NeSSI* - Generation II

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NeSSI - Generation II Revolution or Evolution?
New Sampling/Sensor Initiative

• ISA 2001 - Houston, TX - September 10, 2001
• INTERMAC - Tokyo, Japan - Nov. 8, 2001
• Rob Dubois - Peter van Vuuren - Jim Tatera
• .

Tatera and Associates
the best way to predict the future is to create
it
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Tutorial Outline

• Introduction, Drivers History
• A Vision and the Market Trends
• NeSSI Generation I, II, III Comparisons
• 10 Dimensions of a NeSSI Generation II System
• What will a Generation II prototype look like?
• Some recent developments
• NeSSI Roadmap Summary
• CPAC (Center for Process Analytical Chemistry)
  Review

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Process analyzer systems have been accused of
being...

• complex
• expensive
• proprietary
• big box (battleship)
• hi maintenance
• suspect regarding data integrity
• slow to change

Edvard Munch The Scream
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• Operates under the umbrella of the Center for
  Process Analytical Chemistry (CPAC)
• Originated from various CPAC focus sessions
• IFPAC 2000 plenary paper presented NeSSI vision
• Focus groups Pittcon 2000 ISA Expo2000
  IFPCA2001, Pittcon2001
• ISA2001 Houston Kick-off of NeSSI Generation II

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• Facilitate the acceptance/implementation of...
• modular, miniature smart sample system
  technology
• based on ISA SP76 standardization work
• Promote the concept of...
• field-mounted smart sampling/analytical systems
• integration of sample systems with
  physical/chemical sensors
• Lay the groundwork for...
• open connectivity architecture for sensor
  communications (e.g. Ethernet, DeviceNet, etc.)
• industry standard communication protocols (e.g.
  OPC, DeviceNet, CAN, etc.)
• web enabled technologies (e.g. Browser based HMI)
• Provide a technology bridge to the process for...
• sensor/lab-on-a-chip micro-analytical devices

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Picture Courtesy John Thomas, Parker Hannifin Corp
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(No Transcript)
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What is Driving

• Reduce Cost to Build
• Design, Engineering, Manufacturing,
  Installation, Etc.
• Reduce Cost of Ownership

Maximize Sustained Fit for Use Data
Generation System Validation Representative
Sample Validation Measurement (Data)
Validation Communication Validation
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Market Acceptance Cost Ease of Design System
Reliability
Where In the World Are We?

• Critical Issues
• acceptability by Process Analytical community
• technical challenges
• cost

NeSSI
Analyzer House

• Value
• Reduce capital costs by 35 40 LTCO

On the Post
Time

• Vision
• Plug and Play - modular
• At line/near line
• A platform for microAnalytical

• Whats going on in the world?.
• Fast networks robust electronics
• Lab on a chip lasers wireless

• Market Needs
• Fast, reliable, rugged, reasonable cost

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Vision The End of the Analyzer House System
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An Analytical System
...Will Look More Like Us!

• Single Processor - Overall Control
• Sensor Analytical Manager (SAM)
• System will be Multifunctional
• Equal emphasis on all sensors
• System will be Adaptable
• Predictive maintenance self-healing
• Capable of Multivariate Analysis
• Use many sensors for analysis

Courtesy of Ken Creasy, Honeywell. IFPAC 2001
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Intentof the Gen II Spec

• The NeSSI Generation II specification is
  intended as a vehicle for alerting the
  marketplace to the need for these types of
  products.

"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
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NeSSI Generations

• NeSSI Generation I (circa 2000)
• an arranged marriage
• NeSSI Generation II (circa 2001-2005)
• a courtship - reengineering solution
• NeSSI Generation III (circa 2005)
• wireless, analytical sensors

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Gen. I versus Gen. II
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The Penitent - Weve come a long way!
Courtesy of Health and Safety Executive,
Sheffield, England
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Generation II Dimensions- Shopping List for NeSSI

• 1. Heated Substrate
• 2. Physical Sensors
• 3. Actuators
• 4. SAM ?
• 5. HMI (Graphical)

• 6. Wired Bus
• 7. Wireless Bus
• 8. X Mini Power Bus
• 9. Packaging
• 10. Analytical Sensor

