nessi*: enabling technology for analytical transducers · 2012-11-27 · nessi*: enabling...
TRANSCRIPT
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NeSSI*: Enabling Technology for µAnalytical Transducers
Pittcon 2002 - New Orleans, USA - Mar 20, 2002
Rob Dubois - Peter van Vuuren - Jim Tatera .
C PΛ C
“the best way to predict the future is to create it”
Tatera and Associates
*New Sampling/Sensor Initiative
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Courtesy of Owen Beattie,
University of Alberta, Canada
Q. Is Process Analytical frozen in time?
A. No! A renaissance is in progress.
John Torrington Chief Petty Officer on the HMS Terror - preserved in the permafrost. Victim of lead poisoning. ”The Franklin Expedition” d. 1846 (age 20)
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Tutorial Outline
z Introduction, Drivers & Historyz A Vision and the Market Trendsz NeSSI Generation I and II comparisonz 7 Elements of a NeSSI Generation II Systemz What will a Generation II prototype look like?z Opportunities for microanalyticsz NeSSI Roadmap & Summaryz How do I get involved with NeSSI?
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NeSSI Initiative
z An ad hoc global industry initiative, formed in June, 2000 to drive permanent change in Process Analysis.y NeSSI mail-out has now grown to 250+ subscribersy Composed of End Users, Manufacturing Companies,
Integrators
z Sponsored by the Center for Process Analytical Chemistry (CPAC) - legal umbrella
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z Originated from various CPAC focus sessions z IFPAC 2000 plenary paper presented NeSSI visionz Focus Groups and Workshops
y Pittcon 2000; ISA Expo 2000; IFPAC 2001, Pittcon2001, CPACT Edinburgh, ISA Analytical Division, ISA 2001, IFPAC 2002
z Tutorials:y ISA2001 Houston, INTERMAC 2001 Tokyo,
Pittcon2002
A Brief History of
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NeSSI Objectives
z Facilitate the acceptance/implementation of...y modular, miniature & smart process analytical
technologyz Promote the concept of...
y at the pipe/field-mounted (“byline”) analytical systems
z Lay the groundwork for...y open connectivity communication architecture
z Provide a technology bridge to the process for...y “sensor/lab-on-a-chip” microanalytical devices
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The drivers for change...
z Reduce Cost to Buildy Design and Engineeringy Manufacturing and Installation
z Reduce Cost of Ownershipy Design Standardizationy Simpler, less expensive maintenance
z Enhance Reliabilityy Validate sample, data, communication
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Market AcceptanceLower CostEase of DesignSystem Reliability
Time
What’s going on in the world?What’s going on in the world?
On the Post
AnalyzerHouse
NeSSI
Technology Explosion!
• Fast networks; robust electronics
• Lab-on-a-chip; lasers; wireless
• Open software platforms
What does the Market Need?
• Reliable, rugged, low cost & fast
What are the Critical Issues?
• Adoption of standard footprint
• Component Availability
1938 2000
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Process Analytical systems have been accused of being...
z complexz expensivez proprietaryz “big box”
(battleship)z hi maintenancez suspect
regarding data integrity
z slow to changePhoto Credit: Erich Lessing/Art Resource, NY
Edvard Munch, The Scream.National Gallery, Oslo, Norway.
© 2000 The Munch Museum, The Munch-Ellingsen Group, Artists Rights Society, New York
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Project Segmentation
Gen III
Gen II
Gen I Mechanical (mostly)
Electrical/Smart (Diagnostic)
MicroAnalyticalValue
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Gen I - Standardize on a miniature, modular system
z “Borrowed” from the semiconductor industry
z LEGO® like designz ISA Standard
y rugged
Courtesy of CIRCOR
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Elastomer Seals are desired in HP Industries
Courtesy of the Swagelok Co
Manufacturers…
• Parker-Hannifin
• Autoflow
• CIRCOR
• Kinetics
• Swagelok
• Fujikin
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What is ISA SP76?
Copyright 2001 ISA. All rights reserved.
Reproduced and distributed with permission of ISA.
