NeSSI...New Sampling/Sensor Initiative (NeSSI) CPA : May 7, 2 0 1 CPAC as a Multi-Purpose PA Forum...
Transcript of NeSSI...New Sampling/Sensor Initiative (NeSSI) CPA : May 7, 2 0 1 CPAC as a Multi-Purpose PA Forum...
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
NeSSINeSSI
(Ne(Neww SSampling/ampling/SSensorensor IInitiativenitiative))
2001 Spring Sponsor Meeting
Center for Process Analytical Chemistry
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
AgendaAgenda
•• Status and UpdateStatus and Update -- PV2PV2Introduction (Why CPAC)Introduction (Why CPAC)What is NeSSIWhat is NeSSIWhat has happened/is happeningWhat has happened/is happening
•• NeSSI Team GoalsNeSSI Team Goals -- RduboisRdubois
•• BluetoothBluetooth -- Mike Horton (Crossbow)Mike Horton (Crossbow)
•• ConnectivityConnectivity -- PV2PV2
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
CPAC as a MultiCPAC as a Multi--Purpose PA ForumPurpose PA Forum
•• Legal Umbrella for Sponsors to MeetLegal Umbrella for Sponsors to Meet
R&D: Long Range / Short RangeR&D: Long Range / Short Range
Information Clearing HouseInformation Clearing House
Enabling Mechanism to Address Other Common NeedsEnabling Mechanism to Address Other Common Needs
•• Focus Groups: Forum toFocus Groups: Forum to
Review R&D ProgramsReview R&D Programs
Present Industry Present Industry CommonCommon Needs Needs -- RFPRFP
Address Other Industry Common NeedsAddress Other Industry Common NeedsFieldbusFieldbus Datalink Specification Datalink Specification -- DoneDoneNeSSI /MicroNeSSI /Micro--Reactor Analytics Reactor Analytics -- In progressIn progressChemometrics OnChemometrics On--line/Connectivity line/Connectivity -- Future?Future?
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
What is NeSSI?What is NeSSI?
•• Adapt Modular Surface Mount Technology from the SEMI Adapt Modular Surface Mount Technology from the SEMI Industry to Sampling System Design in the Chemical Industry Industry to Sampling System Design in the Chemical Industry
•• Driving Forces for ChangeDriving Forces for Change
Cost to Build/ Cost of OwnershipCost to Build/ Cost of OwnershipTraditional Sampling System Designs Same for Last 20+ Years Traditional Sampling System Designs Same for Last 20+ Years Weak Link in Overall Analyzer ReliabilityWeak Link in Overall Analyzer Reliability
Integrate Other Sensors (Smart Sampling System)Integrate Other Sensors (Smart Sampling System)SampleSample ValidationValidation
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
What is NeSSI?What is NeSSI?
Picture courtesy Swagelok®
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
What is NeSSI?What is NeSSI?
New 5 Channel Design by Parker
Picture courtesy Parker
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
What is NeSSI? What is NeSSI? -- It is SMARTIt is SMART
VTP
A
SignalIn/Outto ACSensor
AnalyticalManager
(SAM)
Signal Wires Only
Shared Power Bus
PLegend:
Pressure Sensor Temp SensorValve Analytical Sensor
VA
T
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
NeSSI Vision (Now)NeSSI Vision (Now)
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
NeSSI Vision (Next Step)NeSSI Vision (Next Step)
VTP
A
Signalto ACSensor
AnalyticalManager(SAM)
Signal Wires Only
Shared Power Bus
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Background and Chronology of Background and Chronology of NeSSINeSSI ActivitiesActivities
•• Oil&Petrochemical (O&P) Focus Group May 1999Oil&Petrochemical (O&P) Focus Group May 1999
Identified Sampling Systems as Common Area Of InterestIdentified Sampling Systems as Common Area Of Interest
Sponsored Tutorial for Nov99 Sponsor MeetingSponsored Tutorial for Nov99 Sponsor Meeting
•• Tutorial Nov99 CPAC MeetingTutorial Nov99 CPAC Meeting
Background/Reasons for InterestBackground/Reasons for Interest
Presentations by Suppliers/ End UsersPresentations by Suppliers/ End Users
•• Participation in IFPAC2000 MeetingParticipation in IFPAC2000 Meeting
Plenary/General Papers (SS Enjoyed High Profile)Plenary/General Papers (SS Enjoyed High Profile)
WorkshopWorkshop
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Background and Chronology of Background and Chronology of NeSSINeSSI Activities (Activities (cnt’dcnt’d))
•• AdAd--hoc O&P Meeting @ Pittcon2000hoc O&P Meeting @ Pittcon2000
EndEnd--users Discuss Initial Target Designsusers Discuss Initial Target Designs
•• CPAC2000 Spring MeetingCPAC2000 Spring Meeting
Formed SS Focus GroupFormed SS Focus Group
Defined Information Package (basis of RFP)Defined Information Package (basis of RFP)
•• Distributed Request for Proposal (RFP) (July 2000)Distributed Request for Proposal (RFP) (July 2000)
Clarification Meeting at ISAEXPO2000 (40 attendees)Clarification Meeting at ISAEXPO2000 (40 attendees)
Received Proposals/Feedback from Swagelok, Parker,Received Proposals/Feedback from Swagelok, Parker,AutoflowAutoflow,, ABB Analytical, SAAI, Rosemount AnalyticalABB Analytical, SAAI, Rosemount Analytical
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Background and Chronology of Background and Chronology of NeSSINeSSI Activities (Activities (cnt’dcnt’d))
•• CPAC2000 Fall MeetingCPAC2000 Fall Meeting
Previewed Previewed SwagelokSwagelok/Parker Proposals/Parker Proposals
MicroMicro--Reactor Proposal (MicroReactor Proposal (Micro--Analytics)Analytics)
Planning (CD Deliverable, IFPAC2001, Planning (CD Deliverable, IFPAC2001, PittconPittcon etc.)etc.)
