jeff gunnell and peter van vuuren - university of...
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Jeff Gunnell and Peter van Vuuren
ExxonMobil Chemical - Core Engineering
PROCESS ANALYTICAL SYSTEMS- a vision for the future
COMMONLY HEARD PHRASES
“lump sum, turn key”
“industry-standard design”
“trend-line decrease in cost”
“year on year improvements”
“best practices”
PROCESS ANALYTICAL SYSTEMS- a vision for the future
GOALS
Understand the driving forcesRecognise technology trends
Imagine the future
Create change
PROCESS ANALYTICAL SYSTEMS- a vision for the future
STAKEHOLDERS
Petrochemical companiesEngineering contractorsSystem integratorsAnalyser vendorsComponent vendorsAnalyser research groups
PROCESS ANALYTICAL SYSTEMS- a vision for the future
UNDERSTAND THE DRIVING FORCES
Reduce time from concept to productReduce hours for design and development
Reduce cost of buildReduce cost of ownership
Maximise profitability
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS
SAMPLETAKE-OFF
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS
SAMPLETAKE-OFF
A
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS LAN
ANALYSER DATA SYSTEM
SAMPLEPRECONDIT.
SAMPLERECOVERY
SAMPLETRANSPORT
SAMPLETAKE-OFF
SAMPLERETURN
VALIDATIONBLEND
SAMPLECONDITIONING
INSTRUMENT AIRELECTRICAL
GASES
DRAINVENT
SAFETY SYSTEMHVAC
A
AH
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
ANALYSER HOUSE
COMMSXFACE JB
A
SHS
A
SHS
COMMSXFACE
A
SHS
COMMSXFACE
A
SHS
A
DCS LAN
JB
OTHERANALYSER
HOUSESLEVEL 0Field mounted
hardware
LEVEL 1Unit control and
processing
LEVEL 2Distributed control
and processing
LEVEL 3Higher levelprocessing
GATE-WAY MAINT.
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
AH 1
A AAAA
AH 2
A AAAA
AH 3
A AAAA
AH 4
A AAAA
AH 5
A AAAA
AH 6
A AAAA
AH 7
A AAAA
AH 8
A AAAA
DCS LAN
ANALYSER DATA SYSTEM
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
Gas chromatographs 50Other analysers 75Sample systems 125Sample transport 125Analyser houses 8Data system 1Installation costs 1TOTAL
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
K USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
PROCESS ANALYTICAL SYSTEMS- a vision for the future
THE FUTURE
The challenge...
...and the opportunity
Reduce cost of build by 40%
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
K USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
PROCESS ANALYTICAL SYSTEMS- a vision for the future
THE FUTURE
The challenge...
...and the opportunity
Reduce cost of ownership by 35%
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
PROCESS ANALYTICAL SYSTEMS- a vision for the future
ENABLING TECHNOLOGIES
� Modular sample system components�developed by the semi-conductor industry�ISA group working on design standards
� Application specific integrated circuits�provide the smart components
� Open communication architectures�provide the data integration
PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
A
T
PAnalyzer Analyzer
ControllerController
Fiel
d LA
NFi
eld
LAN
Level 0Level 0 Level 1Level 1
Pro
cess
Str
eam
Pro
cess
Str
eam
F
PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
FLAN (Optical Fiber)
Sensor/Signal Bus
IA
Controller
(ASIC)
Original Picture of Gas Delivery System courtesy Valin Corporation;
A
T
PF
Sensor = Moisture Probe
PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
A
T
PF
Sensor = RAMAN Probe
PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
Integrated analysers and sample systemsField-mounted and self containedSmart incorporating diagnostics + controlOpen-architecture data systemsPlug-and-play maintenanceStandard designs for generic applications
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Integrated analysers and sample systems
� analyser vendor provides sample system�one-shop stop
� maximise standardisation�there really aren’t that many special cases
Reduce hours for design and development
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Field-mounted and self contained
� can work anywhere�from the poles to the tropics
� no analyser houses� no long sample transport lines� minimum utilitiesReduce time of design and cost of build
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Smart with diagnostics + control
� full system info available� remote modification of parameters� control of P, T, F
�with flow control, install across control valves
Reduce cost of ownership
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Open-architecture data systems
� one data highway for all systems� single window
�opportunity for remote support
� simple to add new analysersReduce time of design and cost of build
Reduce cost of ownership
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Plug-and-play maintenance
� For failures take a complete system to the field�plug in the new one, repair the old one
back at the workshop
Reduce cost of ownership
PROCESS ANALYTICAL SYSTEMS- a vision for the future
Standard designs for generic applications
Reduce time from concept to productReduce hours for design and development
Reduce cost of buildReduce cost of ownership
Maximise profitability
PROCESS ANALYTICAL SYSTEMS- a vision for the future
CREATE CHANGE
Agree a common visionStandardise sample system componentsStandardise data system architecturePartnerships between stake-holders
PROCESS ANALYTICAL SYSTEMS- a vision for the future
COMMERCIAL BREAK
RELATIONSHIPS IN THE PROCESS ANALYSIS INDUSTRY
discussion of how interactions between the stakeholders need to change
Time: Wednesday 26 Jan, a.m.
PROCESS ANALYTICAL SYSTEMS- a vision for the future
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