Note: Draft provided for promotion
only.
Refer to ISA SP76.
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Imagine the Future after
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Vision: The End of the Analyzer House System
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An Analytical SystemAn Analytical System...Will Look More Like Us!
z Single Processor - Overall Controly Sensor Analytical Manager (SAM)
z System will be Multifunctionaly Equal emphasis on all sensors
z System will be Adaptabley Predictive maintenance; self-healing
z Capable of Multivariate Analysisy Use many sensors for analysis
Courtesy of Ken Creasy, Honeywell. IFPAC 2001
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Gen. I versus Gen. IIFeatureSignalProtection MethodsClassificationSensorsIntelligenceControl PhilosophyRegulating Comp.Passive Comp.ActuatorsHeatingWiring
Generation I4-20 mAPurgeDiv 2Non-substrateLimitedCentralizedSelf-containedMechanicalStand-aloneExternalConduit/Cable
Generation IISerial BusISDiv 1SubstrateSmartDistributed (SAM)PID control loopsElectro-mechanicalSubstrate MountSubstrate integratedIS Wiring
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Generation II Dimensions- 7 Elements
z 1. Heated Substratez 2. Physical t-Sensorsz 3. Combi Valves
z 4. SAM ☺z 5. PC with HMI
z 6. IS Multi-drop busz 7. Enclosure
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1. Heated, Programmable Substrate
AC PowerAC Power
Conduction Heating- cartridge heater(s)
- over-temperature cut-off
Furn. by
substrate mfg.
Heating Fluids
(alternative)
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2a. Physical Sensors for System Diagnostics
z Doing analytical is not good enough!z Miniature Flow, Pressure, Temperature
y Gas and/or liquid servicey Rugged constructiony Intrinsically Safe (IEC Ex ia)y Div/Zone 1 Gp A-D; T4 (135 C)
A/D
COM
FLOW:
∆ P, coriollis,
thermal, other?
Substrate
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2b. Conceptual Sensor for NeSSI
Process Cavity- no unswept voids
- low volume
BARRIER- Process Seal- Electrical Isolation- Thermal
Insulation Skirt- engineered
A/D
Comm.
SensorBase
- pressure rated
µP
Mem
ory
Body- encapsulated
“Top Hat” Comm. Chip
A
Port- standard size/pin
- daisy chain
1.50”
Digital “Smart” Sensor- engineering units
- memory
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3a. Electrical Actuators on the Substrate - COMBO
z Miniature substrate mounty Gas and/or liquid servicey Wide P & T servicey Intrinsically Safe (IEC Ex ia)y Div/Zone 1 Gp A-D; T4 (135 C)
COMBO Valve /w integral solenoid
SV
Comm.
Act.
AIR
On/Off andProportional
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3b. Conceptual “Combo” Valve
A
Actuator
Instrument Air
ValveVent
Vent
Comm.
D/ASolenoid
Conventional pneumatic valve
“TopHat” Comm. Chip
3-way “pilot” solenoidvalve - Intrinsically Safe
Actuator- NO or NC
Engineered InsulationSkirt
Port- standard size/pin
- daisy chain
Digital On-Board
Thermal Barrier
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4a. Introducing SAM “I do 5 jobs!”
Gateway to an Ethernet LAN
- OPC perhaps
Host to a
Sensor/Actuator Bus
Field Interface
- Graphical
- Wireless
- e.g. Bluetooth™, 802.11
Software Applets for
Sample System
Repetitive Tasks
(Industry Common)
“Open” Development Space for Custom Software
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4b. Standalone “SAM” - Wired Sensor/Actuator Bus
SensorAnalyticalManager(SAM)
Analyzer System Ethernet LAN
PLegend:
Pressure Sensor Temp SensorValve/Actuator Analytical Sensor
VA
T
PC or Analyzer Controller
VTP
A
?☺
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4c. Embedded SAM - Wired Sensor/Actuator Bus
Analyzer System Ethernet LAN
PLegend:
Pressure Sensor Temp SensorValve/Actuator Analytical Sensor
VA
T
VTP
A
?Analyzer Controller
w/ Embedded SAM Functionality
☺
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4d. SAM “Pick-list” for Common Sampling Tasks
4Zero & span validation4Pressure regulation4Temperature monitoring3Stream switching4Maintenance diagnosticsz Interoperability
y talk to all analytical systemsSAM
Enabling Technology
for microAnalytical
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5. PC/PDA Graphical HMI (Human Machine Interface)
F Vv T P
☺
FVvA
HMIPersonal digital
assistant
PC
Hello?
