NeSSI
(New Sampling/Sensor Initiative)
2001 Spring Sponsor Meeting
Center for Process Analytical Chemistry
New Sampling/Sensor Initiative (NeSSI)
Agenda
•
Status and Update
- PV2
Introduction (Why CPAC)
What is NeSSI
What has happened/is happening
•
NeSSI Team Goals
- Rdubois
•
Bluetooth
- Mike Horton (Crossbow)
•
Connectivity
- PV2
New Sampling/Sensor Initiative (NeSSI)
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 Other Industry Common Needs
Fieldbus Datalink Specification - Done
NeSSI /Micro-Reactor Analytics - In progress
Chemometrics On-line/Connectivity - Future?
New Sampling/Sensor Initiative (NeSSI)
What is NeSSI?
•
Adapt Modular Surface Mount Technology from the SEMI
Industry to Sampling System Design in the Chemical Industry
•
Driving Forces for Change
Cost to Build/ Cost of Ownership
Traditional Sampling System Designs Same for Last 20+ Years
Weak Link in Overall Analyzer Reliability
Integrate Other Sensors (Smart Sampling System)
Sample Validation
New Sampling/Sensor Initiative (NeSSI)
What is NeSSI?
Picture courtesy Swagelok®
New Sampling/Sensor Initiative (NeSSI)
What is NeSSI?
New 5 Channel
Design by Parker
Picture courtesy Parker
New Sampling/Sensor Initiative (NeSSI)
What is NeSSI? - It is SMART
Legend:
P Pressure Sensor
T Temp Sensor
V Valve
A Analytical Sensor
Signal Wires Only
Sensor
Analytical
Manager
(SAM)
V
T
P
A
Shared Power Bus
New Sampling/Sensor Initiative (NeSSI)
Signal
In/Out
to AC
NeSSI Vision (Now)
New Sampling/Sensor Initiative (NeSSI)
NeSSI Vision (Next Step)
Signal Wires Only
Sensor
Analytical
Manager
(SAM)
V
T
P
A
Shared Power Bus
New Sampling/Sensor Initiative (NeSSI)
Signal
to AC
Background and Chronology of NeSSI Activities
•
Oil&Petrochemical (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
New Sampling/Sensor Initiative (NeSSI)
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 Request for Proposal (RFP) (July 2000)
Clarification Meeting at ISAEXPO2000 (40 attendees)
Received Proposals/Feedback from Swagelok, Parker,
Autoflow, ABB Analytical, SAAI, Rosemount Analytical
New Sampling/Sensor Initiative (NeSSI)
Background and Chronology of NeSSI Activities (cnt’d)
•
CPAC2000 Fall Meeting
Previewed Swagelok/Parker Proposals
Micro-Reactor Proposal (Micro-Analytics)
Planning (CD Deliverable, IFPAC2001, Pittcon etc.)
•
IFPAC2001
Sampling System Session at IFPAC2001
Review and Summary of NeSSI Effort (RD/PV2)
Papers by Swagelok, Parker, Autoflow, ABB, Rosemount
Ad-hoc Meeting (Standing Room only Interest)
New Sampling/Sensor Initiative (NeSSI)
Background and Chronology of NeSSI Activities (cnt’d)
• Pittcon2000 Meeting
NeSSI Ad-hoc Forum Meeting
Confirmed viability of NeSSI designs
Introduced the Role of Wireless (Bluetooth)
Focus on Special Issues/Problems
Swagelok, Parker, ABB Highlighted Special Problems
4 Subteams (Intrinsic Safety, Component availability etc.)
• Miscellaneous/In the Pipeline
Proposal for Additional Resource
Jim Tatera (retiree from Dow Corning)
Part-time to lead key sub-team activities
Deliverables/schedule defined
Report at next CPAC Meeting (Nov)
More details of proposal etc. at SSFG (Wednesday)
New Sampling/Sensor Initiative (NeSSI)
Background and Chronology of NeSSI Activities (cnt’d)
• Miscellaneous/In the Pipeline (cnt’d)
Testing/Evaluation
Two Systems in Design Phase (EMCC)
Rosemount Laboratory Tests Completed (see SSFG)
Test System Available
More Participation by End-users needed
NeSSI Deliverable Completed
CD Issued
NeSSI Website Up-to-date
NeSSI Promotional efforts
Distribution List > 150 names
Present Hour Tutorial at ISA2001 Meeting (Sept01)
Globalization efforts
CPACT Presentation Apr01 (high interest, additional names)
Paper tentatively accepted for INTERMAC Meeting (Nov01)
Extending SP76 to IEC standard
New Sampling/Sensor Initiative (NeSSI)
Acknowledgements
•
Dow
Ron O’Reily/Brian Worthington/Walter Henslee
•
Dow Corning
Jim TateraJ/Gary BokermanJ
•
DuPont
Joe Adrisani, Chuck Miller, Bob Bucher, Bruce
Johnson
•
Rohm&Haas
Joe Sung
•
Honeywell
Ken Creasy, Ullrich Bonne, Troy Francisco
•
ExxonMobil
Dan Podkulski/Rajko Puzic/Paul
Hromadka/John Cumbus/Jeff Gunnell
•
Swagelok
Dave Simko/Rick Ales & Colleagues
•
Parker
Steve Doe, Frank Ruiz & Colleagues
•
Rosemount
John Gajewski & Colleagues
•
ThermoOnix
Jerry Evans
•
CPAC
Lloyd Burgess/Larry Ricker
•
Others
ABB, Panametrics, AAI, Sterling Chemicals
New Sampling/Sensor Initiative (NeSSI)
…. and they lived happily ever after
FINI
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
Driving Forces for Change
• Reduce Cost of Ownership
Non Recurring Costs = Cost to Build
Operating Cost
• Data Validation (Fit for Use)
New Sampling/Sensor Initiative (NeSSI)
Integration of Sample System and Sensors
All System
Components
in Contact
with Sample
including the
Sensors
Sample Conditioning System
Process Stream
New Sampling/Sensor Initiative (NeSSI)
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:
Prepare and Verify a
Representative Sample
(Compatible with Analyzer Sensor)
Sample Conditioning System
Integrated Sampling/Sensor System
Process Stream
A
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
Nov99 CPAC SSISSS Tutorial (Vendor Presentations)
Swagelok
Autoflow
A+
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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;
New Sampling/Sensor Initiative (NeSSI)
IMAGINE THE FUTURE
Sensor = RAMAN Probe
P
T
F
Interface
Module
A
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)
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
New Sampling/Sensor Initiative (NeSSI)