Process Analyzer Connectivity Initiative
(ConnI)
A Status Report
Ron O’Reilly
Dow Chemical Canada Inc.
Fort Saskatchewan, AB
Canada
Process Analyzer System Connectivity (= ConnI)
Peter van Vuuren
ExxonMobil Chemical
Baytown, Texas
USA
Topics
 Functional Domain and Connectivity Model for
Process Analyzer System - Overview
 Measurement Domain
 DCS Domain
 Model - O&M Domain
 Model - Enterprise Model
 A Summary
Process Analyzer System Connectivity (= ConnI)
Connectivity Role
ConnI recognizes that a process analyzer is not a standalone entity but has only added value if through
connectivity it is an integral component of several
related system domains:
– Measurement domain: integrated with other analyzers
– DCS domain: DCS is its primary customer
– Analyzer Operations/Maintenance domain: Support system
for reliable operation and effective user interfaces
– Enterprise domain: Must allow remote access and support
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain* Model for Process Analyzer System - Overview
* Functional Domains NOT Computer Domains
Enterprise
Level 4 Enterprise LAN
Domain
Safety
L3
Level 3 LAN
Control/
Optimization
DCS
Domain
L4
c-LAN
AnLAN
O&M
Domain
L2
Environmental
Level 2 LAN = Field LAN
Primary Data Path >
Requires Maximum
Integrity/Reliability
Secondary Data Path >
Requires High
Integrity/Reliability

eSAM

Measurement Data
(Validated)
Status/Change Info
Limited Control
Functions
SAM
Level 1 Sensor
Bus (CAN)
Measurement
Process Analyzer System Connectivity (= ConnI)
L1
DCS Data +:
Raw Data/Calibration/SQC
Diagnostics/Alarms
Domain
Configuration Data
All Control Functions
L0
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain
Ent
DCS
O&M
eSAM


SAM
Level 1
Bus (CAN)
Modular Smart Sampling System(NeSSI)
Measurement
• Sample, Condition and Validate Process Sample
• Multiple Sensors (may be Physical and Analytical)
eSAM

• Level 1 Sensor Bus (CAN -based SDS or DeviceNet)
Small Footprint
Configuration via Flash Memory
Existing and Mature Technology - Inexpensive Components
CAN-based communications already in use by Major
Suppliers

• Future
Goal is Wireless Communications (NeSSI III)
SAM
Level 1 Sensor
Bus (CAN)
Measurement
Domain
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain
Ent
Sensor/Actuator Manager (SAM)
DCS
O&M
eSAM

• SAM is a Sampling System Controller
Manages all Sampling System Functions and Diagnostics
Collects and Validate Sensor Information (Analytical
Sensor information Converted by Analyzer Controller)

SAM
• Examples of Functions:
Responsible for Stream Sequencing (Valve Actuation)
Control Sampling System Heating/Cooling
Measures all physical Properties of Sample (e.g.. T,P,F)
Collects Maintenance & Diagnostic Information
(SAM is key to successful Preventative Maintenance
System)
Level 1
Bus (CAN)
Measurement
• SAM can be a Stand-alone Level 2 Controller Device
communicating via the Level 2 LAN with it’s Host
Controller
eSAM

Level 1 Sensor
Bus (CAN)

SAM
• SAM Functionality can be embedded in an Analyzer
Controller (e.g. GC Controller)
• Standardized Communications between Sensors and
SAM of critical importance if NeSSI Sampling systems
are to be successful
• Connectivity Issues:
CAN-based specification (2002/2003)
SAM/Host Analyzer Controller Functional Specification
• SAM is likely a WIN CE device which can also support
OPC Communications between SAM and Host Controller
Measurement
Domain
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain
Ent
Analyzer Controller
DCS
• Responsible for the Measurement and Overall
Validation of Result(s)
Support and Validation of Sampling System via SAM
(Embedded or Remote)
O&M
eSAM


SAM
• Update DCS System via OPC Gateway Server or other
Datalink Types (OPC Server may be Embedded)
Level 1
Bus (CAN)
Measurement
• Update Short Term Data Server
• Support User Interface at Workstations (Multiple User
Interfaces from Different Analyzer Controllers must coexist)
• Scalable Platforms (WinCE to Windows XP/2000)
eSAM

Level 1 Sensor
Bus (CAN)
Measurement
Domain
Process Analyzer System Connectivity (= ConnI)

SAM
• Connectivity Issues:
Protocol for Updating OPC DCS Gateway Server
User Interface Communications Protocols
Database Server Protocols
Proposed Connectivity Model for Measurement Domain
Diversity of Analyzer Devices that
makes up the Measurement Domain
FTNIR
Raman
Anlzr Level 2 FLAN
Spectral Fiber
Fiber -optic link
Fiber -optic link
(Private IP Addresses)
GP Area - Control/Analyzer/RIB Room
Field
Anlzr Level 2 FLAN
Analyzer
Control

SAM
SAM
GC
Sampling Systems
Process Analyzer System Connectivity (= ConnI)

