NeSSI-II Network and Sensor Developments
Networked Sampling System
(NeSSI-Generation II)
Development and Field Test
by
John Mosher, Bob Nickels – Honeywell Sensing & Control
and
Ulrich Bonne – Honeywell Laboratories
NeSSI - New Sampling Sensor Initiative
NeSSI-II Network and Sensor Developments
Outline:
Project Team
Definition and NeSSI functions. Status of NeSSI-I
Challenges for NeSSI-II components:
Networked Components
Easy plug-and-play
Intrinsically Safe
Reliable
Affordable
Demo and field test of NeSSI-II
Sensor Developments
NeSSI - New Sampling Sensor Initiative
NeSSI-II Network and Sensor Developments
NeSSI Generation II
Being Developed by a
Supplier Team
Supplier Team:
Steve Doe
Dave Simko
Richard Hughes
Bob Nickels
John Mosher
Ulrich Bonne
(256) 435-2130
(440) 349-5934
(310) 515-2866
(815) 235-5735
(209) 330-4004
(763) 954-2758
Parker-Hannifin
Swagelok
Autoflow
Honeywell-ACS
Honeywell-ACS
Honeywell Labs
NeSSI - New Sampling Sensor Initiative
NeSSI-II Network and Sensor Developments
User Team for Potential DoE NeSSI Project
Peter van Vuuren
(281) 834-2988 ExxonMobil
Rob DuBois
(780) 998-5630 Dow
Joe Andrisani
(302) 695-3156 DuPont
Steve Wright
(423) 229-4060 Eastman
Bob Reed
(215) 652-1691 Merck
Paul Vahey
(973) 455-5977 Honeywell-SM
Don Young/Don Nettles
(510) 242-3298 ChevronTexaco
Frank Schweighardt
(610-481-6683) Air Products
George Vickers
(630) 420-3701 BP
Paul Barnard
(713) 336-5351 EquistarChemicals
Steve Doherty
(847) 982-7465 Pharmacia
Carol Zrybko
Kraft
Michelle Cohn
UOP
Alan Eastman/Randy Heald (918) 661-3475 ConocoPhillips
Center for Process Analytical Chemistry (CPAC)
Mel Koch
(206) 616-4869 U.Washington, CPAC
NeSSI - New Sampling Sensor Initiative
NeSSI Benefits
|------------------------------------+------------------------------------|
|
Now
|
NeSSI
|
|------------------------------------+------------------------------------|
| Analyzer houses
| Analyzer cabinets close to sample |
|
|
point
|
|------------------------------------+------------------------------------|
| Long heat traced lines
| Short heat traced lines
|
|------------------------------------+------------------------------------|
| Extensive design to bring sample
| Minimal Design
|
|
to sensor
|
|
|------------------------------------+------------------------------------|
| One at a time assembly
| Modular "tinker-toy" type assembly|
|------------------------------------+------------------------------------|
| Field repair
| Modular replacement of components |
|
|
or systems, repair in shop or at |
|
|
vendors
|
|------------------------------------+------------------------------------|
| Sample may not reach analyzer
| Sample flow is validated
|
|------------------------------------+------------------------------------|
Compliments of Bruce Johnson, DuPont
NeSSI - New Sampling Sensor Initiative
Fig. 1. Functions of a
Process Sampling System.
Courtesy of ExxonMobil
NeSSI - New Sampling Sensor Initiative
Fig. 1a. Traditional Stream
Sampling System in a
Petrochemical Plant.
No Modular or Standardized
Components
Courtesy of P.vanVuuren,
ExxonMobil
NeSSI - New Sampling Sensor Initiative
NeSSI Generation I
Fig. 3. Sampling System for Measurement of H2O and O2 ppm
in a High-Purity Hydrocarbon Stream. Miniaturized Version
Courtesy of D.Simko, Swagelok
NeSSI - New Sampling Sensor Initiative
NeSSI Generation II
What is Generation II?