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1. Heated Substrate
Div/Zone 1 GP. A-D
Div/Zone 1 or 2 GP. A-D
Conduction Heating - cartridge heater(s) -
over-temperature cut-off
AC Power
AC Power
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2. Physical Sensors for System Diagnostics

• Doing analytical is just not good enough!
• Miniature Flow, Pressure, Temperature
• Gas and/or liquid service
• Rugged construction
• Encapsulated (IEC Ex m)
• Intrinsically Safe (IEC Ex ib)
• Div/Zone 1 Gp A-D T4 (135 C)

FLOW ? P, coriollis, thermal, other?
COM
A/D
Substrate
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2. Conceptual Sensor for NeSSI
Top Hat Comm. Chip
Parallel Ports - standard size/pin - daisy chain
A
B
Body - encapsulated
Comm.
Digital Smart Sensor - engineering units -
memory
µP
BARRIER - Process Seal - Electrical Isolation -
Thermal
Memory
A/D
Process Cavity - no unswept voids - low volume
Insulation Skirt - engineered
1.50
Base - 316 SS - pressure rated
Sensor
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3. Electrical Actuators on the Substrate - COMBO
COMBO Valve /w integral solenoid

• Miniature substrate mount
• Gas and/or liquid service
• Wide P T service
• Rugged, encapsulated (IEC Ex m)
• Intrinsically Safe (IEC Ex ib)
• Div/Zone 1 Gp A-D T4 (135 C)

Comm.
SV
AIR
On/Off and Proportional
Act.
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3. or Direct Electrical Actuators on the
Substrate

• solenoid valves
• motorized valves
• again suitable for Div/Zone 1

Solenoid or Motorized Valve
Comm.
On/Off and Proportional
SV
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3. Conceptual Combo Valve
Parallel Ports - standard size/pin - daisy chain
TopHat Comm. Chip
B
A
Comm.
D/A
3-way pilot solenoid valve - Intrinsically Safe
Vent
Solenoid
Instrument Air
Digital On-Board
Actuator
Actuator - NO or NC
Vent
Conventional pneumatic valve
Valve
Engineered Insulation Skirt
Thermal Barrier
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4a. Introducing SAM - Sensor Analytical Manager
Standalone SAM
Analyzer
?
?
Embedded SAM
Analytical Sensor
F
Vv
T
P
F
Vv
A

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4b. SAM does 5 jobs!
Gateway to an Ethernet LAN - OPC perhaps
Field Interface - Graphical - Wireless - e.g.
Bluetooth, 802.11
Software Applets for Sample System Repetitive
Tasks (Industry Common)
Host to a Sensor/Actuator Bus
Open Development Space for Custom Software
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4. SAM - Provides a Pick-list of Common SS
Tasks

• Zero span validation
• Pressure regulation
• Stream switching
• Maintenance diagnostics
• Temperature control
• Interoperability
• talk to all analytical systems

Enabling Technology for microAnalytical
SAM
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4. SAM - Suggested Package
Courtesy of Adalet
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5. HMI (Human Machine Interface)
PDA
?
?
?
?
Hello?
PC
F
Vv
T
P
F
Vv
A
Vvautomatic valve Ppressure sensor FFlow
Sensor AAnalytical SensorTTemp. Sensor
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6. Standalone SAM with Wired Sensor/Actuator Bus
Analyzer System Ethernet LAN

• IEC Ex ib intrinsically safe
• Leverage FISCO power concept
• Standard Plug Play Conn.
• DeviceNet or SDS

SensorAnalyticalManager(SAM)
?
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6. Embedded SAM With Wired Sensor/Actuator Bus

• IEC Ex ib intrinsically safe
• Leverage FISCO power concept
• Standard Plug Play Conn.
• DeviceNet or SDS

Analyzer System Ethernet LAN
?
Analyzer Controller w/ Embedded SAM Functionality
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7. Wireless Signal (Gen III?)
Analyzer System Ethernet LAN

• Bluetooth? or 802.11
• Plug and Play!
• Power I.S.
• X-proof miniature power bus

?
SensorAnalyticalManager(SAM)
?
P.S.
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8. What the world need is...
Sensors (typ)