SAM
GC
GC

GC

GC
Anlzr Level 1
Sensor Bus (CAN)
Embedded
SAM
ConnI Goals
• Define the Physical Layers for Level 1/2/3
* Level 1 : CAN bus
* Level 2/3:
Ethernet TCP/IP (Industrial)
• Identify Compatible High-level Communication Protocols
(peaceful co-existence on same workstations, servers etc.)
* OPC
* HTTP
* Fieldbus etc.
• Define Functional requirements for Data Server, Workstations
and Long Term Historian
• Define Requirements for Analyzer-DCS Data Link Interface
* Draft Specification posted on CPAC ConnI website
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - DCS Domain
Ent
DCS
O&M

eSAM

SAM
Long
Term
Historian
Level 1
Bus (CAN)
Measurement
DCS
Domain
Embedded
DCS OPC
Client
(EDC)
OPC Client
Bridge
(CB)
Analyzer
Gateway
OPC Server
(AGS)
FTNIR
DCS OPC
Server
Not showing Operator Consoles
Process Analyzer System Connectivity (= ConnI)
Embedded
Analyzer
OPC Server
(AES)
Hierarchical/Domain Model for Process Analyzer System - DCS Domain
Ent
DCS
• How do we “stitch these together?
* Ethernet & TCP/IP
O&M
• What information do we exchange?
* Draft OPC DCS/Analyzer Datalink
* Soliciting Comments
* Soliciting Endorsements
* Testing Underway or Planned with
Several Process Control and
Process Analyzer Vendors

eSAM

SAM
Level 1
Bus (CAN)
Measurement
DCS
Domain
EDC
FTNIR
CB
AGS
Not showing Operator Consoles
Process Analyzer System Connectivity (= ConnI)
AES
Hierarchical/Domain Model for Process Analyzer System - DCS Domain
Ent
DCS Analyzer OPC Client
DCS
• DCS Analyzer OPC Client:
* Setup and Configuration based on Analyzer OPC
Server Database
* Should be based on OPC Standard 2.0
* DCS Client linked to DCS Specific OPC Server
* Communication with OPC Analyzer Server via
Ethernet TCP/IP
O&M
eSAM


SAM
Level 1
Bus (CAN)
Measurement
• Configuration of OPC Client should be based on using
standard OPC 2.0 Configuration Software e.g.,
“subscribing” to the individual analyzer OPC data elements
such as “Analyzer Status”
DCS
Domain
• The DCS Client can be implemented as:
* Embedded DCS Client (integrated with the DCS OPC
Server and supported by the DCS Supplier)
* Client Bridge i.e., “Double Headed Client”
- Presents itself as a Client to the Analyzer OPC Server
- Presents itself as a Client to the DCS OPC Analyzer
Server
- Typically provided/supported by a Third Party
EDC
FTNIR
CB
AGS
AES
Not showing Operator Consoles
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - DCS Domain
Ent
DCS
O&M
eSAM

Analyzer OPC Server
• Implemented either as a “Gateway” (AGS) or
Embedded Server (AES)

SAM
Level 1
Bus (CAN)
• TCP/IP - OPC is currently the protocol of choice for
communications between computers in the DCS
World - in process of adapting it as the basis for an
Analyzer/DCS Datalink
Measurement
DCS
• Progress:
Preliminary Specification Developed:
* Client/Server Topologies
* Addressing Scheme
* OPC Server Content
Summarized Later
Domain
EDC
FTNIR
CB
AGS
AES
Not showing Operator Consoles
Process Analyzer System Connectivity (= ConnI)
• Status/Plans:
* Draft specification posted on CPAC ConnI
website 2Q02
* Complete Specification in 1Q03 as part of
ConnI effort
* Testing to continue 3Q02 - 2Q03
(Several Control System/Analyzer Vendors)
* Solicit endorsements from end-users, analyzers
suppliers and DCS vendors
Hierarchical/Domain Model for Process Analyzer System - DCS Domain
Ent
DCS/Analyzer OPC Datalink Specification
DCS
• Draft Specification posted for comments on CPAC ConnI
website
O&M
eSAM

