Ne SSI Generation II Revolution or Evolution New

Ne. SSI* - Generation II “Revolution or Evolution? ” *New Sampling/Sensor Initiative ISA 2001 - Houston, TX - September 10, 2001 INTERMAC - Tokyo, Japan - Nov. 8, 2001 Rob Dubois - Peter van Vuuren - Jim Tatera and. Associates “the best way to predict the future is to create it” 10/3/2020 1

Tutorial Outline z Introduction, Drivers & History z A Vision and the Market Trends z Ne. SSI Generation I, III Comparisons z 10 Dimensions of a Ne. SSI Generation II System z What will a Generation II prototype look like? z Some recent developments… z Ne. SSI Roadmap & Summary z CPAC (Center for Process Analytical Chemistry) Review 10/3/2020 2

Process analyzer systems have been accused of being. . . z complex z expensive z proprietary z “big box” (battleship) z hi maintenance z suspect regarding data integrity z slow to change Edvard Munch “The Scream” 10/3/2020 3

A Brief History of z Operates under the umbrella of the Center for Process Analytical Chemistry (CPAC) z Originated from various CPAC focus sessions z IFPAC 2000 plenary paper presented Ne. SSI vision z Focus groups: Pittcon 2000; ISA Expo 2000; IFPCA 2001, Pittcon 2001 z ISA 2001 Houston: Kick-off of Ne. SSI Generation II 10/3/2020 4

Major Goals of z Facilitate the acceptance/implementation of. . . y modular, miniature & smart sample system technology ybased on ISA SP 76 standardization work z Promote the concept of. . . yfield-mounted smart sampling/analytical systems yintegration of sample systems with physical/chemical sensors z Lay the groundwork for. . . yopen connectivity architecture for sensor communications (e. g. Ethernet, Device. Net, etc. ) yindustry standard communication protocols (e. g. OPC, Device. Net, CAN, etc. ) yweb enabled technologies (e. g. Browser based HMI) z Provide a technology bridge to the process for. . . y“sensor/lab-on-a-chip” micro-analytical devices 10/3/2020 5

A Modular Picture of Picture Courtesy John Thomas, Parker Hannifin Corp 10/3/2020 6

Imagine the Future after the 10/3/2020 7

What is Driving • Reduce Cost to Build Design, Engineering, Manufacturing, Installation, Etc. • Reduce Cost of Ownership Maximize Sustained “Fit for Use” Data Generation System Validation Representative Sample Validation Measurement (Data) Validation Communication Validation 10/3/2020 8

Market Acceptance Cost Ease of Design System Reliability Where In the World Are We? Critical Issues • acceptability by Process Analytical community Ne. SSI On the Post Analyzer House Time • technical challenges • cost Value • Reduce capital costs by 35% ; 40% LTCO Vision What’s going on in the world? . • Plug and Play - modular • Fast networks; robust electronics • At line/near line • “Lab on a chip”; lasers; wireless • A platform for micro. Analytical Market Needs 10/3/2020 • Fast, reliable, rugged, reasonable cost 9

Vision: The End of the Analyzer House System 10/3/2020 10

An Analytical System. . . Will Look More Like Us! z Single Processor - Overall Control y Sensor Analytical Manager (SAM) z System will be Multifunctional y Equal emphasis on all sensors z System will be Adaptable y Predictive maintenance; self-healing z Capable of Multivariate Analysis y Use many sensors for analysis Courtesy of Ken Creasy, Honeywell. IFPAC 2001 10/3/2020 11

Intent…of the Gen II Spec z“The Ne. SSI Generation II specification is intended as a vehicle for alerting the marketplace to the need for these types of products. ” "When men got structural steel, they did not use it to build steel copies of wooden bridges. " Ayn Rand. Atlas Shrugged. 1957. 10/3/2020 12

Ne. SSI Generations z. Ne. SSI Generation I (circa 2000) yan “arranged marriage” z. Ne. SSI Generation II (circa 2001 -2005) ya “courtship” - reengineering solution z. Ne. SSI Generation III (circa 2005+) ywireless, analytical sensors 10/3/2020 13

Gen. I versus Gen. II 10/3/2020 14

The Penitent - We’ve come a long way! 10/3/2020 Courtesy of Health and Safety Executive, Sheffield, England 15

Generation II Dimensions - Shopping List for Ne. SSI z 1. Heated Substrate z 2. Physical Sensors z 3. Actuators z 4. SAM z 5. HMI (Graphical) 10/3/2020 z 6. Wired Bus z 7. Wireless Bus z 8. X Mini Power Bus z 9. Packaging z 10. Analytical Sensor 16

