Ne SSI Generation II The Elements Power of

Ne. SSI™ - Generation II The Elements & Power of an Automated Analytical System Rob Dubois CPAC/Ne. SSI™ Workshop – AM Session Seattle, Washington, USA May 3 -6, 2004 “the best way to predict the future is to create it” rnd/May 6, 2004

The Vision of Success • We are able to… – design, auto-document & assemble. . . an analytical system at our workbench. • Lego®-like (unskilled) assembly – increase reliability by predicting system failure by full, integrated automation – reduce time to configure/install by 75% – reduce total cost by 40% rnd/May 6, 2004 Gregor Rasputin – “Visionary” 2

Objective 1 Facilitate the acceptance/implementation of modular, miniature & smart sample system technology based on ANSI/ISA SP 76 standard substrate Objective 2 Provide a technology bridge to the process for. . . “sensor/lab-on-a-chip” micro-analytical devices Courtesy of Dow Chemical, Fort Saskatchewan, Canada rnd/May 6, 2004 3

Objective 3 Promote the concept of. . . field-mounted (By-Line) smart analytical systems Objective 4 Lay the groundwork for Pipe to Pixel™ open connectivity architecture for intrinsically safe transducer communications (e. g. CAN, Profi. Bus, etc. ) and industry standard communication protocols (e. g. Ethernet, OPC, etc. ) OPC Gateway IS bus T Courtesy of Dow Chemical, Freeport, Texas rnd/May 6, 2004 Gas Analyzer SAM Sample System 4

Ne. SSI™ Development Progress 2006 -07 2004 -05 Gen III u. Analytical & Wireless Today END USER VALUE Gen II Electrical Networked & Smart Gen I Mechanical/4 -20 m. A rnd/May 6, 2004 5

A Brief History of Ne. SSI™ • Concept of Modular Sampling System based on SEMI design conceived at ISA AD Meeting, 1998 • Groundwork for Ne. SSI™ started at CPAC focus group. (Nov 99) • Ne. SSI™ (CPAC Initiative) formally initiated in June 2000 at ISA • SP 76 (Gen I) standard approved by ANSI/ISA – June 2002 • Gen II Proof of Concept (POCA) delivered to Dow & Exxon. Mobil – Mar 2003 • $10 MM Do. E Sensors and Wireless AWARDED to Honeywell in Nov. 2003 • project will help co-fund 12 Ne. SSI™ prototype systems • Chronology of events and Gen II specification can be found at … http: //www. cpac. washington. edu/Ne. SSI. htm rnd/May 6, 2004 6

Today’s Technology – some room for improvement Intrinsically Safe Solenoid Valves Manual flow & pressure control Multiple fittings & valves tubed by skilled inst. fitter rnd/May 6, 2004 Custom purging assemblies Explosion-proof fittings and filled seals – custom assembly by skilled electrician Explosionproof flow switches 7

What are the Drivers for Change? • Reduce Cost to Build • Design, Engineering, Manufacturing, Installation • Reduce Cost of Ownership • Infrastructure, Utility Usage, Support Costs • Increase Reliability • Measurement & Communication Validation rnd/May 6, 2004 8

7 Elements of Generation II 1. Multi-Drop Intrinsically Safe Bus 2. mini-Sensors 3. “Combi”-Valve Actuators 4. SAM* – Sensor Actuator Manager 5. PC/PDA with HMI** [Local Wireless] 6. Programmable Substrate Heater 7. micro. Climate Enclosure * SAM = Sensor Actuator Manager; **HMI = Human Machine Interface rnd/May 6, 2004 9

1 a. Multi-drop Bus “Ne. SSI™-bus” V T P A • Intrinsically Safe Ex ib • Utilizes FISCO low power concept • Handles up to 25 transducers (IIB) – sensors and actuators rnd/May 6, 2004 10

1 b. Why not 4 -20 m. A for Gen II/III? • labor intensive wiring • space hungry • expensive and difficult to wire for hazardous electrical areas “This Dog Don’t Hunt” Ne. SSI™-box Test Platform, Dow Chemical rnd/May 6, 2004 11

1 c. Early Gen II System (POCA*) Features - serial connectivity (Device. Net) - PC controlled – smart features - simple plug and play M 8 connector Benefits - predict failures before they happen - remote operation in hostile locations - decrease maintenance - increase confidence GET SMART! rnd/May 6, 2004 * POCA – Proof of Concept Apparatus - Dow, EMCC, Honeywell 12

