Modular Sampling System
Initiative
Background and Status
2000 Fall Sponsor Meeting
Center for Process Analytical Chemistry
Modular Sampling System Initiative
Agenda
•
Status and Update
•
Preview of Swagelok Proposal
Modular Sampling System Initiative
CPAC as a Multi-Purpose PA Forum
•
Legal Umbrella for Sponsors to Meet
R&D: Long Range / Short Range
Information Clearing House
Enabling Mechanism to Address Other Common Needs
•
Focus Groups: Forum to
Review R&D Programs
Present Industry Common Needs - RFP
Address Industry Common Needs
Fieldbus Datalink Specification - Done
NeSSI - In progress
MatLab On-line/Connectivity - Future?
Modular Sampling System Initiative
Background and Chronology of NeSSI Activities
•
O&P Focus Group May 1999
Identified Sampling Systems as Common Area Of Interest
Sponsored Tutorial for Nov99 Sponsor Meeting
•
Tutorial Nov99 CPAC Meeting
Background/Reasons for Interest
Presentations by Suppliers/ End Users
•
Participation in IFPAC2000 Meeting
Plenary/General Papers (SS Enjoyed High Profile)
Workshop
Modular Sampling System Initiative
Sampling System Vision
FLAN (Optical
Fiber)
Sensor = Moisture
Probe
P
T F
A
Sensor/Signal
Bus
Modular Sampling System Initiative
IA
Control
ler
(ASIC)
Process Analyzer Vision
Modular Sampling System Initiative
Background and Chronology of NeSSI Activities (cnt’d)
•
Ad-hoc O&P Meeting @ Pittcon2000
End-users Discuss Initial Target Designs
•
CPAC2000 Spring Meeting
Formed SS Focus Group
Defined Information Package (basis of RFP)
•
Distributed RFP (July 2000)
Clarification Meeting at ISAEXPO2000 (40 attendees)
Received Proposals from Swagelok, Parker
Expect Additional Proposals/Comments from Autoflow,
ABB Analytical, SAAI, Rosemount Analytical
Modular Sampling System Initiative
Background and Chronology of NeSSI Activities (cnt’d)
•
CPAC2000 Fall Meeting
Preview of Swagelok Proposal
Other Feedback
Micro-Reactor Proposal (MicroAnalytics)
•
What is Next?
Distribute Proposals to All Interested Parties
Follow-up by Report
Sampling System Session at IFPAC2001
Review and Summary of NeSSI Effort
Papers by Swagelok, Parker, Autoflow, ABB, Rosemount
Modular Sampling System Initiative
Acknowledgements
•
Dow
Rob Dubois/Ron O’Reily/
Brian Worthington
•
Dow Corning
Jim Tatera/Gary Bokerman
•
DuPont
Bob Bucher
•
Rohm&Haas
Joe Sung
•
Honeywell
Ken Creasy
•
Akzo Nobel
Foad Mozayeni
•
ExxonMobil
Dan Podkulski/Rajko Puzic/
John Cumbus/Jeff Gunnell
•
Swagelok
Dave Simko
•
CPAC
Lloyd Burgess/Larry Ricker
Modular Sampling System Initiative
The End
Modular Sampling System Initiative
O&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 a
basis for future micro-analytical techniques
•
O&P decided to sponsor a SSISSS (Small Smart Integrated Sensor
and Sampling System) Tutorial at CPAC Nov Meeting
Modular Sampling System Initiative
Nov99 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
Modular Sampling System Initiative
Driving Forces for Change
• Reduce Cost of Ownership
Non Recurring Costs = Cost to Build
Operating Cost
• Data Validation (Fit for Use)
Modular Sampling System Initiative
Integration of Sample System and Sensors
All System
Components
in Contact
with Sample
including the
Sensors
Modular Sampling System Initiative
Sample Conditioning System
Process Stream
Field LAN
A
Mainly a Trust Configuration
Now a Trust & Verify Configuration
P
T
F
Level 0
Analyzer
Controller
All Additional Electronic
and Computing
Components Required
to Generate Analytical
Result
Level 1
Level 0 Subsystem Integration
Purpose:
Modular Sampling System Initiative
Prepare and Verify a
Representative Sample
(Compatible with Analyzer Sensor)
Sample Conditioning System
Integrated Sampling/Sensor System
Process Stream
A
P
Opportunity:
T
•
Size
•
Cost
F
Level 0
Packaging as an Integrated
Sensor and Sampling System
Issues:
•
Size
•
Standardization
•
VMAS
Separation or Integration of Level 0/1 Subsystems
Objective:
Close to
Sample Tap
Field LAN
Integrated Sampling/Sensor System
Process Stream
A
P
T
F
Analyzer
Controller
Options:
• Remote
• Separate but Close
• Integrated
Modular Sampling System Initiative
Level 0
Level 1
Integration of Level 0/1 Subsystems
Integrated Sampling/Sensor/Controller System
Process Stream
Field LAN
A
P
$$
T
Analyzer
Controller
F
Modular Sampling System Initiative
Level 0
Level 1
Nov99 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
Modular Sampling System Initiative
Nov99 CPAC SSISSS Tutorial (Vendor Presentations)
Swagelok
Autoflow
A+
Modular Sampling System Initiative
Rosemount
Nov99 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
Modular Sampling System Initiative
IFPAC2000
•
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
Modular Sampling System Initiative
TODAY’S COST OF BUILD
For a major greenfield project
Number
Gas chromatographs
50
Other analysers
75
Sample systems
125
Sample transport
125
Analyser houses
8
Data system
1
Installation costs
1
TOTAL
Modular Sampling System Initiative
K USD
each
30
10
10
5
200
150
125
K USD
total
1500
750
1250
625
1600
150
125
6000
PCT
38
30
27
3
2
TODAY’S COST OF OWNERSHIP
Lifetime
Number of equivalent analysers
Equivalent analyser per technician
Cost of spares per equivalent analyser / yr
Technician
Engineer
Spares
Consumables
TOTAL / yr
TOTAL / life
Number
5
1
Modular Sampling System Initiative
USD / hr
30
50
15 years
250
50
1200 USD
K USD / yr
300
100
300
100
800
12000
IMAGINE THE FUTURE
P
T
Analyzer
Controller
F
Level 0
Modular Sampling System Initiative
Field LAN
Process Stream
A
Level 1
IMAGINE THE FUTURE
FLAN (Optical Fiber)
Sensor = Moisture Probe
P
T
F
A
IA
Controller
(ASIC) &
Interface
Module
Sensor/Signal Bus
Original Picture of Gas Delivery System courtesy Valin Corporation;
Modular Sampling System Initiative
IMAGINE THE FUTURE
Sensor = RAMAN Probe
P
T
F
Interface
Module
A
Modular Sampling System Initiative
IFPAC2000
•
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
Modular Sampling System Initiative
IFPAC2000
•
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
Modular Sampling System Initiative
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
Modular Sampling System Initiative
Status
•
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
Modular Sampling System Initiative
TBD
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
Modular Sampling System Initiative