1. Heated Substrate Div/Zone 1 GP. A-D AC Power Div/Zone 1 or 2 GP. A-D Conduction Heating - cartridge heater(s) - over-temperature cut-off Furn. by substrate mfg. Heating Fluids (alternative) 10/3/2020 17

2. Physical Sensors for z Doing analytical is just not good enough! System Diagnostics z Miniature Flow, Pressure, Temperature y. Gas and/or liquid service y. Rugged construction y. Encapsulated (IEC Ex m) y. Intrinsically Safe (IEC Ex ib) y. Div/Zone 1 Gp A-D; T 4 (135 C) FLOW: P, coriollis, thermal, other? COM A/D Substrate 10/3/2020 18

2. Conceptual Sensor for Ne. SSI Parallel Ports - standard size/pin - daisy chain “Top Hat” Comm. Chip A Body - encapsulated Memory Comm. BARRIER - Process Seal - Electrical Isolation - Thermal Insulation Skirt - engineered 1. 50” Sensor 10/3/2020 B µP Digital “Smart” Sensor - engineering units - memory A/D Process Cavity - no unswept voids - low volume Base - 316 SS - pressure rated 19

3. Electrical Actuators on the Substrate - COMBO z. Miniature substrate mount y. Gas and/or liquid service y. Wide P & T service y. Rugged, encapsulated (IEC Ex m) y. Intrinsically Safe (IEC Ex ib) y. Div/Zone 1 Gp A-D; T 4 (135 C) COMBO Valve /w integral solenoid Comm. SV AIR Act. On/Off and Proportional 10/3/2020 20

3. …or Direct Electrical Actuators on the Substrate z …solenoid valves z …motorized valves Solenoid or Motorized Valve z…again suitable for Div/Zone 1 Comm. SV On/Off and Proportional 10/3/2020 21

3. Conceptual “Combo” Valve “Top. Hat” Comm. Chip A B Comm. 3 -way “pilot” solenoid valve - Intrinsically Safe Actuator - NO or NC Vent D/A Solenoid Actuator Vent Valve Engineered Insulation Skirt 10/3/2020 Parallel Ports - standard size/pin - daisy chain Instrument Air Digital On-Board Conventional pneumatic valve Thermal Barrier 22

4 a. Introducing SAM - Sensor Analytical Manager Standalone SAM Embedded SAM Analytical Sensor A 10/3/2020 Analyzer F Vv T Vv P F 23

4 b. SAM does 5 jobs! Field Interface Gateway to an Ethernet LAN - OPC perhaps - Graphical - Wireless - e. g. Bluetooth™, 802. 11 Software Applets for Sample System Host to a Repetitive Tasks Sensor/Actuator Bus (Industry Common) 10/3/2020 “Open” Development Space for Custom Software 24

4. SAM - Provides a “Picklist” of Common SS Tasks 4 Zero & span validation 4 Pressure regulation 6 Stream switching 4 Maintenance diagnostics 4 Temperature control z. Interoperability ytalk to all analytical systems Enabling Technology for micro. Analytical SAM 10/3/2020 25

4. SAM - Suggested Package 10/3/2020 Courtesy of Adalet 26

5. HMI (Human Machine Interface) PDA Hello? PC A 10/3/2020 F Vv T Vv P Vv=automatic valve; P=pressure sensor; F=Flow Sensor; A=Analytical Sensor; T=Temp. Sensor F 27

6. Standalone “SAM” with Wired Sensor/Actuator Bus Analyzer System Ethernet LAN z IEC Ex ib intrinsically safe z Leverage FISCO power concept z Standard Plug & Play Conn. z Device. Net or SDS Sensor Analytical Manager (SAM) ? V T P A 10/3/2020 Analyzer Controller Legend: P Pressure Sensor T Temp Sensor V Valve/Actuator A Analytical Sensor 28

6. Embedded SAM With Wired Sensor/Actuator Bus z IEC Ex ib intrinsically safe z Leverage FISCO power concept z Standard Plug & Play Conn. z Device. Net or SDS Analyzer System Ethernet LAN ? Analyzer Controller w/ Embedded SAM Functionality V T P A 10/3/2020 Legend: P Pressure Sensor T Temp Sensor V Valve/Actuator A Analytical Sensor 29

7. Wireless Signal (Gen III? ) Analyzer System Ethernet LAN z Bluetooth or 802. 11 z Plug and Play! z Power & I. S. y X-proof miniature power bus V Analyzer Controller Sensor Analytical Manager (SAM) T P A P. S. 10/3/2020 30

8. What the world need is. . . Sensors (typ) z…a Miniature wiring method y “plug & socket” y. Division/Zone 1 y. MTL (England) AC Power 10/3/2020 Mini-Power Bus AC/DC 31

