“the best way to predict the future is to create it”
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Transcript of “the best way to predict the future is to create it”
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
NeSSI* – An Enabling Platform for the NeSSI* – An Enabling Platform for the Reduction in TCO** of Process Reduction in TCO** of Process
Analytical SystemsAnalytical Systems(* New Sampling/Sensor Initiative
** Total Cost of Ownership)
“the best way to predict the future is to create it”
IFPAC2008 NeSSI Day29 January 2008
Peter van VuurenPeter van VuurenApplication and Technical Consultant
SpectraSensors Inc.
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
+
TCO$Measurement
value$“Analyzer Credits”
$Bottom-line Value$
TCO
PA/NeSSI Value Proposition
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
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
J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV
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
To Build/Install
To Own
Cost to Build/Install/Own – Major Greenfield Project
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
What to DO?
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensors
• Phase IIIPhase IIIPromote/Apply Micro-Analytical Sensors onPromote/Apply Micro-Analytical Sensors onNeSSI Sampling PlatformNeSSI Sampling Platform
A Three Phase Proposed TCO Optimization Strategy
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pictures Courtesy ExxonMobil Chemical
Intrinsically Safe NeSSI: Modular Smart Sampling System
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Benefits of Smart NeSSI
TCO Benefits of Smart NeSSI:• Push Validation down to Sampling System level • More reliable operation• Improves EQA of analyzer
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Simplified Topographical Diagram of a Process Analytics installation
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Implementation Today)Utilize NeSSI as a Platform for Spectroscopic Sensorspreferably at the Sampling Point (By-line Mode)
• Phase IIIPhase IIIPromote/Apply Micro-Analytical Sensors in By-Promote/Apply Micro-Analytical Sensors in By-Line ModeLine Mode
A Three Phase Proposed TCO Optimization Strategy
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
VO2
Micro- Climate enclosure
The NeSSI Platform = Sampling & Communications Platform
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
VO2
R
Micro- Climate enclosure
TDL
RAMAN
Spectroscopic Sensors with NeSSI as Enabler
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
NeSSI: Enabling Topographical Changes
AN
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
Optograph
TDL
NeSSI: Enabling Topographical Changes
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
Optograph
Other
AN
TDL
NeSSI: Enabling Topographical Changes
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Field LANField LAN
Pro
cess
Pro
cess
Str
eam
Str
eam
SS
AN
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
XX
X
XX
Cost Benefits of TOPOGRAPHICAL Changes
X
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensorspreferably at the Sampling Point (By-line Mode)
• Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode
A Three Phase Proposed TCO Optimization Strategy
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManag
er (SAM)IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
V
Micro- Climate enclosure
Micro- GasAnalyzer(UV, MIR, MS, GC, …
NeSSI & Next Generation Micro Analyzers
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Pro
cess
Pro
cess
Str
eam
Str
eam
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S S I
SAM
Control Room
Instrument Room
Analyzer Shop
P
Optograph
TDL
NeSSI Enabled Spectroscopy/Micro-Analytics Topography
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Understand the NeSSI Platform Concept (Enabler)* Provides a Standardized Micro-Infrastructure Environment
for Deploying micro-analytical sensors/Analyzers* At the same time, allows for IP protection
• IS has to be designed in up front * NeSSI platform can be installed anywhere (Zone 0/1/2 GP) – no costly purge systems
• Design for temperature accommodation/correction
•Design for validation of results (Good Housekeeping Seal)* Use all the analytical process information for validation
•Design for no or little consumables
•Design for mechanical simplicity – no or few moving parts
•Design for extensive but smart diagnostics
Spectroscopic/Micro-Analytics Design Requirements
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of Smart NeSSI:• Push Validation down to Sampling System level • More reliable operation• Improves EQA of analyzer
TCO: The BIG PICTURE of Cost Savings
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of Spectroscopic Analyzers: :• Inherent reliability, low EQA index• No consumables
TCO: The BIG PICTURE of Cost Savings
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Cost to Build/Install Benefits of Spectroscopic Sensors:• Integrate Probe with NeSSI and Move to Sampling Point• Separate Probe and Analyzer Locations (Fiber-coupled)• No Consumables
TCO: The BIG PICTURE of Cost Savings
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up & Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Cost to Build/Install Benefits of Spectroscopic Sensors:• Integrate Probe with NeSSI and Move to Sampling Point• Separate Probe and Analyzer Locations (Fiber-coupled)• No Consumables
TCO: The BIG PICTURE of Cost Savings
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
+
TCO$Measurement
value$“Analyzer Credits”
$Bottom-line Value$
TCO
PA/NeSSI Value Proposition Revisited
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Acknowledgements
• All the Believers (all of you and many others)
• My ex-colleagues at ExxonMobil
• CPAC (adopted NeSSI as a new IURC “business model”)
• Special Thank You to Rob Dubois
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NeSSI – Enabling TCO OptimizationNeSSI – Enabling TCO Optimization 29 January 2008 – IFPAC2008, 29 January 2008 – IFPAC2008, Baltimore MDBaltimore MD
Thank You