This Dog Dont Hunt

1
This Dog Dont Hunt
NeSSI
...or why classic 4-20 mA communication and
conventional hazardous protection methods are not
enablers for the further development of
miniature, modular, and smart analytical systems

• Rob Dubois
• IFPACSM
• Arlington, Virginia, USA
• January 13, 2004

the best way to predict the future is to create
it
2
This Dog Dont Hunt
Courtesy of M. and D. Dubois
Chance
3
Presentation Topics

• NeSSI Objectives Recap
• Progress Update
• The Impact of ANSI/ISA SP76
• Generation II Update
• The NeSSI-box A Case Study
• The I/O and Interface Dilemma
• The problem with hazardous compliance
• The problem with 4-20 mA Communication
• Conclusions and Acknowledgments

4
Objective 1 Modular, miniature smart process
analytical systems
Courtesy of Dow Chemical, Fort Saskatchewan,
Canada
Courtesy of Dow Chemical, Fort Saskatchewan,
Canada
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Objective 2 A platform for microAnalytical
devices
Oxygen Sensor
Courtesy of Swagelok and GE/Panametrics
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Objective 3 An enabler for By-Line Analysis
Both pictures Courtesy of Dow Chemical, Freeport,
Texas
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Objective 4 Common Communication Architecture
Field
microClimate Enclosure
Div/Zone 1
Sensor - Level 0 LAN DeviceNet lt100 ft
Segment 1 (NIS)
Segment 2 (IS)
Wireless Handheld HMI
Gas Analyzer
By-Line Analysis
Sample System
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Its all about Standard Interfaces(the rail
concept)
Standard Electrical (Digital) Interface Rail
SAM
Standard robust miniPC
Anyones Actuator
Anyones Sensor
Standard Mechanical Interface Rail
Sensor/Actuator Manager
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NeSSI Development Progress
2006
2004-05
END USER VALUE
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Gen I The Impact of a Standard Mechanical
Interface

• No confusion within our manufacturing community
  on which footprint to build to
• Lowers the cost to build
• Allows interchangeability between various
  components irregardless of manufacturer

Courtesy of Parker-Hannifin

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Gen I The Impact of Adopting the ANSI/ISA SP76
Standard

• Over 50 SP76 components now available
• Price point has decreased from x3 to about x1.2
  classical
• New product categories are in the pipeline
  including microPumps, aspirators, sensors...

Courtesy of CIRCOR
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Gen I SP76 Component Availability
Projected
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2003 New Developments

• New substrate designs
• Swagelok (Jan IFPAC)
• CIRCOR (May ISA-AD)
• Parker (Oct. ISAexpo)
• New SP76 Components
• Brooks MFC (2p)
• Porter MFC (2 p/Div2)
• Horiba/STEC MFC (1p)
• Bronkhörst MFC (Zone1)

• New SP76 Components
• FlowMatrix
• Flow (insens. to press.)
• Hanbay mini-actuators
• Teledyne (PPB Oxygen)
• Rotameters (Porter, Brooks)
• Function Blocks (CIRCOR, Parker)
• Auxiliary Systems
• Intertec smart heater

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SP76 Surface Mount Component Trends

• A move from high purity to process
• A trend to Functional Blocks
• atmospheric reference vent valve module
• leak detection/purge modules
• bypass modules
• back-pressure control module
• sample injection module
• Analytical cluster applications (eg H2O)

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Gen II So why Get Smart?
Maxwell Smart

• Benefits to Industry
• predict failures before they happen
• decrease maintenance
• increase confidence
• remote operation in robust environments
• ARC Advisory Group suggests that 40 maintenance
  savings can be achieved by automation

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Recap of the Seven Elements of a Gen II Miniature
System
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Status Update Gen II/III(encouraging news)

• DOE award for NeSSI systems (3MM)
• Won by Honeywell led consortia
• Smart Gas/Liquid System (2004-05)
• microGC (2006)
• wireless, robust standard (2006 funded sep.)
• Generation II Specification
• working version at hand
• www.cpac.washington.edu/NeSSI/NeSSI.htm

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Status Update Gen II/III(work in progress)

• Who can cut the Gordian knot?
• No clear target to industry on an industrially
  robust low cost digital standard to build to.
• DeviceNet requires 0.5MM to certify for
  Intrinsic Safety
• IEEE 1451.6 standard for IS in progress (with
  CiA/CANopen)
• Profibus or FF an option?
• Power to operate multiple actuators and sensors
  within IS (low power) constraint is a formidable
  goal. (target 20-30 devices)

Alexander the Great cutting the Gordian Knot
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Case Study Hard-earned lessons from the
NeSSI-box installation
Upper Enclosure PLC with 4-20mA
Bottom Enclosure Heated Sample System
in Propylene Service
Courtesy of Dow Chemical, Fort Saskatchewan,
Canada
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Upper Enclosure Control System (SAM Jr.)

• Conventional PLC controller (Div. 2)
• 12 I/O points
• Expensive to design and build
• Custom programming
• Highly engineered

Courtesy of Dow Chemical, Fort Saskatchewan,
Canada
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Lower Enclosure Sample Handling Conditioning

• X-purged pressurized enclosure/interlock
• LEL gas detector/interlock
• Integrated an x-proof heating system into the
  control strategy

Courtesy of Dow Chemical, Fort Saskatchewan,
Canada
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The Field Human Machine Interface (NeSSI-box)
Courtesy of Danny Quevillon. Dow Chemical, Fort
Saskatchewan, Canada
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The I/O Dilemma

• Conventional analyzers do not support flexible
  I/O interfacing with sample systems
• expensive to implement
• multiple interfaces (RS-232, analogue, digital,
  proprietary bus, etc.)
• lack of HMI for monitoring data
• may have limited AI/AO/DI/DO Input/Output

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4-20 mA Communication not viable for NeSSI Gen
II/III

• highly engineered and labor intensive
• space hungry
• expensive to wire for haz. electrical areas
• conduit and cabling systems can be larger than
  the actual components and do not support
  miniaturization
• different global certification rules
• this dog dont hunt

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The Solution Low cost Intrinsically Safe Serial
Comm. for Gen II/III

• First analytical serial bus now demonstrated
  (POCA project)
• simple wiring and connections

Courtesy of Dow Chemical, Fort Saskatchewan
POCA Proof of Concept Apparatus
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Free at Last

• A wiring method with no conduits, cables
• Plug and play identification of sensors and
  actuators
• An industry standard connector
• Smart diagnostics
• Global certification

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Conclusions

• Gen I products are streaming to market
• DOE award will bring Gen II/III prototypes to
  market in 2-3 years
• 4-20 mA I/O is not optimal for NeSSI miniature
  systems
• target the NeSSI-bus

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Acknowledgments

• Special Thanks
• Peter van Vuuren (ret.) ExxonMobil Chemical
• Jeff Gunnell (EMCC)
• John Cumbus (EMCC)
• John Mosher (Hwell)
• Bob Nickels (Hwell)
• Ulrich Bonne (Hwell)
• Dave Veltkamp (CPAC)
• Mel Koch (CPAC)
• Rick Ales (Swagelok)

• Special Thanks (Dow)
• D. Quevillon, R. Hartwig, H. Quartel (Fort Sask.)
• P. Williams, B. Vu, J. Leach, D. Yates, D. Gay,
  W. Henslee, M. Walsh, C. Snook (Texas)
• G. Timmermans, E. Engelen (Netherlands)
• Paul Landry (Louisiana)
• Ralf Schade (Germany)
• M. Dittenhafer, M. Buchmann (Michigan)

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Thanks Peter!