8. Mini X-proof connector - Div/Zone 1 Can we make this small? 10/3/2020 32

9. Enclosure/Package Convection Heater X-Proof (OPTIONAL) Temp. Sensor Intrinsic Safe Div/Zone 1 GP. A-D Div/Zone 1 or 2 GP. A-D AC Power No Purge or Pressurization 10/3/2020 NEMA or IP Rated Enclosure - insulated 33

10. Analytical Sensors Fiber Optic AT SAM One sensor per component “lab on a chip” One Sensor and Multiple Analytes “laser scanning device” A 10/3/2020 F Vv T A 34

Connectivity! - CPAC “Conn. I” Initiative 10/3/2020 35

Elements of a Ne. SSI Gen II Smart Prototype z. Programmable, heated substrate z. Digital sensors: F, P & T; serial bus z. Division/Zone 1 z. SAM; control algorithms z. Wireless/graphical HMI z. Packaged for outdoor installation 10/3/2020 36

Globalize, harmonize. . . z IFPAC y 2001. USA. z CPACT y 2001. Europe. z ISA 2001. y 2001. USA. z INTERMAC y 2001. Japan. 10/3/2020 37

Design & certify to global requirements. . . z NEC, UL, FM (USA) z CEC, CSA (Canada) z CENELEC (Europe) z ATEX Directive (Europe) z CE Mark 10/3/2020 38

New Developments! 10/3/2020 39

O 2 Measurement New 10/3/2020 Courtesy of Panametrics & Swagelok Co. 40

First Ne. SSI H 2 O Probe New Courtesy of Panametrics & Swagelok Co. 10/3/2020 41

First p. H Sensor New Courtesy of Rosemount Analytical 10/3/2020 42

Mass Flow Controller 10/3/2020 Courtesy of Porter Instruments and the Swagelok Co. New 43

First Optical Cell New 10/3/2020 Courtesy of Applied Analytics, Inc. 44

IGC-II c/w Elastomer Seals New Courtesy of the Swagelok Co 10/3/2020 45

Petrochemical installs. . . Courtesy of a major. Texas gulf coast petrochemical facility 10/3/2020 46

A 5 year Roadmap North A merica Europe z A Plan to Achieve the Vision Asia 10/3/2020 47

Ne. SSI Roadmap Definition Analytical & Wireless Gen. III Smart/”Electrified” Gen. II Mechanical Gen. I Analytics/Sensors (e. g. laser based)/Wireless Simple Analyzers (H 2 O, O 2, p. H, etc. ) Prototype - Physical Sensors/Heating/SAM Mechanical Components e. g. filters, valves, etc. Ne. SSI/CPAC Vision SP 76 Substrate Available 2000 10/3/2020 01 Mech. Field Trials 02 Smart Field Trials 03 Time (years) 04 05 06 48

Acknowledgements I z Dow y. Danny Quevillon y. Reg Hartwig y. Christoph Kleimeier y. Walt Henslee y. Bac Vu (SP 76) y. David Gay z Syncrude y. Ian Verhappen 10/3/2020 z Exxon. Mobil Chemical y. Dan Podkulski (SP 76) y. Jeff Gunnell y. John Cumbus y. Rajco Puzic z CPAC y. Mel Koch y. Lloyd Burgess y. Brian Marquardt 49

Acknowledgements II y. Doug Mitchell Panametrics y. John Wawrowski Swagelok y. Rick Ales - Swagelok y. Yoav Barshad Applied Analytics y. Trevor Knittel Analytical Specialties y. Mike Marsceill - Porter 10/3/2020 y. Carl Jones Rosemount Analytical y. CD Feng - Rosemount Analytical y. Bob Nickels Honeywell y. Ron Eddleman Measurementation y. Chris Towle & David Blisset - MTL 50

Summary z. Evolution as opposed to revolution z. Spin-offs…. ymicro. Analytical devices ymicro. Reactors y. Conn. I (connectivity initiative - CPAC) z. Release of Generation II Spec y. December 2001 (*revised) y. To Ne. SSI Distribution List 10/3/2020 51

. . . a few references you may want to look over. z The Ne. SSI portion of the CPAC web site at www. cpac. washington. edu z The ISA Draft Standard - ISA Draft 76. 00. 03 , “Modular Component Interfaces for Surface-Mount Fluid Distribution Components--Part 2: Elastomeric Seals” z "The New Sampling/Sensor Initiative", Terence K. Mc. Mahon, Control, August/2001, Vol XIV, No. 8, page 158 z "Molding the Future of Process Analytical Sampling", Ellen Fussell, In. Tech, August/2001, page 32 10/3/2020 52