic

link

Field

GC

Anlzr Level 2 FLAN

☺

Anlzr Level 1Sensor Bus (CAN)

SAM

Level 3 c-LAN

DCS Level 2 LAN

HistorianServer

PDC

L3 "Historian" Server and PDC to be shared between DCS

and Analyzer Domains

HistorianDCS Data

ServerOPC ClientBridge (CB)

Fibe

r -op

tic

link

Anlzr Level 2 FLAN

(Private IP Addresses)

Data Server/RouterRouter

GC GCRaman FTIR GC ☺GC

EmbeddedSAM

SAM☺AnalyzerControl

Sampling Systems

☺

OPC AnalyzerGateway

Server (AGS)

Integration of Analyzers into a PA/DCS System

Note: In this scenario, for a fully integrated analyzer system with the DCS via an OPC Gateway Server, each analyzer will have to have an embedded client.

Analyzer Gateway

OPC Server(AGS)

Requiresan OPC Client

Requiresan OPC Client

OPC ClientBridge (CB)

DCS OPCServer

IFPAC2010

Level 3 an-LANEnterprise IP AddressesSecurity & Controls Rqrments

AnlzrWorkstation

AnlzrWorkstation

e.g. SAAI

Router

GP Area - Control/Analyzer/RIB Room

DesktopWorkstation

DesktopWorkstation

DesktopWorkstationIM/Desktop

Level 4 Enterprise LAN

DesktopWorkstation

L3 PC/ANRouter/Bridge

L4/L3Router

Fibe

r -op

tic

link

Field

GC

Anlzr Level 2 FLAN

☺

Anlzr Level 1Sensor Bus (CAN)

SAM

Level 3 c-LAN

DCS Level 2 LAN

HistorianServer

PDC

L3 "Historian" Server and PDC to be shared between DCS

and Analyzer Domains

HistorianDCS Data

ServerOPC ClientBridge (CB)

Fibe

r -op

tic

link

Anlzr Level 2 FLAN

(Private IP Addresses)

Data Server/RouterRouter

GC GCRaman FTIR GC ☺GC

EmbeddedSAM

SAM☺AnalyzerControl

Sampling Systems

☺

Integration of Analyzers into a PA/DCS System

Note: In this scenario, for a fully integrated analyzer system with the DCS via an OPC Client Bridge, each analyzer will have to have an embedded OPC Server.

OPC ClientBridge (CB)

Requiresan embedded OPC Server

Requiresan embedded OPC Server

DCS OPCServer

IFPAC2010

TYPE 1aSingle ControllerSingle CAPSingle Detector/Probe/StreamSingle Component

• pH• Conductivity• Oxygen• Autotitrator

TYPE 1bSingle ControllerSingle CAPSingle Detector/Probe/StreamMultiple Components

TYPE 2aSingle ControllerSingle CAPMultiple Detectors/Probes/StreamsSingle Component

TYPE 2bSingle ControllerSingle CAPMultiple Detectors/Probes/StreamsMultiple Components

TYPE 3Single ControllerMultiple CAPMultiple Detectors/Probes/StreamsSingle/Multiple Components

1

Controller

CAP Detector/ProbeStreams = STRM

Components = COMP

1

1

1

2

n

1

• Photometer• Simple GC

• Panametrics

• GC Regular• GC Master/Slave• FTIR• RAMAN

• Mass Spec• GC Master/Master• FTIR • RAMAN

ExamplesConfiguration Types

OPC Data Structures

IFPAC2010

TYPE 1aSingle ControllerSingle CAPSingle Detector/Probe/StreamSingle Component

• pH• Conductivity• Oxygen• Autotitrator

TYPE 1bSingle ControllerSingle CAPSingle Detector/Probe/StreamMultiple Components

TYPE 2aSingle ControllerSingle CAPMultiple Detectors/Probes/StreamsSingle Component

TYPE 2bSingle ControllerSingle CAPMultiple Detectors/Probes/StreamsMultiple Components

TYPE 3Single ControllerMultiple CAPMultiple Detectors/Probes/StreamsSingle/Multiple Components

1

Controller

CAP Detector/ProbeStreams = STRM

Components = COMP

1

1

1

2

n

1

• Photometer• Simple GC

• Panametrics

• GC Regular• GC Master/Slave• FTIR• RAMAN

• Mass Spec• GC Master/Master• FTIR • RAMAN

ExamplesConfiguration Types

OPC Data Structures

☺

Where does SAM (Type 3) Fit in?

IFPAC2010

Topics

Remote Access

IFPAC2010

Manpower/Skills – Some Tier Level Considerations

Technician Level ON-Site

• Basic Maintenance Skills

• Limited Troubleshooting Capabilities

Tier 1

Analyzer Engineer ON-Site

• Performance evaluation OFF-Site

• Good Troubleshooting Capabilities

• New Technology Evaluation etc.

Tier 2

Manufacturers Rep/Service Engineer OFF-Site

• High Level Troubleshooting skills

• Spare Part Repairs

Tier 3

Factory Support (Last Resort) OFF-Site

• Service Engineer

• Full Technical Backup

• Full Troubleshooting Capabilities

Tier 4

IFPAC2010

Pro

cess

Str

eam

SS

AN

GP Area

Field – Classified Area (Typically ZONE2)

Analyzer House

AN

DCS

Control Room

Process Analytics Maintenance Resources: On-Site Considerations

Operations & Maintenance (O&M) Users

Lab/Engineering Offices

AnEng

Analyzer Shop

AnTech

IFPAC2010

Pro

cess

Str

eam

SS

AN

DCS

GP AreaField – Classified Area (Typically ZONE2)

Analyzer House

AN

Lab/Engineering Offices

Analyzer Shop

Control Room

Process Analytics Installation – Data Supplier/Customer Relationship

Operations & Maintenance (O&M) Users

AnEng

AnTech

Diagnostic Data (Validation) Representative Sample (P, T, F )

Analyzer Diagnostics* Flame, Laser On, Temperatures etc.

Communications Diagnostics

Data Integrity/AvailabilityNON -CRITICAL

AN

Process Analysis Data Safety, Control, Environmental

“Fit for Use” Qualification (extensive validation)

Data Integrity/Availability CRITICAL

IFPAC2010

Pro

cess

Str

eam

SS

AN

DCS

GP AreaField – Classified Area (Typically ZONE2)

Analyzer House

AN

Lab/Engineering Offices

Analyzer Shop

Control Room

Process Analytics Installation – Two Different Communication Paths

Operations & Maintenance (O&M) Users

AnEng

AnTech

Cellular NetworkG3 Wireless Router

Process Composition/Validation Data

Performance/Diagnostic Data

IFPAC2010

Programmable Substrate Heater

Ethernet LAN

V

A

A A

SAM

CANbus

Auxiliary Heating/Cooling

SubstrateT

T

dcs o&muser

Type 3: SAM as Sampling Manager, Controller and Communications Gateway

☺

Process Data Pathway Diagnostic/Validation Data Pathway

IFPAC2010

Multiple SAM Implementations possibleQ: How can we build a consensus as to which ones

should be promotedIntegration Connectivity not trivialQ: How to develop a connectivity strategy which

will ensure standardized implementation of a few appropriate protocols (Wide range of stakeholders)

Remote access (troubleshooting, diagnostics, performance monitoring) combined with a visual interface is critical to the success of NeSSI GenIIQ: How can we promote cellular wireless

communications as a vehicle for remote access

Summary

IFPAC2010

Q & A Time

IFPAC2010

Thank You