NeSSI II = SP76 + IS + CAN + SAM
SP76 = NeSSI Generation I from SEMI
IS
= Intrinsic Safety
CAN = Controller Area Network – DeviceNet
SAM = Sensor Actuator Manager – Open Interface
to Plant-wide Network and/or Analyzer
Reliable, Networked, Modular, Safe, Open, and Affordable!
NeSSI - New Sampling Sensor Initiative
NeSSI Generation II
IS
NeSSI II = SP76 + IS + CAN + SAM
CAN
SAM
SP76
NeSSI - New Sampling Sensor Initiative
NeSSI Generation II
PROJECT ABSTRACT
The Problem: Need for a networked, standardized, int.safe,
modular, affordable and reliable process stream sampling and
sensor system. Sampling systems now are causes for downtime and questionable process stream samples followed by
costly control errors.
Objectives are to:
 Accelerate development of the prototype system component
such as intrinsically safe, digital pressure, temperature and
flow (p, T, F), sensors, smart valves, flow-controllers, and a
sensor/actuator networking capability
 Build, demonstrate, and test 1-2 NeSSI-II units, and
 Provide a platform for incorporating analytical sensors right
into the sampling system.
NeSSI - New Sampling Sensor Initiative
ABSTRACT (cont’d.)
Benefits Enabled by Full NeSSI Implementation:
 Reduce down time, energy use & operating & sampling cost:
U.S.: 0.1-0.2 Q/y or $10-20 billion
 Bring these savings to the end-users at an earlier date, and
 Reduce the business risk to the Supplier and End-User
End-Users are members from across the processing industries:
chemical,
petrochemical, power generation, refining, food, beverage and dairy, pulp & paper
 One year for design, build and lab-test
 One year for installation and field testing
Deliverables:  Interim and Final Reports (no hardware) on
design of sensor hard- and software, NeSSI
test results, benefits and recommendations
Schedule:
Management of the Program: Honeywell + Consortium
NeSSI - New Sampling Sensor Initiative
Table 1. NeSSI Generation I versus II
Feature
Signal
Protection Methods
Classification
Sensors
Intelligence
Control Philosophy
Regulating Comp.
Passive Comp.
Actuators
Heating
Wiring
Communications
Generation I
4-20 mA
Purge, X-proof
Div.2 (seldom f.)
Non-substrate
Limited
Centralized
Self-contained
Mechanical
Stand-alone
External
Conduit/Cable
Individual
Generation II
Serial Bus
Mostly IS
Div.1 (often flamm)
(mini)Substrate
Processor on board
Distributed (SAM)
PID control loops
Electro-mechanical
Substrate, combi
Substrate integrated
IS Plug and Play
Networked
From Rob Dubois, Dow, May’02
NeSSI - New Sampling Sensor Initiative
Diagram of NeSSI-Gen2-POCA (Proof of Concept Assembly) to Check
Networking and Control of Flow, Pressure and Temperature. (Courtesy of
R.DuBois, DowChemical)
NeSSI - New Sampling Sensor Initiative
Comparison of NeSSI Generation Designs
Feature
Generation I
Generation II Generation III
Signal Type
4-20 mA; discrete
Serial bus
Protection
Enclos.Classif.
Sensor Locat’n
Analyzer Locat
Intelligence
Ctrol.Philosophy
Regulat’g Comp.
Passive Comp.
Valves
Heating
Wiring Pwr/Sig
Communication
Cost
Purging, X-proof
Div.2(Seldom Flam.)
Off-Substrate
Off-Substrate
Limited
Centralized
Self-Contained
Pure Mechanical
Manual or Pneum., Off
External
X-proof conduit/cable
Individual Hard-Wired
High
Serial bus
Wireless; Opt.Fiber
Low-Power IS
Low-Power IS
Div.1(Often Flam.) Div.1 (Often Flam.)
On-Substrate
Mini-Substrate
On/Off-Substr.
MicroAnalytical
Processor OB
Processor OB
Distrib’d (SAM)
Distributed (SAM)
On-Substr.w/PID
On-Substr. w/PID
Electro-Mechan.
Int. Electro-Mechan.