•• IFPAC2001IFPAC2001
Sampling System Session at IFPAC2001Sampling System Session at IFPAC2001Review and Summary of NeSSI Effort (RD/PV2)Review and Summary of NeSSI Effort (RD/PV2)Papers by Swagelok, Parker, Autoflow, ABB, RosemountPapers by Swagelok, Parker, Autoflow, ABB, RosemountAdAd--hoc Meeting (Standing Room only Interest)hoc Meeting (Standing Room only Interest)
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Background and Chronology of Background and Chronology of NeSSINeSSI Activities (Activities (cnt’dcnt’d))
•• Pittcon2000 MeetingPittcon2000 Meeting
NeSSI AdNeSSI Ad--hoc Forum Meetinghoc Forum MeetingConfirmed viability of NeSSI designsConfirmed viability of NeSSI designsIntroduced the Role of Wireless (Introduced the Role of Wireless (BluetoothBluetooth))Focus on Special Issues/ProblemsFocus on Special Issues/Problems
SwagelokSwagelok, Parker, ABB Highlighted Special Problems, Parker, ABB Highlighted Special Problems4 4 SubteamsSubteams (Intrinsic Safety, Component availability etc.)(Intrinsic Safety, Component availability etc.)
•• Miscellaneous/In the PipelineMiscellaneous/In the Pipeline
Proposal for Additional ResourceProposal for Additional ResourceJim Jim Tatera Tatera (retiree from Dow Corning)(retiree from Dow Corning)PartPart--time to lead key subtime to lead key sub--team activitiesteam activitiesDeliverables/schedule definedDeliverables/schedule definedReport at next CPAC Meeting (Nov)Report at next CPAC Meeting (Nov)More details of proposal etc. at SSFG (Wednesday)More details of proposal etc. at SSFG (Wednesday)
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Background and Chronology of Background and Chronology of NeSSINeSSI Activities (Activities (cnt’dcnt’d))
•• Miscellaneous/In the Pipeline (Miscellaneous/In the Pipeline (cnt’dcnt’d))
Testing/EvaluationTesting/EvaluationTwo Systems in Design Phase (EMCC)Two Systems in Design Phase (EMCC)Rosemount Laboratory Tests Completed (see SSFG)Rosemount Laboratory Tests Completed (see SSFG)
Test System AvailableTest System AvailableMore Participation by EndMore Participation by End--users neededusers needed
NeSSI Deliverable CompletedNeSSI Deliverable CompletedCD IssuedCD IssuedNeSSI Website UpNeSSI Website Up--toto--datedate
NeSSI Promotional effortsNeSSI Promotional effortsDistribution List > 150 namesDistribution List > 150 namesPresent Hour Tutorial at ISA2001 Meeting (Sept01)Present Hour Tutorial at ISA2001 Meeting (Sept01)Globalization effortsGlobalization efforts
CPACT Presentation Apr01 (high interest, additional names)CPACT Presentation Apr01 (high interest, additional names)Paper tentatively accepted for INTERMAC Meeting (Nov01)Paper tentatively accepted for INTERMAC Meeting (Nov01)Extending SP76 to IEC standard Extending SP76 to IEC standard
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
AcknowledgementsAcknowledgements• Dow Ron O’Reily/Brian Worthington/Walter Henslee
• Dow Corning Jim Tatera�/Gary Bokerman�
• DuPont Joe Adrisani, Chuck Miller, Bob Bucher, BruceJohnson
• Rohm&Haas Joe Sung
• Honeywell Ken Creasy, Ullrich Bonne, Troy Francisco
• ExxonMobil Dan Podkulski/Rajko Puzic/PaulHromadka/John Cumbus/Jeff Gunnell
• Swagelok Dave Simko/Rick Ales & Colleagues
• Parker Steve Doe, Frank Ruiz & Colleagues
• Rosemount John Gajewski & Colleagues
• ThermoOnix Jerry Evans
• CPAC Lloyd Burgess/Larry Ricker
• Others ABB, Panametrics, AAI, Sterling Chemicals
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
…. and they lived happily ever after…. and they lived happily ever after
FINIFINI
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
O&P Focus Group Meeting May 99O&P Focus Group Meeting May 99
• Recognized Modular Sampling System Efforts in Semi Conductor Industry (Standard)
• Vendors like Autoflow, A+, Swagelok etc. promoted modular designs
• Recognized that current implementations of sample systems designs have not changed for many years
• CPAC has promoted Versatile Micro Analytical Systems (VMAS) as abasis for future micro-analytical techniques
• O&P decided to sponsor a SSISSS (Small Smart Integrated Sensor and Sampling System) Tutorial at CPAC Nov Meeting
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Nov99 CPAC SSISSS TutorialNov99 CPAC SSISSS Tutorial
• ExxonMobil/DuPont Provided Introduction to Tutorial
Validation of Sample System Performance
Integration of Sensor with Sampling System
• Four Suppliers of Sampling/Analyzer Systems Participated in Tutorial:
A+, Autoflow, Swagelok, Rosemount
