A REVIEW OF PROCESS ANALYTICS IN THE YEAR 2012

(selected highlights from IFPAC 2002 presentation)

Rob Dubois Jeff Gunnell Dow Chemical ExxonMobil

Chemical

In the years up to 2012 the demand for more difficult measurements

increased Matched by growth in new Process

Analytical technologies...• nanotech TDL lab-on-a-chip

microGC NMR spectrometer-on-chip eNose CRD MS-on-a-chip

… but the old technologies remained...• GC MS FT-(N)IR

CEMS water

… and it became impossible for one person to provide high level support such a wide range of techniques

Computing developments which we used...

PDAs became a standard tool• wireless connectivity• human-machine interface for many devices• used with GPS to pinpoint equipment

Wearable PCs became common

• Heads-up displays and data entry improved– voice entry of data– voice recognition “action” commands

The web ruled...• browser access to everything from everywhere

Security became better and easier• retinal recognition

ConnI Architecture - 4 domains

Level 2 LAN = Field LAN

Level 3 LAN

INFORMATION D0MAIN

AnLAN

PROCESS CONTROL DOMAIN

c-LAN

ENTERPRISE DOMAIN

MEASUREMENT DOMAIN

SAM

eSAM

Level 1 SensorBus (CAN)

Level 4 Enterprise LAN

- Highbandwidth data pipelines

- Traffic routers send data to the “need to know” domains

Courtesy of P. van Vuuren and R.J. O’Reilly

Predictive maintenance replaces planned

• Intelligent diagnostics watch analyser systems...all the time...

• ‘I need help’ flags are sent in real time to wireless Personal Digital Assistants (PDAs)

………………

A typical troubleshooting task for a technician starts when her PDA buzzes and indicates a possible problem...

Please help me...

A smart application in an analyser system has detected something strange - relevant information is sent out...

The technician taps down for more info...

Background data and recent history is sent

Key sensor data have been monitored and unusual conditions have been detected...

The technician taps down for more details...

Recent history is shown graphically

The technician starts to think about the cause of the problem…

…and sees the problem…clearly...

A pinched valve is quickly discovered and the problem resolved…pronto!

Appl-I: Smart applications

Functions are part of a shell which is used by all analyser vendors…(much like Excel)

•monitoring of key parameters• flow, pressure, temperature…as well as analytical

•self-validation, both continuous and periodic

•intelligent statistical tools identify abnormal events

•users notified when trouble is suspected

•data presented in a user-friendly way

Excel is a registered trademark of Microsoft Corp.

The technician takes her toolkit, including her wearable PC, out to the

field...

Courtesy of Oxford Technologies

She has access to an on-line manual

The wearable PC means that useful information is readily available:

There are up-to-date descriptions of tasks

Video clips* show how jobs are done.* Video Courtesy of Andy Jopek

ScAN microSpectrometer

Web-based manual

Model : 42 General manualTag : NA733 Specific manual

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Section 4.3 Valve maintenance

h h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h

h h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h

h h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h

h h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h h h h h h hh h h h h h h h h h h h h

Valve maintenance video clip

Links to other systems facilitate work

Equipment parts lists are linked to warehousing - both in house and external.

She identifies spares which she needs and orders them as she works using the manual and warehousing tool

ScAN microSpectrometer

Web-based manual

Model : 42 General manualTag : NA733 Specific manual

__________________________________________________________________________

Section 4.8 Spares

h h h h h h h h h h h h h h h hh h h h h h h h h h hh h h h h h h h h h h h h h hh h h h h h h h hh h h h h h h h h h h h h

Record keeping is built in

Intelligent checklists and voice entry make record keeping easy:

The manual helps her fill in a work record - using voice data entry

ScAN microSpectrometer

Web-based manual

Model : 42 General manualTag : NA733 Specific manual

__________________________________________________________________________

Section 4.3 Valve maintenance checklist

Say "Voice entry" and "your name "

h h h h h h h h h h h h h h h hh h h h h h h OK

h h h h h h h h h h h h h h h hh h h OK

h h h h h h h h h h h h h h h hh h h h h

h h h h h h h h h h h

h h h h h h h h h h h h h h h hh h h h h h h h h h h h h

Say "Comments"

Wizards help with many tasks

On completion she runs the smart health check wizard

She requests two day data watch so she can personally check that everything is OK. A maintenance encounter is booked into her calendar

ScAN microSpectrometer

Web-based manual

Model : 42 General manualTag : NA733 Specific manual

__________________________________________________________________________

Section 5.1 Auto check wizard

Say "Run autocheck" and select options

h h h h h h h h h h h h h h h hh h h h h h h Yes

h h h h h h h h h h hYes

h h h h h h h h h h h h h h h hh h h h h h h h h h h h h No

Section 5.1 Data watch wizard

Say "Run data watch" and select options

h h h h h h h h h h h h h h hYes

h h h h h h h h h h h hYes

h h h h h h h h h h h h h hNo

h h h h h h h h h h hYes

Key points: Technician level

Technicians in plants retain the prime responsibility of maintaining analyser systems

Human knowledge, skills, thought processes are needed more than ever

Logic and intelligence in machines help technicians to use their human skills better• real-time health checks of systems

– focus on predictive maintenance• data presentation helps troubleshooting• …and bureaucracy is unburdened

Key points: Engineer level

Highly complex analyser technologies abound

Sites are spread all around the globe

Technical support and troubleshooting is a team game• collaboration tools facilitate virtual teams• support round the clock, round the globe• changes in

– responsibility– behaviour– relationships

This is life in 2012 - how did we get here?

NeSSI came through:• modular sample systems• integrated with analysers sensors• in smart, field mounted units

ConnI • delivered an architecture which linked

everything together

Appl-I• provided a common application shell

…and collaboration delivered benefits for all

Smart

artificially intelligent

analysers