• a Miniature wiring method
• plug socket
• Division/Zone 1
• MTL (England)

Mini-Power Bus
AC Power
AC/DC
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8. Mini X-proof connector- Div/Zone 1
Can we make this small?
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9. Enclosure/Package
Convection Heater X-Proof (OPTIONAL)
Div/Zone 1 GP. A-D
Div/Zone 1 or 2 GP. A-D
Temp. Sensor Intrinsic Safe
AC Power
No Purge or Pressurization
NEMA or IP Rated Enclosure - insulated
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10. Analytical Sensors
Fiber Optic
SAM
?
One sensor per component lab on a chip
AT
One Sensor and Multiple Analytes laser
scanning device
A
F
Vv
T
A
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Connectivity! - CPAC ConnI Initiative
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Elements of a NeSSI Gen II Smart Prototype

• Programmable, heated substrate
• Digital sensors F, P T serial bus
• Division/Zone 1
• SAM control algorithms
• Wireless/graphical HMI
• Packaged for outdoor installation

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Globalize, harmonize...

• IFPAC
• 2001. USA.
• CPACT
• 2001. Europe.
• ISA 2001.
• 2001. USA.
• INTERMAC
• 2001. Japan.

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Design certify to global requirements...

• NEC, UL, FM (USA)
• CEC, CSA (Canada)
• CENELEC (Europe)
• ATEX Directive (Europe)
• CE Mark

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New Developments!
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O2 Measurement
Courtesy of Panametrics Swagelok Co.
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First NeSSI H2O Probe
Courtesy of Panametrics Swagelok Co.
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First pH Sensor
Courtesy of Rosemount Analytical
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Mass Flow Controller
Courtesy of Porter Instruments and the Swagelok
Co.
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First Optical Cell
Courtesy of Applied Analytics, Inc.
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IGC-II c/w Elastomer Seals
New
Courtesy of the Swagelok Co
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Petrochemical installs...
Courtesy of a majorTexas gulf coast petrochemical
facility
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A 5 year Roadmap

• A Plan to Achieve the Vision

North America
Europe
Asia
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NeSSI Roadmap
Definition
?Analytical Wireless Gen. III
Smart/Electrified Gen. II
Mechanical Gen. I
? Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, etc.)
Prototype - Physical Sensors/Heating/SAM
Mechanical Components e.g. filters, valves, etc.
NeSSI/CPAC Vision
Mech. Field Trials
Smart Field Trials
SP76 Substrate Available
2000
Time (years)
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Acknowledgements I

• Dow
• Danny Quevillon
• Reg Hartwig
• Christoph Kleimeier
• Walt Henslee
• Bac Vu (SP76)
• David Gay
• Syncrude
• Ian Verhappen

• ExxonMobil Chemical
• Dan Podkulski (SP76)
• Jeff Gunnell
• John Cumbus
• Rajco Puzic
• CPAC
• Mel Koch
• Lloyd Burgess
• Brian Marquardt

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Acknowledgements II

• Doug Mitchell - Panametrics
• John Wawrowski - Swagelok
• Rick Ales - Swagelok
• Yoav Barshad - Applied Analytics
• Trevor Knittel - Analytical Specialties
• Mike Marsceill - Porter

• Carl Jones - Rosemount Analytical
• CD Feng - Rosemount Analytical
• Bob Nickels - Honeywell
• Ron Eddleman - Measurementation
• Chris Towle David Blisset - MTL

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Summary

• Evolution as opposed to revolution
• Spin-offs.
• microAnalytical devices
• microReactors
• ConnI (connectivity initiative - CPAC)
• Release of Generation II Spec
• December 2001 (revised)
• To NeSSI Distribution List

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...a few references you may want to look over.

• The NeSSI portion of the CPAC web site at
  www.cpac.washington.edu
• The ISA Draft Standard - ISA Draft 76.00.03 ,
  Modular Component Interfaces for Surface-Mount
  Fluid Distribution Components--Part 2
  Elastomeric Seals
• "The New Sampling/Sensor Initiative", Terence K.
  McMahon, Control, August/2001, Vol XIV, No. 8,
  page 158
• "Molding the Future of Process Analytical
  Sampling", Ellen Fussell, InTech, August/2001,
  page 32