Many components commercially Available
GCX example of self-contained miniaturized GC (GC on a pole)
• Recognition
Modular Sampling System can be a platform to integrate VMAS
Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Driving Forces for ChangeDriving Forces for Change
• Reduce Cost of Ownership
Non Recurring Costs = Cost to Build
Operating Cost
• Data Validation (Fit for Use)
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
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ControllerController
Fiel
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NFi
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Integration of Sample System and SensorsIntegration of Sample System and Sensors
Sam
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Level 0Level 0 Level 1Level 1
Pro
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All System All System Components Components in Contact in Contact with Sample with Sample including the including the SensorsSensors
All Additional Electronic All Additional Electronic and Computing and Computing Components Required Components Required to Generate Analytical to Generate Analytical ResultResult
Mainly a Trust ConfigurationMainly a Trust ConfigurationNow a Trust & Verify ConfigurationNow a Trust & Verify Configuration
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Inte
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ampl
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Level 0 Subsystem IntegrationLevel 0 Subsystem Integration
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Level 0Level 0
Pro
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Purpose:
Prepare and Verify a Representative Sample (Compatible with Analyzer Sensor)
Opportunity:
Packaging as an Integrated Sensor and Sampling System
• Size
• Cost
Issues:
• Size
• Standardization
• VMAS
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
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Separation or Integration of Level 0/1 SubsystemsSeparation or Integration of Level 0/1 Subsystems
Level 0Level 0 Level 1Level 1
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Objective:Objective:
Close to Close to Sample TapSample Tap
Options:Options:
•• RemoteRemote
•• Separate but CloseSeparate but Close
•• IntegratedIntegrated
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Integrated Sampling/Sensor/Controller SystemIntegrated Sampling/Sensor/Controller System
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ControllerController
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Integration of Level 0/1 SubsystemsIntegration of Level 0/1 Subsystems
Level 0Level 0 Level 1Level 1
Pro
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Pro
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$$$$
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Nov99 CPAC SSISSS TutorialNov99 CPAC SSISSS Tutorial
• ExxonMobil/DuPont Provided Introduction to Tutorial
Validation of Sample System Performance
Integration of Sensor with Sampling System
• Four Suppliers of Sampling/Analyzer Systems Participated in Tutorial:
A+, Autoflow, Swagelok, Rosemount
Many components commercially Available
GCX example of self-contained miniaturized GC (GC on a pole)
• Recognition
Modular Sampling System can be a platform to integrate VMAS
Bridge between Process Sample (Macro world) Micro Fluidics Sensors/Analyzers
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Nov99 CPAC SSISSS Tutorial (Vendor Presentations)Nov99 CPAC SSISSS Tutorial (Vendor Presentations)
Autoflow
RosemountA+
Swagelok
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Nov99 CPAC SSISSS TutorialNov99 CPAC SSISSS Tutorial
• ExxonMobil/DuPont Provided Introduction to Tutorial
Validation of Sample System Performance
Integration of Sensor with Sampling System
• Four Suppliers of Sampling/Analyzer Systems Participated in Tutorial:
A+, Autoflow, Swagelok, Rosemount
Many components commercially Available
GCX example of self-contained miniaturized GC (GC on a pole)
• Recognition
Modular Sampling System can be a platform to integrate VMAS
Bridge between Process Sample (Macro world) and Micro Fluidics Sensors/Analyzers
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IFPAC2000IFPAC2000
• ExxonMobil Presented Plenary Paper Promoting SSISSS
Sample System Infrastructure accounts for 50+% Cost to Build
Proposed Conceptual Design for SSISSS
Highlighted sensor and analyzer transmitter configurations
• Sampling System Session
Presentations by A+, Autoflow, etc.
