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NeSSI™ - Learning's from Real Life Installations & the Integration Challenge

Rob DuboisISA EXPO

Houston, Texas, USAOctober 5, 2004

“the best way to predict the future is to create it”

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Presentation Outline

• NeSSI Objectives• NeSSI Implementation Strategy (2004)• NeSSI Evaluation Objectives (2004)• Dow Installation Activities• Testing Activities in Dow• The Design & Integration Dilemma

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NeSSI Objectives• Facilitate the acceptance/implementation of...

– modular, miniature & smart sample system technology– based on ANSI/ISA SP76 standard substrate

• Promote the concept of...– field-mounted (By-Line) smart analytical systems

• Lay the groundwork for...Pipe to Pixel™ architecture (GenII)– open connectivity architecture for intrinsically safe

transducer communications (e.g. CAN, ProfiBus, FF, etc.)

– industry standard communication protocols (e.g. Ethernet, OPC, etc.)

• Provide a technology bridge to the process for...– “sensor/lab-on-a-chip” micro-analytical devices (Gen

III)

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Dow Installation Strategy (2004)

• Deploy SP76 substrates and components from allsuppliers in various businesses with NeSSI-net team…– chlor-vinyl, hydrocarbon, energy, solvents,

glycol/ethylene oxide, styrenics, environment, polyolefins

• Target applications: CEMS, flare monitoring, multi-stream hydrocarbon measurements, air monitoring, lethal service, on substrate moisture and oxygen measurements– 7 applications field operated - 9 in progress

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Dow NeSSI-net Geographical Activities

Plaquemine, LAFreeport, TX

Fort Saskatchewan, Canada

Terneuzen, Netherlands

Schopau, Germany

Stade, Germany

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Dow/NeSSI Evaluation Objectives (2004)

• Explore a “Drop Ship” Integration Concept• Fill gaps in modular product offerings by ordering

emerging products• Get a deeper understanding of cost issues,

barriers & design issues• Keep the door open near term for all suppliers• Conduct a comprehensive testing program.• Work with strategic partners to drive prototype

development of smart sensors and actuators as outlined in the CPAC NeSSI Gen II specification

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Challenge: Replace a Complex & Critical Conventional System Using Modular Technology

Hydrocarbon Distribution Service

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Modular Solution…

• Complex System - 3 streams, 2 GC’s, 2 cals.

• New Features– Balanced orifice stream

switching– Diaphragm Valves– No DB&B Valving

• 0.66 cost of conventional system

• 1/5th size of conventional• 6 weeks from order to

operation• delighted customer

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In-Situ Enviro. Project(Impurity in a Vent System)

• New Modular FeaturesOn-board aspiratorAtmospheric reference and block for GC samplingGenie™ Membrane Liquid/Vapour Separator

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On-Board SP76 Moisture AnalyzerAnalytical Diversity in Action!

Celerity

Swagelok

Parker

GE/Panametrics

Hoke

Brooks

SwagelokSwagelok

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Upgraded System• SP76 Rotameters• But Flow Switch issue• Still hybrid…fabrication

CEMS Application

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flowswitch/rotameter

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Dow Detailed Evaluation• The NeSSI-box Experimental Platform:

– Installed in Hydrocarbon Plant

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NeSSI-box Upper Compartment

• Monitor & Control

• Power Supplies

• Programmable Logic Controller (PLC)

• Graphic User Interface

• Wireless Transmitter

• Class I Div.2 Gp C,D

• First Sensor Actuator Manager (SAMjr)

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NeSSI-box Lower Compartment

• Houses substrate under test

• Electrical interface to a PLC

•Declassified to General Purpose• X-Purged & Haz. Gas Detector• allows use of non-certified equip.

• Temperature Controlled

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SAMjr* Displays – Smart System

Control & MonitoringFlow Paths

* SAM = Sensor Actuator Manager

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Dow Test Objectives

• Field Test & conduct team post-evaluation using 4 different systems for approximately 4 weeks (reuse many of the surface mounted components)

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CIRCOR µMS3 System

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Swagelok® MPC System

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Parker Intraflow™ System

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Celerity CrossFlo™ System

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Learning's from the NeSSI-box:4-20 mA not viable for Gen II/III

• labor intensive wiring• space hungry• expensive and difficult to wire

for hazardous electrical areas• need for a Sensor Actuator

Manager to unload I/O• need for a serial bus

Dow Chemical, Fort Saskatchewan“This Dog Don’t Hunt”

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Gen II Proof of Concept Apparatus (POCA) -Dow, EMCC, UOP, Honeywell

Features- serial connectivity - PC controlled – smart features- simple plug and play M8 connector

Benefits - predict failures before they happen- remote operation in hostile locations- decrease maintenance- increase confidence

GET SMART!

ARC Advisory Group suggests that 40%maintenance savings can be achieved by

automation

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Tighter Integration In Progress

• Recommended Improvements– Lower cost interconnections– Substrate panel fits

enclosure mtg. system– Modular entries for tubing

and heat tracing– More elegant integration of

heating system into the enclosure

– Enclosure, heating products & tagging included in the software configuration package

Courtesy of Swagelok

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An Ideal Gen I System• No tube bending or skilled assembly• A modular enclosure system• Low cost (Div 1) F & P switch/transmitter which operates

either vertical & horizontal (+/- 5%)• minimal non-modular components• Highly flexible in both x and y directions• Ease of End User reconfiguration• Ease of design & assembly• Low part count & light weight• Better visibility of flow paths by means of indicating

sensors, colour coding, valve position indicators

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Integration Dilemma

• With a software configurator who designs?– end user, analyzer manufacturer, sample system

manufacturer or system integrator• Assuming unskilled labour to build who

assembles and tests?– end user, analyzer manufacturer, sample system

manufacturer or system integrator

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Where are we today?• Gen I products widely available

– approximately 80 components• Increased adoption and acceptance of

NeSSI™ as an industrial platform• Early Gen II “smart” concept

demonstrated– DOE consortium will drive a standard

• Gen I Costs – slowly coming into line– typically x1.2 conventional

• Need more work with the drop-ship concept and integration into an enclosure

• What is better? A Lego® block or Tinker Toy approach?

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Acknowledgements• External

– P. van Vuuren (ret.) (EMCC)– J. Gunnell (EMCC)– J. Cumbus (EMCC)– J. Mosher (Honeywell)– U. Bonne (Honeywell)– D. Veltkamp (CPAC)– M. Koch (CPAC)– R. Ales (Swagelok)– R. Sherman (CIRCOR)– B. Keen (CIRCOR)– M. Cohn (UOP)– D. Podkulski (EMCC)

• Dow Chemical– D. Quevillon, R. Hartwig (ret.), H.

Quartel, H. Woo, C. Jones, M. Fairhurst

– P. Williams, D. Yates, D. Gay, C. Snook, D. Mack, A. Faulk

– G. Timmermans, E. Engelen– P. Landry– R. Schade, S. Bach– M. Dittenhafer