NeSSI*: Shiftin

1
NeSSI Shiftin GearsMoving to the Project
Stage
New Sampling/Sensor Initiative

• CPAC - Seattle, WA - May 6, 2002
• Rob Dubois - Peter van Vuuren - Jim Tatera
• .

Tatera and Associates
the best way to predict the future is to create
it
2
Presentation Outline

• Summary of NeSSI Objectives Drivers
• Activities Update
• Quick Gen I, II, III Comparison
• Project Plans
• Progress Rating of Gen II Elements
• Installs Late Breaking Developments
• Summary and Acknowledgements

3
Question Is Process Analytical frozen in
time? Answer No! A renaissance is in progress.
John Torrington Chief Petty Officer on the HMS
Terror - preserved in the permafrost. Victim of
lead poisoning. The Franklin Expedition d.
1846 (age 20)
Courtesy of Owen Beattie, University of Alberta,
Canada
4
NeSSI Structure

• An ad hoc global industry initiative, formed in
  June, 2000 to drive permanent change in how we do
  Process Analysis.
• NeSSI mail-out has now grown to 300 subscribers
• Represents over 31 End Users from Oil and
  Petrochemical as wells as Manufacturing
  Companies, Academia, National Labs, etc.
• Center for Process Analytical Chemistry (CPAC) is
  our sponsor and legal umbrella

5
NeSSI Objectives

• Facilitate the acceptance/implementation of...
• modular, miniature smart process analytical
  technology
• Promote the concept of...
• at the pipe/field-mounted (byline) analytical
  systems
• Lay the groundwork for...
• open connectivity communication architecture
• Provide a technology bridge to the process for...
• sensor/lab-on-a-chip microanalytical devices

6
Activities Update

• Activities since Fall CPAC, 2001
• Tutorial - INTERMAC November, 2001 Tokyo
• Plenary Paper, Session Roundtable - IFPAC
  Jan2002 San Diego
• Talk - IEC SC65D Maintenance Mtg, Feb. 2002
  Frankfurt
• UMIX Workshop Pittcon March, 2002 New
  Orleans
• Talk IEC SC65D Full Committee Mtg, April, 2002
  Beijing
• Tutorial Session - ISA Analytical Div. April,
  2002 Denver
• X-team (hazardous area focus group) activities
  completed
• NeSSI Marketing Survey - Included in AD
  newsletter

Posted on CPAC website
7
NeSSI Generation Segmentation Pyramid
Value
MicroAnalytical Wireless
Gen III
Electrical/Smart (Diagnostic)
Gen II
Mechanical (mostly)
Gen I
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Gen I - Mechanicalminiature, modular footprint

• Adapted from the semicon industry
• LEGO like design
• ISA SP76 Standard

Courtesy of Swagelok
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Gen II SystemPlug and Play Electrical
10
Gen III SystemPlug Play ?Analytical
Enabling Technology for ?Analytical
Ethernet LAN
One sensor per component lab on a chip
Fiber Optic
AT
SAM
One Sensor and Multiple Analytes
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Gen III Plug Play Wireless Signal
Ethernet LAN

• Bluetooth? , 802.11 Wi-Fi
• Power Supplied by...
• X-proof MINI bus
• ...or IS miniature power bus

SAM
P.S.
12
Gen I Installs Tests in progress...
Coutesy of a gulf coast petrochemical facility
13
Gen II Development CampaignLead - Honeywell
Labs/Ulrich Bonne

• 1. Finalize NeSSI Gen II spec
• 2. Fabricate an alpha unit. Lab evaluate.
• 3. Fabricate 10-20 beta units. Field tests years
  2004
• 4. 2005 Commercial Product available

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Gen II DevelopmentInvolvement and Funding

• 1-2M funding request to DoE-OIT
• Submit White Paper (June 2002)
• 50 of funding to be borne by prototype testers
  as work in kind
• commitment of 50K/participant
• ExxonMobil Chemical, Air Products, ChevronTexaco,
  Honeywell, Dow
• We would like 10-20 participants!
• Possibly other funding sources (eg ATP)

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Generation II DimensionsProgress to Date...