On-Substr.Combi On-Substr.Combi
Substr.-Integrated Substr.-Integrated
IS Plug & Play
IS Plug & Play
Networked
Networked
Moderate
Moderate to low.
NeSSI - New Sampling Sensor Initiative
CAN Communications - Issues and Background
ISO OSI
7-Layer Model
Application Layer
Presentation Layer
Session Layer
Transport Layer
Network Layer
Data Link Layer
Physical Layer
Issues/Questions:
1. Is it feasible to embed all required device electronics,
microcontroller, and CAN communications into a NeSSI
SP-76 1.5 x 1.5” footprint?
2. Is a CAN network capable of operating through an IS barrier?
Selection of CAN as a communications enabler for NeSSI
High Level Protocol
SDS, DeviceNet, CANOpen - all publicly available & proven
Data Link Layer
Master/slave, peer-to-peer, multicast messaging
All data types supported
Diagnostics
Carrier Sense Multiple Access with Collision Resolution
16-bit CRC error checking, intell.network mgmt.capability
Physical Layer
Trunkline/multidrop with branches
Separate twisted pairs for signal and device power distribution
Up to 64 nodes, up to 500 meters trunk length
Intrinsic Safety
NeSSI - New Sampling Sensor Initiative
Adaptation of Honeywell Temperature, Pressure, & Flow Sensors to
NeSSI design standards.
Microbridge flow
sensor interfaced to a
typical miniature CAN
microcontroller and
12 mm connector.
A similar interfacing
approach will be used
in this project to
connect existing
sensors and
actuators to
the CAN network.
12 mm
by Bob Nickels, Honeywell
NeSSI - New Sampling Sensor Initiative
CAN Communication - Feasibility and Intrinsic Safety Evaluation
DESCRIPTION OF TESTING:
• Lab tests utilized SDS protocol and devices
• A standard Zener Intrinsic Safety Barrier was used in series with both CAN communication
signals. Component values were varied down to 4.3 volt Zeners and up to 100 ohms of
series current-limiting resistance
• 20 CAN devices were connected over trunk lines varying from 5 to 250 meters
• Devices were configured to generate bus traffic as high as 20% bandwidth utilization to
simulate worst-case conditions.
• A CAN network analyzer was connected to monitor traffic and detect errors
TEST RESULTS:
• After over 72 hours of operation, a total of 87 million messages had been sent with only two
CAN error frames. This is well within normal expectations for a CAN bus.
CONCLUSION: (tentative)
• It appears that industrial CAN networks are entirely suitable for applications
such as NeSSI when used with a properly-designed IS barrier.
NeSSI - New Sampling Sensor Initiative
Adaptation of Honeywell S1 Series Pressure Sensor to NeSSI
design standards.
Current Status:
• Sensor Design and SP76 housing qualified
Intrinsically Safe (IS).
• CAN controller and transceiver chipsets
identified.
• DeviceNet protocol selected and pretested
in selected chipset.
• Preliminary CAN IS mode testing done.
• First POCA units being built for February
delivery to Dow and ExxonMobil.
Next Steps:
• Design and build PCBs incorporating selected sensing and communication chipsets/circuits.
• Design and build PCBs into SP76 Housings and qualify full product as IS.
• Establish and incorporate DeviceNet connector architecture for NeSSI applications.
• Test Assemblies in full DeviceNet network.
• Identify DeviceNet IS network restrictions and rules.
• Propose establishment of DeviceNet IS Special Interest Group (SIG) to
ODVA (Open DeviceNet Vendors Association).
NeSSI - New Sampling Sensor Initiative
Preliminary Investigation of SAM Controller Choices.
