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Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Modular Sampling System Modular Sampling System InitiativeInitiative
Background and Status
2000 Fall Sponsor Meeting
Center for Process Analytical Chemistry
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
AgendaAgenda
• Status and UpdateStatus and Update
• Preview of Swagelok ProposalPreview of Swagelok Proposal
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
CPAC as a Multi-Purpose PA ForumCPAC as a Multi-Purpose PA Forum
• Legal Umbrella for Sponsors to MeetLegal Umbrella for Sponsors to Meet
R&D: Long Range / Short RangeR&D: Long Range / Short Range
Information Clearing HouseInformation Clearing House
Enabling Mechanism to Address Other Common Enabling Mechanism to Address Other Common NeedsNeeds
• Focus Groups: Forum toFocus Groups: Forum to
Review R&D ProgramsReview R&D Programs
Present Industry Present Industry CommonCommon Needs - RFP Needs - RFP
Address Industry Common NeedsAddress Industry Common Needs
Fieldbus Datalink Specification - DoneFieldbus Datalink Specification - Done
NeSSI - In progressNeSSI - In progress
MatLab On-line/Connectivity - Future?MatLab On-line/Connectivity - Future?
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Background and Chronology of NeSSI Background and Chronology of NeSSI ActivitiesActivities
• O&P Focus Group May 1999O&P Focus Group May 1999
Identified Sampling Systems as Common Area Of Identified Sampling Systems as Common Area Of InterestInterest
Sponsored Tutorial for Nov99 Sponsor MeetingSponsored Tutorial for Nov99 Sponsor Meeting
• Tutorial Nov99 CPAC MeetingTutorial Nov99 CPAC Meeting
Background/Reasons for InterestBackground/Reasons for Interest
Presentations by Suppliers/ End UsersPresentations by Suppliers/ End Users
• Participation in IFPAC2000 MeetingParticipation in IFPAC2000 Meeting
Plenary/General Papers (SS Enjoyed High Profile)Plenary/General Papers (SS Enjoyed High Profile)
WorkshopWorkshop
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
FLAN (Optical Fiber)
Sensor/Signal Bus
IA
Controller
(ASIC)A
TP
F
Sensor = Moisture Probe
Sampling System VisionSampling System Vision
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Process Analyzer VisionProcess Analyzer Vision
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Background and Chronology of NeSSI Activities Background and Chronology of NeSSI Activities (cnt’d)(cnt’d)
• Ad-hoc O&P Meeting @ Pittcon2000Ad-hoc O&P Meeting @ Pittcon2000
End-users Discuss Initial Target DesignsEnd-users Discuss Initial Target Designs
• CPAC2000 Spring MeetingCPAC2000 Spring Meeting
Formed SS Focus GroupFormed SS Focus Group
Defined Information Package (basis of RFP)Defined Information Package (basis of RFP)
• Distributed RFP (July 2000)Distributed RFP (July 2000)
Clarification Meeting at ISAEXPO2000 (40 Clarification Meeting at ISAEXPO2000 (40 attendees)attendees)
Received Proposals from Swagelok, ParkerReceived Proposals from Swagelok, Parker
Expect Additional Proposals/Comments from Expect Additional Proposals/Comments from Autoflow,Autoflow,
ABB Analytical, SAAI, Rosemount AnalyticalABB Analytical, SAAI, Rosemount Analytical
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Background and Chronology of NeSSI Activities Background and Chronology of NeSSI Activities (cnt’d)(cnt’d)
• CPAC2000 Fall MeetingCPAC2000 Fall Meeting
Preview of Swagelok ProposalPreview of Swagelok Proposal
Other Feedback Other Feedback
Micro-Reactor Proposal (MicroAnalytics)Micro-Reactor Proposal (MicroAnalytics)
• What is Next?What is Next?