• 1. Programmable Substrate
• 2. mini-Sensors
• 3. Combi Valve
• 4. SAM - Sensor/Actuator Manager ?
• 5. PC/PDA with HMI Wireless
• 6. Multi-Drop IS Bus
• 7. Micro Climate Enclosure

HMI Human Machine Interface
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1. Programmable substrate temp.IEC Ex d
Div/Zone 1 Haz. Locations
Purpose Maintain the substrate/sample at the
appropriate temperature to maintain dewpoint and
optimize simplify sample heating. Improve
reliability, minimize utility load and reduce
LTCO. Strengths Available from certain solid
block substrate mfgs. Commercial technology
avail. Weaknesses Difficult to implement in
substrate suspended designs No IS version of
control portion
AC Power
AC Power
4/10
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2. mini-SensorsIEC Ex ia (low power) Haz.
Location
Purpose Provides measurements for validation and
control. Simplify and standardize. Lower cost
implementation. Increase reliability by increased
vigilance of the system and reduce maintenance
by predictive as opposed to preventive
maintenance. Strengths Excellent results from
Honeywell - this appears to be the genesis of
process ready mini instrumentation suitable for
use in hazardous locations. Suspect wide
applicability in industry as well as analytical.
Enables plug and play with extremely low
power. Weaknesses Currently untried in industry.
We need to know the operating characteristics
such as range, accuracy, robustness, etc.
FLOW PRESSURE TEMP
4/10
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Smart T-Comp. TC Sensor Smart T-Comp Flow Sensor
17 mm
Smart T-Comp Flow Sensor
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3. COMBI ValveIEC Ex ia Low Power Haz. Location
Purpose On/off and/or modulation of sample and
validation fluids. Combining a pneumatic valve
and solenoid in one package simplifies design.
Low power gives plug and play multi-drop
capabilities. Safe design reduces
maintenance. Strengths Some commercial products
for the pilot valve are available. C/w haz.
certifications and very low (1.45 mA) power
drain. Weaknesses No one has integrated this
product into a 1.5 substrate. No modulation
product.
3/10
20
4. Sensor/Actuator ManagerEx d microPC c/w CE
operating system
Purpose Standardizes repetitive operating tasks
and provides networking hardware. Strengths Simpl
ify maintenance across all platforms. Reduces
design engineering. Weaknesses - Competes with
some product offerings of existing analytical
mfgs. - No standards for applets - foundation
like organization req. for over-sight. - Cost
and size must be minimized. Remains to be seen if
this can be accomplished.
Wireless Field Interface to HMI
Gateway to an Ethernet LAN
Host to a Sensor/Actuator Bus
Software Applets
Open Development Space
3/10
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5. Graphical HMIIntrinsically Safe Field PC/PDA
Purpose Allows field adjustment and interrogation
of an analytical system. (mimics remote
PC) Simplifies and uncomplicates maintenance by
standardizing interface. Strengths Commercial
Intrinsically Safe PCs, PDAs available. One
unit may service many field devices. Weaknesses Ha
vent set whether IrDA, Bluetooth or Wi-Fi
wireless. Need standard way to do HMI software.
Oversight needed.
PDA/PC
?
SAM
HMI
5/10
HMI Human Machine Interface
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6. Serial Multi-drop BusEx ia Intrinsically Safe
CANbus
Purpose Simplify maintenance. Vendors can sell
their product with value added software applets
on board their devices. Plug and Play with no
gas test. Strengths Many existing multi-drop
buses and software. DeviceNet has critical mass
in the industry for a bit bus. Low
cost. Weaknesses Confusion and lack of thrust on
identifying an IS product (and cost) to do this
properly.
2/10
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7. MicroClimate Enclosure
Div/Zone 1 GP. A-D, T4
Purpose Provides a practical temperature
controlled microenvironment to handle sampling
and analytical equipment in varied climatic
conditions in the field. Simplifies
design. Strengths All technology available to
implement. Simplifies design by standardizing
on an area classification inside the enclosure
which accounts for any hazardous fluid leakage.
Weaknesses Cooling not addressed at this
time.

6/10
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Announced at Pittcon...
Courtesy of Applied Analytics (also Wilks)
25
The Race to the PipeWhat will it be? An In-ey or
Out-ey? Suggest both...
Analytical sensor (typ.)
tx
tx
SS
Like a thermocouple in situ - inline In-ey
Like a pressure transmitter ex situ -
byline Out-ey
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AcknowledgementsEnd Users

• Dow
• Danny Quevillon
• Reg Hartwig
• Bac Vu (SP76)
• Craig Snook
• Walter Henslee
• Air Products
• Frank Schweighardt
• ChevronTexaco
• D. Nettles/D. Young

• ExxonMobil Chemical
• Dan Podkulski (SP76)
• Jeff Gunnell
• John Cumbus
• Rajko Puzic
• Kelley Bell
• Honeywell
• Kenneth Creasy
• John Mosher
• Ulrich Bonne
• Bob Nickels

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Summary...

• Gen I products achieving traction in industry
• Rapidly moving from the definition stage to the
  project stage on Gen II
• Some technical opportunities...
• White Paper to be submitted to DoE
• Looking for (more) beta Partners