Citius Fortius Altius A New SamplingSensor Initiative Ne

Citius, Fortius, Altius: A New Sampling/Sensor Initiative (Ne. SSI) Rob Dubois & Peter van Vuuren 1

Process analyzer systems have been accused of being. . . • • complex expensive proprietary “big box” (battleship) • hi maintenance • suspect regarding data integrity • slow to change Edvard Munch “The Scream” Photo Credit: Erich Lessing/Art Resource, NY National Gallery, Oslo, Norway. © 2000 The Munch Museum, The Munch-Ellingsen Group, Artists Rights Society, New York 2

Citius (Faster) • Faster to design & build – modular design – at the pipe: field mounted – “analytical transmitter” – engineering tool kit • Faster to modify – plug and play sample sys. • Faster sensor to analyzer development cycle 3

Fortius (Stronger) • Rugged and compact • Reduced maintenance – predictive model • Sample system as a science rather than art • Standard components • Standard sampling systems for industry wide “common” applications 4

Altius (Higher) • • • How can we reduce cost to build -35%*? How can we reduce cost of ownership -40%*? How can we obtain higher reliability? How can we achieve higher data confidence? How do obtain common validation protocols? *Ref. To Gunnell/van Vuuren IFPAC 2000 Presentation 5

A Brief History - Ne. SSI • Operates under the umbrella of the Center for Process Analytical Chemistry (CPAC) • Originated from various CPAC focus sessions • IFPAC 2000 plenary paper: J. Gunnell/P. van Vuuren • Focus groups: Pittcon 2000; ISA Expo 2000 • Ne. SSI: ad hoc group interested in new sample systems • Ne. SSI: supportive of the ISA SP 76 standard • Ne. SSI: no affiliations; sponsored by CPAC 6

Ne. SSI objectives. . . • Facilitate the acceptance/implementation of. . . – modular, miniature & smart sample system technology • based on semiconductor (SEMI) standards & ISA SP 76 work • Promote the concept of. . . – field-mounted analytical systems – integration of sample systems with physical/chemical sensors • Lay the groundwork for. . . – open connectivity architecture (e. g. Ethernet, wireless) – industry standard protocols (e. g. OPC, Hart, Fieldbus, Profibus) – web enabled technology (e. g. browser, HMI, I/O Servers) • Provide a technology bridge to the process for. . . – “lab-on-a-chip” analytical sensors 7

“Request for Proposals” (RFP’s) 1 Paper designs requested for six “typical” petrochemical industry sampling scenarios – Measurement of PPM H 2 O and O 2 in a high Purity Hydrocarbon – Measurement of p. H in an Aqueous Acid/Base Stream – O 2 Measurement in a Stack Gas (low pressure) – Sampling System for Toxic Gas Measurement – Two stream sampling system (includes Liquid Vaporization) – Eight (8) Stream Sampling System • INTENT: DIVERSE SAMPLING SCENARIOS 8

“Request for Proposals” (RFP’s) 2 3 4 5 Provide electrical layout and interface drawings Provide a functional description of the design Propose a “sampling system/electrical bus” Propose ideas to standardize the software protocol interface 6 Describe compliance/non-compliance and barriers to the use of ISA standard SP 76 (modular component interface draft standard) • INTENT: ESTABLISH ISSUES, BARRIERS & SYNERGIES 9

Response to “RFP’s” Swagelok • Complies with SP 76 – Metallic ‘C’ seal design now • Elastomer seals later Courtesy of Swagelok – 3 channels – 1. 5” blocks; downmounts • Lego like assembly – IGC II technology – highly engineered • Investigating flow & Xproofing solutions 10

Response to “RFP’s” Parker-Hannifin • Compliant with SP 76, but. . . – – 5 channels 1. 5 & 2. 25” block available ability to isolate sections elastomer seals • Hybrid design – manifold and tube & block • Heating – fluid heating “channel” Courtesy of Parker-Hannifin • Investigating flow & Xproofing solutions 11

Response to “RFP’s” Autoflow • Fully compliant with SP 76 – TFE loaded elastomer seals – 3 channels – 1. 5” blocks Courtesy of Autoflow • Division 1 cartridge heating • Div. 2 thermal flow meter, flow switches • Utilizing current electrical X-proofing concepts 12

Response to “RFP’s” Rosemount-Swagelok • Example of synergy that can drive Ne. SSI • Field mounted chromatograph with a miniature/modular sample system • THESE COLLABORATIONS AND ALLIANCES ARE CRUCIAL Courtesy of Rosemount & Swagelok 13

Response to “RFP’s” ABB Analytical At-Line • Demonstrates intuitive Human Machine Interface (HMI) Graphical User Interface (GUI) for a sample system • Demonstrates digital comm. to a sample system(Profibus, Ethernet, Vista. NET) • Autoflow miniature, modular system Courtesy of ABB Analytical – 5 x reduction in volume! 14

