NeSSI™ - Real Products at Work Today
Rob Dubois
CPAC Spring Session
Seattle, Washington, USA
May 3, 2004
“the best way to predict the future is to create it”
Presentation Topics
• NeSSI™ Objectives & Roadmap
• Dow Chemical “real-time” activities
• NeSSI™ Hi-Lites 2003/04
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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
– open connectivity architecture for intrinsically safe
transducer communications (e.g. CAN, ProfiBus, 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
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NeSSI™ Development Progress
2006-07
2004-05
Gen III
uAnalytical
Wireless
Today
END USER VALUE
Gen II
Electrical Networked & Smart
Gen I
Mechanical
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Dow NeSSI™ Geographical
Penetration
Terneuzen, Netherlands
Stade, Germany
Fort Saskatchewan, Canada
Freeport, TX
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Schopau, Germany
Plaquemine, LA
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Dow Business Installations
• Employing SP76 substrates and components from
all suppliers in our businesses…
– chlor-vinyl, hydrocarbon, energy, solvents,
glycol/ethylene oxide, styrenics, environment,
polyolefins
• 2004 applications include CEMS* (NOx), flare
monitoring, multi-stream hydrocarbon
measurements, air monitoring, lethal service, on
substrate moisture and oxygen measurements
– 7 applications in operation - 9 in progress
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* CEMS = Continuous Emission Monitoring
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Dow Evaluation
• The NeSSI™-box Experimental Platform:
– Installed in Hydrocarbon Plant, Fort Sask., Canada
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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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Lower Compartment
• Houses substrate under test
• Electrical interface to PLC
• Utilities Interface
• Sample system interface
•Declassified to General Purpose
• X-Purged & Haz. Gas Detector
• allows use of non-certified &
general purpose SP76 comp.
• Temperature Controlled
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SAMjr* Displays – Smart System
Flow Paths
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Control & Monitoring
* SAM = Sensor Actuator Manager
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Learning's from the NeSSI™-box:
4-20 mA not viable for Gen II/III
• labour intensive wiring
• space hungry
• expensive and difficult to
wire for hazardous
electrical areas
“This Dog Don’t Hunt”
Dow Chemical, Fort Saskatchewan
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Contrast: Gen II Proof of Concept
Apparatus (POCA) - Dow, EMCC, Honeywell
Features
- serial connectivity (CANbus)
- 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!
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ARC Advisory Group suggests that 40%
maintenance savings can be achieved by
automation
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CIRCOR µMS System
3
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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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Diversity in Action!
GE/Panametrics
Brooks
Parker
Swagelok
Celerity
Swagelok
Swagelok
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Hoke
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Recent Hi-Lites
(very encouraging news)
•
$10MM DOE award Wireless and Sensing Solutions Advancing
Industrial Efficiency won by Honeywell led consortia. Will provide:
– 12 x NeSSI™ Smart Gas/Liquid prototypes (2004-06)
• Honeywell PHASED™ microGC
• industrial robust wireless
•
NeSSI™ Gen II specification working version release at hand
•
•
•
CPAC SP76 component web site operational
POCA projects demonstrate smart, serial connectivity
intrinsically safe bus (CANopen) project approved
•
ProfiBus established as an Intrinsically Safe candidate
•
– include connectivity to legacy analytical systems
– Pipe to Pixel™ connectivity (harmonization with ConnI spec)
– NIST IEEE 1451.6
NeSSI™ featured in Chemical Engineering Progress Magazine
– “the incredible shrinking sample system” – Dec. ‘03
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NeSSI™ II/III – DOE Project Participants
Participant
Role
Honeywell Laboratory & Sensing &
Control Business
Develop PHASED™ gas composition
microAnalyzer
Honeywell Laboratory & Industrial
Measurement Business
Develop solid state reference electrode
(SSRE)
Honeywell Sensing & Control
Develop and integrate NeSSI™-III
systems
Caviton / U of Illinois
Develop micro discharge detectors
ExxonMobil Chemical
Field test GC w/ NeSSI™ in an ethylene
plant. Also liquid systems.
3
Dow Chemical
Field test NeSSI™ w/GC – gas system
(hydrocarbons) – liquid system (water
treatment) – PHASED microGC
3
DuPont
Field test humidity sensor on NeSSI™
for titanium oxide drying
1
Air Products
Field test PHASED™ and Raman spec. in
gas processing plants
2
Honeywell Specialty Materials
Field test NeSSI™ w/GC for refrigerant
distillation control
1
UOP LLC
Field test NeSSI™ O2 for heater control
1
1
CPAC
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Number of Systems
Portions of this Table Courtesy of Honeywell
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Where are we?
• DOE award will bring Gen II/III
prototypes to market in 2-3 years
• Gen I products widely available
• Increased adoption and acceptance of
NeSSI™ as an industrial platform
• Early Gen II concept proven by POCA
– But…struggle adopting a low cost digital,
intrinsically safe platform for Process
Analytical needs
• Costs – slowly coming into line
• Come – participate - in the NeSSI™
workshop – Thursday, May 6
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Acknowledgments
• Special Thanks
– Peter van Vuuren (ret.)
ExxonMobil Chemical
– Jeff Gunnell (EMCC)
– John Cumbus (EMCC)
– John Mosher (H’well)
– Bob Nickels (H’well)
– Ulrich Bonne (H’well)
– Dave Veltkamp (CPAC)
– Mel Koch (CPAC)
– Rick Ales (Swagelok)
– Robert Sherman (CIRCOR)
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• Special Thanks (Dow)
– D. Quevillon, R. Hartwig, H.
Quartel (Fort Sask.)
– P. Williams, D. Yates, D. Gay,
W. Henslee, C. Snook (Texas)
– G. Timmermans, E. Engelen
(Netherlands)
– Paul Landry (Louisiana)
– Ralf Schade, S. Bach
(Germany)
– M. Dittenhafer, M. Buchmann,
L. Wright (Midland)
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Thanks Peter & all the best in all
your future endeavors!
…last seen hunting big game in South Africa
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