“how to trust your process analyzer"

“How to Trust Your Process Analyzer"

NeSSI™ Workshop May 11, 2006

Steve DoeParker Hannifin

Topics Case Study New Tools to Improve Sample Handling System Reliability Field Results Next Steps

Case Study: Background Lanxess

Born of Bayer AG strategic realignment in 2004 Produces Performance Chemicals, Chemical Intermediates,

Engineering Plastics & Performance Rubber Sarnia, Ontario Plant: Butyl Rubber producer >60 years Moisture analysis & control is key Process Engineers & Plant Operators lacked confidence

in analyzer results due to Sample Handling System (SHS) legacy problems

Plant shutdowns resulted – big bucks lost on several occasions!

Analyzer PM had been properly completed within 48 hours of a moisture increase trend

Midnight callout from operations: “Your Analyzer Isn’t Working!”

Analyzer Engineer twisted operations arm over the phone: “Act On The Analyzer’s Results!!!”

Operations listened- and set a new production record that very day!

“High-fives” for everyone- but Analyzer Engineer reminded the team about the “dodged bullet”

Cross-functional team was created to increase SHS reliability and “customer confidence”

Case Study: Early 2004

New Tools for SHS Reliability Robust, modular, remote actuation double block

& bleed stream (DBB) switching valve

New Tools for SHS Reliability Differential pressure

flow indication w/ integral relief function (I.S., 4-20mA output)

New Tools for SHS Reliability

Smart, Proportional Heater & Purge Preheater

Field Results System Commissioned June 24, 2005 Zero Downtime After Commissioning

Field Results

Operations has authority via DCS stream switch reference gas to validate analyzer calibration

DBB Stream Switch

Reference Gas Dryer

Field Results Remote analyzer and bypass flow indication available

to operators via DCS

Bypass Flow Bypass Flow IndicationIndication

Analyzer Analyzer Flow Flow

IndicationIndication

Reference Gas Reference Gas Flow (9min 25sec)Flow (9min 25sec) Switching Switching

valve cycledvalve cycled Sample Gas Sample Gas Flow (9min Flow (9min

25sec)25sec)

Cycles repeated during Cycles repeated during commissioningcommissioning

Field Results

Process Engineers & Operations TRUST THE ANALYZER

Several analyzers in the Sarnia plant are running closed loop control

Plant Shutdowns HAVE BEEN AVERTED

5 additional “smart” systems have since been commissioned in the Sarnia plant- more planned

Next Steps

Incorporate Human Machine Interface (HMI) in field; Class 1, Division 2 compliant

Provides local host for “Smart Shelters”

>

4-20 mA to PLC- For Now!

Ethernet to Technician Workstation

Smart Shelter

Onboard PLC Ethernet to HMI