Response to RFP’s Electrical Issues • Electrical codes do not support simple, safe wiring methods – NIS Methods: bulky x-proof conduit, MI, metal sheath – IS Methods: simple braided cable not yet approved – Physical separation required between IS and NIS • Simple sensors such as temperature, proximity flow & strain gauge pressure do support Intrinsic Safe wiring methods • Conventional pressure/flow controllers need high energy and are unsuitable for IS Safety methods • Enclosure mounted components should be rated Div/Zone 1 15

Comments versus “RFP’s” Viable and Practical? • We may be “trading labour to build for labour to engineer” • Programmed substrates require detailed design engineering – possible loss of flexibility offered by tube & block • Costs, at least for initial systems, will not be any cheaper • Need vendors who can provide novel X-proof wiring solutions and association with Fieldbus style agencies • A linear, singular substrate is not feasible • Small ports may have problems with liquid streams • Need a base plate or substrate port for signal air • Viable & Practical: YES, with limitations 16

So what are the barriers/issues? • • Lack of Div. 1 explosion proof components Need for new, miniature flow devices Need for new IS/NIS Div. 1 miniature wiring methods Std. communication methods Need for integral heating Cost & flexibility? “Brute force” legacy 17

Clever Sample Systems Needed! • Self-adjusting for optimal performance under varying conditions – On board delta/Pressure, Flow, Temp. Measure & Control • Tracks reliability and operation metrics – tally valve cycles, gas usage – maintenance log, operation manuals • Self-diagnostic Graphical User Interface (GUI) – show Sample System operation • Embedded processors • Decentralized control • “Since the oft quoted 8090% of the problems with analyzers are sample system related then perhaps our efforts should be focussed in this area!” 18

Tower of Babel or Open Standards? • Opportunity for standard sample system software “applets”. Examples. . . – – stream selection protocols validation protocols monitoring packages sample system diagnostics, etc. • Opportunity for… – common communication protocols – hard wire, wireless & fiber optic connectivity buses 19

- A Call to Action… • Component manufacturers we need new, miniature Div. /Zone I manifold mounted components – – flow measurement devices pressure/temp. transducers motorized valves; solenoids mini-purged components! • We need an effort to define Div/Zone 1 signal & power ‘bus’. . . – IS (signal) and NIS (power) – wireless; fiber optic signals? 20

- A Call to Action… • We need a task force to define. . . – stand alone sample system controllers – standard communication protocols – interoperable software “applets” to make sample systems “clever” • Analyzer manufacturers, universities we need: – simple/small analytical devices – substrate mounted; X-proof – “lab on a chip” devices 21

- A Call to Action… • Substrate manufacturers… – we need Div. 1 integral electrical/fluid heated bases – “design guides” for 3 rd parties • We need to. . . – – – Promote; synergize Publish test results Harmonize regulatory barriers Bring in key technical players Work with groups like Fieldbus, Profibus, OPC… 22

Ne. SSI Next Steps… Sunrise…. . Sunset? • Ne. SSI deliverable. . . – Compact Disk (CD) – final report • Should Ne. SSI continue? – In what form, membership, etc. • Is there a need for a Process Analytical Foundation? • YOU ARE CORDIALLY INVITED: – to an open forum … Tuesday 6: 30 - 7: 30 PM in the Ossabaw Room. 23

Summary…let’s stay on track! • • • Three excellent but diverse substrate designs Good synergies emerging Ne. SSI “list” is growing. . . Opportunities abound … Some barriers to overcome (esp. Electrical issues) Petro-chemical end users desire change! – Citius, Fortius, Altius! 24

Acknowledgements • ISA • Dow Chemical – Jim Tatera – David Gay; Reg Hartwig; Walt Henslee; François Ramond; Ron O’Reilly; Brian Worthington • Expo 2000 forum, etc. – Dan Podkulski • SP 76 Contribution! • Exxon. Mobil Chemical • Focus group (Pittcon 2000) • Focus group (ISA Expo 2000) • IFPAC 2001 – Jeff Gunnell; Dan Podkulski; John Cumbus; Paul Hromadka; Rajko Puzic • CPAC – Mel Koch; Lloyd Burgess; Larry Ricker 25

Acknowledgements Ne. SSI contributors • Kelley Bell (ABB PA) • Richard Hughes (Autoflow) • John Gajewski (FRCO) • Bud Keyes (FRCO) • Stephen Staphanos (FRCO) • Steve Doe (Parker) • John Morse (Parker) • CD Feng (Rosemount. Uniloc) • Frank Ruiz (Ruiz and Assoc. ) • Dave Simko (Swagelok) • Richard Ales (Swagelok) • Doug Nordstrom (Swagelok) • All Ne. SSI contributors not acknowledged or mistakenly omitted! 26

Acknowledgements Ne. SSI contributors • Kelley Bell (ABB Analytical) • Richard Hughes (Autoflow) • John Gajewski (FRCO) • Bud Keyes (FRCO) • Stephen Staphanos (FRCO) • Steve Doe (Parker) • John Morse (Parker) • CD Feng (Rosemount. Uniloc) • Frank Ruiz (Ruiz and Assoc. ) • Dave Simko (Swagelok) • Richard Ales (Swagelok) • Doug Nordstrom (Swagelok) • All Ne. SSI contributors not acknowledged or mistakenly omitted! 27