Distribute Proposals to All Interested PartiesDistribute Proposals to All Interested Parties
Follow-up by ReportFollow-up by Report
Sampling System Session at IFPAC2001Sampling System Session at IFPAC2001
Review and Summary of NeSSI EffortReview and Summary of NeSSI Effort
Papers by Swagelok, Parker, Autoflow, ABB, Papers by Swagelok, Parker, Autoflow, ABB, RosemountRosemount
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
AcknowledgementsAcknowledgements
• 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
The EndThe End
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
O&P Focus Group Meeting May 99O&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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Nov99 CPAC SSISSS TutorialNov99 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Driving Forces for Driving Forces for ChangeChange
• Reduce Cost of Ownership
Non Recurring Costs = Cost to Build
Operating Cost
• Data Validation (Fit for Use)
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
A
F
T
P
Analyzer Analyzer
ControlleControllerr
Fie
ld
Fie
ld
LA
NLA
N
Integration of Sample System and Integration of Sample System and SensorsSensors
Sam
ple
Con
dit
ion
ing
S
am
ple
Con
dit
ion
ing
S
yste
mS
yste
m
Level 0Level 0 Level 1Level 1
Pro
cess
Pro
cess
Str
eam
Str
eam All System All System
ComponentComponents in Contact s in Contact with Sample with Sample including including the Sensorsthe Sensors
All Additional All Additional Electronic and Electronic and Computing Computing Components Components Required to Required to Generate Analytical Generate Analytical ResultResult
Mainly a Trust ConfigurationMainly a Trust ConfigurationNow a Trust & Verify ConfigurationNow a Trust & Verify Configuration
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Inte
gra
ted
Sam
plin
g/S
en
sor
Inte
gra
ted
Sam
plin
g/S
en
sor
Syste
mS
yste
m
A
F
T
P
Level 0 Subsystem IntegrationLevel 0 Subsystem Integration
Sam
ple
Con
dit
ion
ing
S
am
ple
Con
dit
ion
ing
S
yste
mS
yste
m
Level 0Level 0
Pro
cess
Pro
cess
Str
eam
Str
eam
Purpose:
Prepare and Verify a Representative Sample
(Compatible with Analyzer Sensor)
Opportunity:
Packaging as an Integrated Sensor and Sampling System
• Size
• Cost
Issues:
• Size
• Standardization
• VMAS
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
A
F
T
P
Analyzer Analyzer
ControlleControllerr
Fie
ld
Fie
ld
LA
NLA
N
Separation or Integration of Level 0/1 Separation or Integration of Level 0/1 SubsystemsSubsystems
Level 0Level 0 Level 1Level 1
Pro
cess
Pro
cess
Str
eam
Str
eam
Inte
gra
ted
Sam
plin
g/S
en
sor
Inte
gra
ted
Sam
plin
g/S
en
sor
Syste
mS
yste
m
Objective:Objective:
Close to Close to Sample Sample TapTap
Options:Options:
• RemoteRemote
• Separate but Separate but CloseClose•IntegratedIntegrated
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Integrated Sampling/Sensor/Controller Integrated Sampling/Sensor/Controller SystemSystem
A
F
T
P
Analyzer Analyzer
ControlleControllerr
Fie
ld
Fie
ld
LA
NLA
N
Integration of Level 0/1 SubsystemsIntegration of Level 0/1 Subsystems
Level 0Level 0 Level 1Level 1
Pro
cess
Pro
cess
Str
eam
Str
eam $$$$
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Nov99 CPAC SSISSS TutorialNov99 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Nov99 CPAC SSISSS Tutorial (Vendor Presentations)Nov99 CPAC SSISSS Tutorial (Vendor Presentations)
Autoflow
Rosemount
A+
Swagelok
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Nov99 CPAC SSISSS TutorialNov99 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IFPAC2000IFPAC2000
• 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
TODAY’S COST OF BUILDTODAY’S COST OF BUILD
For a major greenfield projectFor a major greenfield project
NumberK 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
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
TODAY’S COST OF OWNERSHIPTODAY’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
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IMAGINE THE FUTUREIMAGINE THE FUTURE
A
T
P
Analyzer Analyzer
ControlleControllerr
Fie
ld
Fie
ld
LA
NLA
N
Level Level 00
Level Level 11
Pro
cess
Pro
cess
Str
eam
Str
eam
F
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IMAGINE THE FUTUREIMAGINE THE FUTURE
FLAN (Optical Fiber)
Sensor/Signal Bus
IA Controller(ASIC) & Interface Module
Original Picture of Gas Delivery System courtesy Valin Corporation;
A
T
PF
Sensor = Moisture Probe
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IMAGINE THE FUTUREIMAGINE THE FUTURE
A
T
PF
Sensor = RAMAN Probe
Interface
Module
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IFPAC2000IFPAC2000
• 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
IFPAC2000IFPAC2000
• 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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
Pittcon2000 (New Orleans)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 InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
StatusStatus• CPAC Meeting May 1999 Done
O&P Identified Modular Sampling Systems
• CPAC Meeting Nov 1999 Done
O&P Sponsored Tutorial
• IFPAC2000 MeetingDone
Plenary Presentation Promoted SSISS
Session on Modular Sampling Systems
CPAC Sponsored Workshop
• Pittcon2000Done
Ad-hoc O&P Meeting
Propose Candidate Sampling System Descriptions
• CPAC Meeting May 2000 TBD
Modular Sampling System InitiativeModular Sampling System Initiative CPAC: Nov 6, 2000
What is Next?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