Sampling Systems enjoyed a High Profile
• CPAC/ExxonMobil sponsored Workshop
Confirmed high interest in Modular Sampling System
Provided input for the ISA Standardization effort
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
TODAY’S COST OF BUILDTODAY’S COST OF BUILD
For a major For a major greenfieldgreenfield projectproject
NumberK USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
TODAY’S COST OF OWNERSHIPTODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IMAGINE THE FUTUREIMAGINE THE FUTURE
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Level 0Level 0 Level 1Level 1
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New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IMAGINE THE FUTUREIMAGINE THE FUTURE
FLAN (Optical Fiber)
Sensor/Signal Bus
IA Controller(ASIC) & Interface
Module
Original Picture of Gas Delivery System courtesy Valin Corporation;
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Sensor = Moisture Probe
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IMAGINE THE FUTUREIMAGINE THE FUTURE
A
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Sensor = RAMAN Probe
Interface
Module
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IFPAC2000IFPAC2000
• ExxonMobil Presented Plenary Paper Promoting SSISSS
Sample System Infrastructure accounts for 50+% Cost to Build
Proposed Conceptual Design fro SSISSS
Highlighted sensor and analyzer transmitter configurations
• Sampling System Session
Presentations by A+, Autoflow, etc.
Sampling Systems enjoyed a High Profile
• CPAC/ExxonMobil sponsored Workshop
Confirmed high interest in Modular Sampling System
Provided input for the ISA Standardization effort
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
IFPAC2000IFPAC2000
• ExxonMobil Presented Plenary Paper Promoting SSISSS
Sample System Infrastructure accounts for 50+% Cost to Build
Proposed Conceptual Design fro SSISSS
Highlighted sensor and analyzer transmitter configurations
• Sampling System Session
Presentations by A+, Autoflow, etc.
Sampling Systems enjoyed a High Profile
• CPAC/ExxonMobil sponsored Workshop
Confirmed high interest in Modular Sampling System
Provided input for the ISA Standardization effort
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
Pittcon2000 (New Orleans)Pittcon2000 (New Orleans)
• O&P Ad-Hoc Meeting of Sponsor End-users
DuPont, Dow, Dow-Corning, CPAC, Rohm&Haas, ExxonMobil
• Main Goal: Identify Typical Sample System Designs as Candidates for Modular Design
Reviewed some typical gas/liquid sample System Designs
Rob DuBois Presented a Modular Component/Service Matrix
• Discussed next steps
Present Sample System Data at May CPAC Meeting
Next Step is to Open Up Discussion (3rd parties)
Leverage ISA Meeting in New Orleans (Aug00)
• Role of CPAC in Facilitating Development/Testing of a Prototype System
Larry Ricker/Lloyd Burgess to Present Proposal
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
StatusStatus• CPAC Meeting May 1999 Done
O&P Identified Modular Sampling Systems
• CPAC Meeting Nov 1999 Done
O&P Sponsored Tutorial
• IFPAC2000 Meeting Done
Plenary Presentation Promoted SSISS
Session on Modular Sampling Systems
CPAC Sponsored Workshop
• Pittcon2000 Done
Ad-hoc O&P Meeting
Propose Candidate Sampling System Descriptions
• CPAC Meeting May 2000 TBD
New Sampling/Sensor Initiative (NeSSI)New Sampling/Sensor Initiative (NeSSI) CPAC: May 7, 2001
What is Next?What is Next?
• CPAC Meeting May 2000 (Sampling Focus Group – Wednesday)
Review and Agree on Sample System Information Package
Involvement of 3rd parties
How do we distribute package (Distribution List, Meeting?)
Expectations for proposals from Suppliers (Paper designs?)
Joint Effort with ISA (Meeting in Aug, New Orleans)
Evaluation of Designs - Recommendation
• Prototype design/manufacturing/testing at CPAC
Larry Ricker/Lloyd Burgess proposal
• Program to Evaluate Test Platforms fro Micro Analytical Devices
CPAC Proposal – Lloyd Burgess