• Complete Final Specification in 1Q03 as part of ConnI
effort

SAM
• Continue testing with several Process Control/Process
Analyzer Vendors
Level 1
Bus (CAN)
Measurement
• Solicit endorsements from other analyzer and DCS
vendors
• Specification Addresses Three Key Functions:
DCS
* Client/Server Topologies
* Addressing Scheme
* OPC Server Content/Failure Recovery
Domain
EDC
FTNIR
CB
AGS
AES
Not showing Operator Consoles
Process Analyzer System Connectivity (= ConnI)
OPC Datalink Specification - Analyzer Operations as Event Driven Functions
Event
1
2
3
4
5
6
7
8
9
10
11
12
Description
Specification allows for Bidirectional control:
Initialization
during startup of analyzer server(s)
DCS Console Operator can Request Status Change e.g.
Initialization
of DCS
database after a DCS restart
* Start/Stop
an Analyzer
* Enable/Bypass a Stream
Completion
of a process stream analysis
* Change the Sequence of Streams to be Analyzed
Completion of a validation stream analysis (optional)
Completion of a calibration stream analysis (optional)
Analyzer State Change
Control/Application Program (CAP) State Change
Stream State Change
Stream Sequence/Frequency Change
AGS loses Communications with a remote analyzer
AGS/AES lose Communications with CB/EDC
CB/EDC lose communications with AGS/AES
Initialization
Data
Process Analyzer System Connectivity (= ConnI)
Status Change
Fault Recovery
Summary of Possible Analyzer Controller and Stream Configurations
Configuration Types
Controller
CAP
Examples
1
1
Photometer
Simple GC
Single Controller
Single CAP
Single
Detector/Probe/Stream
Single Component
Single Controller
Single CAP
Single Detector/Probe/Stream
Multiple Components
Components = COMP
pH
Conductivity
Oxygen
Autotitrator
TYPE 1a
TYPE 1b
Detector/Probe
Streams = STRM
TYPE 2a
Single Controller
Single CAP
Multiple Detectors/Probes/Streams
Single Component
1
Panametrics
1
GC Regular
GC Master/Slave
FTIR
RAMAN
Mass Spec
TYPE 2b
Single Controller
Single CAP
Multiple Detectors/Probes/Streams
Multiple Components
TYPE 3
Single Controller
Multiple CAP
Multiple
Detectors/Probes/Streams
Single/Multiple Components
1
2
n
Process Analyzer System Connectivity (= ConnI)
GC Master/Master
FTIR
RAMAN
Proposed OPC Datalink Specification - Address Hierarchy
Process Analyzer System Connectivity (= ConnI)
AD0
Gateway/
Server
AD1
Analyzer/
Controller
AD2
Control/
Application
Program
AD3
Stream
AD4
Component
Hierarchical/Domain Model for Process Analyzer System - O&M Domain
Ent
DCS
O&M
eSAM


SAM
Level 1
Bus (CAN)
Measurement
O&M
Domain
AnLAN
Analyzer Workstation
• Primary Maintenance/Operations Window into Process Analyzer
System
• Key Functions:
* Upload and Download of Analyzer Configuration/Methods
* Access of Real-time Diagnostic/Analyzer Data @ Analyzer
* Access of Diagnostic/Analyzer Data @ Analyzer Server
* Access and Configuration of SQC Data/Run-time Rules @
Server
• Specification Work to begin in 2003
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - O&M Domain
Ent
DCS
O&M
Analyzer Server
eSAM

Level 1
Bus (CAN)
Measurement

SAM
• Short Term ( ~ 1 month(?)) Data Archive
* Raw Data for all assigned Analyzers
* Operational Data Storage (Methods/Configurations etc.)
* Primary Database for Workstation Access
* Serves as Front-end to Long-term Data Archive
O&M
• Connectivity/Specification Issues:
* Database Type(s)- ODBC vs. Others
* Co-existence of Analyzer Data from Different Vendors
* Communications Protocol for Data Exchange between
Analyzer and Server
Domain
• Specification Work to begin in 2003
AnLAN
Process Analyzer System Connectivity (= ConnI)
Hierarchical/Domain Model for Process Analyzer System - O&M Domain
Ent
DCS
O&M
eSAM

Level 1
Bus (CAN)
Measurement

SAM
Analyzer/DCS Long Term Data Archive
• May be located in O&M Domain or DCS Domain
(see DCS Domain functions)
• If located and supported in the O&M Domain,
typically would only store Analyzer Data
O&M
Domain
• May require translation software to Update Long
Term Archive from Short Term Analyzer Archive
(See Analyzer O&M Domain)
AnLAN
Process Analyzer System Connectivity (= ConnI)
Proposed Connectivity Model - DCS Datalink Client/Server Topologies
Workstation
One of many ways
a system can be
stitched together
Workstation
Plant LAN
IntraNet
OPC Client
Bridge
(CB)
LEVEL 3/4
Router
PDC
Analyzer
Gateway
OPC Server
(AGS)
Historian
Embedded
DCS OPC
Client
(EDC)
DCS OPC
Server
Server/ Workstations
DCS Level 2 LAN (TDC=LCN)
Raman
E.g. Cisco
2950 VLAN
Switch/Router
Anlzr Level 2 FLAN
(Private IP Addresses)
Process Analyzer System Connectivity (= ConnI)
FTNIR
Embedded
Analyzer
OPC Server
(AES)
ConnI Status Report: Summary
• Draft OPC DCS/Analyzer Datalink specification published for comments
* Testing Planned or Underway with Several Process Control/Process
Analyzer Vendors
• Solicitation of Endorsements/comments/changes from analyzer suppliers/DCS
vendors and end-users underway
• Overall Architecture well in place - Generic Functional Specification aimed for
2003
• Functional specification for NeSSI Sensor bus and SAM (part of NeSSI Gen II
specification) to be published soon (NeSSI Website)
• Prototype Proof of Concept Apparatus (POCA) systems being developed by
Honeywell
* Based on IS CANbus
* Will allow for testing of SAM functionality
Process Analyzer System Connectivity (= ConnI)
FINI
Process Analyzer System Connectivity (= ConnI)