 MKS Instruments RMUd:
• DeviceNet in/Ethernet out
• 4” x 4” x 2”
• USB and Serial Ports
• 32 bit RISC Power PC Processor
• 2-16MB ROM, 32-64MB SDRAM
• Linux OS w/ JavaVirtual Machine
• HMI Development Software Included
AutomationDirect 205: 
• DeviceNet in/Ethernet out
• 3” x 4” x 6”
• Expandable local I/O, Serial Ports
• Windows CE OS
• Flowchart Programming
• Visio HMI/Control Software
NeSSI - New Sampling Sensor Initiative
NeSSI-II Sensor Developments… Cont’d
Compatibility with SP76 Footprint:
Pressure and Temperature
Flow (Gases and Liquids)
Self-Normalizing Flow Sensor
Thermal Conductivity for Process Monitoring
PHASED MicroAnalyzer
NeSSI - New Sampling Sensor Initiative
Thermal Microbridge Flow Sensors for NeSSI-II
NeSSI - New Sampling Sensor Initiative
Thermal Microbridge Flow Sensors for NeSSI-II
NeSSI - New Sampling Sensor Initiative
Smart, IS, Miniature, p, T, F Sensors for NeSSI Adaptation.
(Courtesy of Honeywell)
Smart,
T-Compens.
TC Sensor
Smart,
T-Compens.
Flow Sensor
NeSSI - New Sampling Sensor Initiative
PHASED, a GC MicroAnalyzer
NeSSI - New Sampling Sensor Initiative
Multi-Stage Pre-concentration
Side Views
of PHASED
structure
and
Operation
Cross section of PHASED structure
Multi-stage release of analyte
increases its concentration:
~100-fold with 1st stage
~100 x n-fold after n stages
To
Separator
NeSSI - New Sampling Sensor Initiative
NeSSI Benefits, Nominal Ethylene Plant
Output: 1-2 billion pounds ethylene / year.
Savings enabled by smart, modular sampling (NeSSI I-III):
 430$k/y due to building and ownership cost savings, over
15 year life, of 2.4 and 4$M, respectively (per P.VanVuuren et al)
 100K$/y to 2+M$/y plant operational savings, due to
conservative assumption of only a 1% improvement in
process control (afford more measurements, and achieve
greater efficiencies, less waste and less down time)
Significance:
 1-2% total savings by processing industries
 Total US energy use & GDP: 1017 Btu/year & $1013/year
 Assume US Process Industry uses 10% of total
 NeSSI: 1-2% of 1016 Btu/y (0.1-0.2 quads/y) or $10-20B/y.
NeSSI - New Sampling Sensor Initiative
NeSSI-II Network and Sensor Developments
CONCLUSIONS
• Loaded CAN bus network error rate of 2: 87,000,000
is smaller than expected
• Sensors compatible with NeSSI-II are around the corner:
PT, FT,
• IS certifications of P, F sensors were obtained before and
need to be renewed
• NeSSI-compatible microanalyzers are under development
• Energy and cost savings are projected to be significant: 1020 B$/y after NeSSI saturation of all industrial processes
• Team approach enhances risk of success
NeSSI - New Sampling Sensor Initiative
Acronyms
CAN
ConnI
CPAC
DoE-OIT
EDS
F
GC
GUI
HMI
IFPAC
IR
IS
NeSSI
NRE
ODVA
OLE
OPC
OSI
p
PC
PDA
SAM
SDS
SIG
T
TEDS
V
Controller Area Network
Connectivity Initiative
Center for Process Analytical Chemistry
Department of Energy, Office of Industrial Technologies
Electronic Data Sheet
Flow
Gas chromatography
Graphical User Interface
Human-Machine Interface
International Forum for Process Analytical Chemistry
Infra-red
Intrinsically safe
New Sampling/Sensor Initiative
Non-Recurring Engineering labor
Open DeviceNet Vendors Association
Object Linking and Embedding
OLE for Process Control based on Microsoft's OLE/COM technology
Open System Interconnect
Pressure
Personal computer
Personal Digital Assistant
Sensor-Actuator Manager
Smart Distributed System
Special Interest Group
Temperature
Transducer Electronic Data Sheet
Valve
NeSSI - New Sampling Sensor Initiative
NeSSI-II Network and Sensor Developments
Thank You!
Contact Information:
John Mosher
Bob Nickels
Ulrich Bonne
(209) 330-4004 Honeywell ACS
(815) 235-5735 Honeywell ACS
(763) 954-2758 Honeywell Labs
NeSSI - New Sampling Sensor Initiative