Vv=automatic valve; P=pressure sensor; F=Flow Sensor; A=Analytical Sensor;T=Temp. Sensor
☺HMI
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6. Serial Multi-drop Bus -“Au Revoir 4-20 mA?”
z CANbusy DeviceNet, SDS, etc.y Intrinsically Safe
z Engineering units on board sensors
z Reduces wiring loady multi-drop
z Eliminates I/Oz Rugged, low cost
VTP
A
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7. Enclosure“X-team” Haz. Review Process
AC Power
Div/Zone 1GP. A-D, T4
Enclosure- NEMA 4/IP56 Rated- all climate operation- no purges- no X-proof tubs- low cost of operation
Sensor Bus
Intrinsically Safe (IEC Ex ia)- no gas “sniff” tests req..- allows hot disconnects- plug & play
Heaters- Substrate & Enclosure- IEC Ex d- programmable temp.
AC Power
Designed forGlobal Use
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Gen. II“Get on the substrate (bus)!”
A
Actuator
ValveVent
Vent
Comm.D/A
SolenoidFlow Sensor
A
A/D
Comm.
µP
Mem
ory
“combi” valve
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Programmable Substrate Heater
Let’s build a Gen II system
VP
A
F
Ethernet LAN
Analyzer
Controller
SAM
CANbus
PDA
Auxiliary Heating/Cooling
SubstrateT
T
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Gen III Wireless SignalAnalyzer System Ethernet LAN
VTP
A
z Eg Bluetooth , 802.11z Plug and Play!z Power Supplied by...
y X-proof or IS miniature power bus
SensorAnalyticalManager(SAM)
☺
P.S.
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Generation IIIPlug & Play µAnalytical
F Vv T
☺
A
SAM
Fiber Optic
ATOne sensor
per component“lab on a chip”
One Sensor and Multiple Analytes
A
Ethernet
Transducer Bus
Enabling Technologyfor µAnalytical - GC-on-a-chip
- micro MS
- chem. sensors
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Application Ranges Notespecific Compounds/Properties
Moisture in gases/vapours 0-1 PPM; 0-10 PPM; 0-100 PPMv/v
Moisture in liquids 0-10 PPM w/w; 0-100 PPM w/wOxygen 0-1 PPM; 1-10 PPM; 0-100
PPM; 0-1%; 0-25%; 0-100%ranges (typ.)
Mini pH liquidDissolved oxygen liquid
Conductivity liquidORP liquid
Hydrogen PPM, hi and low percentSulphur PPM; PPB
LEL 0-100 LELElectrochemical sensors component specific
Multi-Analyte TechniquesMiniature spectrometers: Includes UV, VIS, IR, NIR TDL
and Raman - scanningMiniature mass spectrometers Time of Flight, others…Gas chromatograph module
Some examples of MicroAnalytical Sensors Wanted
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Keys to development
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Don’t (re)invent…leverage existing standards
z Make use of existing connectivity and communication...
x Ethernetx OPCx CANbusx wireless e.g. Bluetooth™ x WEB servers/Internet
Personal Digital Assistant (PDA)
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Communicate…globally!
z Internationaly Europe, Japan,
Canada, USA
z Consortiay CPAC, CPACT
z Upcomingy ISA - AD 2002
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Design & certify to globalrequirements...
z NEC, UL, FM (USA)z CEC, CSA (Canada)z CENELEC (Europe)z ATEX Directive
(Europe)z CE Markz JAPAN, ASIA…
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Around the Loop: The New Sampling/Sensor Initiative
CONTROL MAGAZINE
Great publicity...
“It's estimated that 70-80%
of analyzer outages can
be traced to the sample system”Terrence McMahon
August 01, 2001
Also ISA InTech Magazine; Chem. & Eng. News
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New Developments
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NeSSI Analyzers - here today
Courtesy of Panametrics & Swagelok Courtesy of Rosemount Analytical
Courtesy of Rosemount AnalyticalCourtesy of Panametrics & Swagelok
Oxygen
H2O
pH
Conductivity
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Just announced...
Courtesy of Applied Analytics
MIR ATR
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Courtesy of Porter Instruments and the Swagelok Co.
MFC’s here today
y Porter Inst. (Div. 2)y Others…Gen Purpose
x Unit Instrumentsx Brooks
Undergoing
Certification
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Today’s Typical Technology - Sasquatch Size
Armored rotametersand flow switches
Explosion ProofFittings
and Conduit SealsCustom each job
Skilled electricianMultiple fittings, valves
tubed by skilledinst. fitter
IS SolenoidValves and
Pneumatic Valves
Z-purge
assemblies
Courtesy of a major petrochemical facility
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Petrochemical installs...
Coutesy of a
gulf coast
petrochemical facility
Courtesy of an east coast petrochemical facility
and Parker-Hannifin
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What’s New - Generation II Specification
z Draft version now competez Global Review Teams in Progress
y X-team (hazardous areas)y C-team (connectivity issues)y A-team (simple applets)
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White Paper in Progress
z Driven by Honeywell Automationz Will adapt final NeSSI Gen II spec as
criteria for buildz Expand End Users, Manufacturers
y Looking for involvement!!
z 10-20 Gen II prototypes will be builtz DoE being approached for funding in June
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Time (years)
03 04
NeSSI Roadmap
02
Mechanical Components e.g. filters, valves, etc.
Mechanical FieldInstallations
SP76 Substrate Available
NeSSI/CPAC Vision & Roadmap
2000
Design /Prototype - Gen II Smart/Heating/SAM
Smart Field Installations
MechanicalGen. I
Smart/”Electrified”Gen. II
µAnalytical & WirelessGen. III
01 0605
Rev. 1, Dec. 2001
µ Analytics/Sensors (e.g. laser based)/Wireless
Simple Analyzers (H2O, O2, pH, UV/VIS, etc.)
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References & involvement...
...a few references you may want tolook over.z The NeSSI portion of the CPAC web site at
www.cpac.washington.eduz The ISA Draft Standard - ISA Draft 76.00.02 , “Modular
Component Interfaces for Surface-Mount FluidDistribution Components--Part 2: Elastomeric Seals”
z "The New Sampling/Sensor Initiative", Terence K.McMahon, Control, August/2001, Vol XIV, No. 8, page158
z "Molding the Future of Process Analytical Sampling",Ellen Fussell, InTech, August/2001, page 32
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Acknowledgements I
z Dowy Danny Quevillony Reg Hartwigy Walt Hensleey Bac Vu (SP76)y John Leach IIy Craig Snook
z ExxonMobil Chemicaly Dan Podkulski (SP76)y Jeff Gunnelly John Cumbusy Rajko Puzic
z CPACy Mel Kochy Dave Veltkamp
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Acknowledgements II
y Doug Mitchell -Panametrics
y John Wawrowski, Rick Ales, Dave Simko -Swagelok
y Yoav Barshad -Applied Analytics
y Nick van Bruggen -Porter
y Gary Frank, Raj Adani- Kinetics
y CD Feng - RosemountAnalytical
y Bob Nickels, Ulrich Bonne, Ken Creasy -Honeywell
y Chris Towle/Don Long - MTL
y Steve Doe - Parkery X-Team
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A parting thought...
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
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Summary...Enabling technology for...
y Miniature physicalsensors
• Flow• Temperature• Pressure
y Miniature chemicalsensors
x “lab-on-a-chip”
y Component Mfgs.x Calibrators, pumps &x dryers, etc.
Courtesy of Mass-Sensors Inc.