1 d. Why an IS network? The most compelling reason for an bus IS is the ability to operate miniature, modular transducers in a hazardous environment using “normal” wiring. reduce electrical seals no purging & pressurization limited conduits/cables no maintenance gas tests no special maint. permits *POCA = Proof of Concept Apparatus min. X proof boxes allows hot “disconnects” plug and play rnd/May 6, 2004 13

2 a. Mini-Sensors A Memory Comm. µP A/D Substrate rnd/May 6, 2004 • Doing analytical is not good enough! – sensors needed for validation & health – predictive maintenance model • General Needs – Flow, Pressure, Temp. – Gas and/or liquid apps. – Encapsulated (IEC Ex m) – Intrinsically Safe (IEC Ex ib) – FOR: Div/Zone 1 Gps A-D 14

2 b. Conceptual Sensor for Ne. SSI™ Port - standard size/pin - daisy chain “Top Hat” Comm. Chip A Body - encapsulated BARRIER - Process Seal - Electrical Isolation - Thermal Memory Comm. Insulation Skirt - engineered 1. 50” Sensor rnd/May 6, 2004 µP Digital “Smart” Sensor - engineering units - memory A/D Process Cavity - no unswept voids - low volume Base - 316 SS - pressure rated 15

3 a. COMBI-valve Actuators A Comm. D/A Solenoid Vent Air Actuator Valve rnd/May 6, 2004 Inst Air • Take control… – Zero/Span/Stream Select – F, P, T control • General Requirements – Gas and/or liquid service – Encapsulated (IEC Ex m) – Intrinsically Safe (IEC Ex ib) – FOR: Div/Zone 1 Gps A-D – on/off (Vo) & modulating (Vm) • Challenge to meet low power requirements (1 -2 m. A/unit) 16

3 b. “Combi”-Valve Actuator “Top. Hat” Comm. Chip A Device. Net 3 -way “pilot” solenoid valve - Intrinsically Safe c/w o-ring std interface to actuator Comm. Vent D/A Solenoid Single Female Port - M 8 - daisy chain/trunk SAE x 1/8 tube connections 40 -110 psig inst. air Actuator - NO or NC Engineered Insulation Skirt Actuator Vent Valve Digital On-Board - Eng. Data Sheet Thermal Barrier rnd/May 6, 2004 Aug. 26, 03 17

3 c. Other actuator options Comm. SV • Direct mount solenoid valves – useful for non-hazardous applications – limited by physics • Motorized electro/hydraulic valves SP 76 Actuator rnd/May 6, 2004 18

4 b. SAM-Sensor Analytical Manager** - stand-alone Standalone SAM V T P A **hockey-puck/PC rnd/May 6, 2004 Analytical Sensor 19

4 c. SAM - Sensor Analytical Manager** - embedded Embedded SAM V Anyone’s Analyzer T P A **hockey-puck/PC rnd/May 6, 2004 20

4 d. Distributed Control is Essential - Sensor Actuator Manager PDA/PC Local Field Port Gateway to an Ethernet LAN (DCS/maintenance systems) can use multiple com protocols - Local Wireless - OPC/HTTP/FF/PB, etc. - Remote Wireless (Gen III) Host Port for… (1) Intrinsically Safe Ne. SSI™-Bus (2 chan. ) (2) Remote I/O Provides “Open” Development SAM Software Applets for Sampling System Repetitive Tasks - App. LI (monitoring/control) Space for Developers Custom Software (e. g. micro. Analytical) rnd/May 6, 2004 21

4 e. SAM App. LI* Repetitive Tasks 4 Validation – zero/span 4 Control… • • Sample pressure, flow, temperature Enclosure/substrate heating Heat Tracing Pumps 4 Health of analytical system (F, P, T) 4 Short term historical data 4 Stream Switching 4 DCS** interface protocol rnd/May 6, 2004 * App. LI = Application **DCS = Distributed Control System 22

5. Graphical HMI* Div II , Portable Field PC/PDA “Tool” • Purpose – Allows field (local) adjustment and interrogation of an analytical system. (mimics remote PC) – A Graphical User Interface – System information PDA/PC SAM HMI V T P A rnd/May 6, 2004 • • instruction manuals parts list maintenance procedures application data * HMI = Human Machine Interface 23

6. Programmable substrate heater Div/Zone 1 GP. A-D TE AC Power rnd/May 6, 2004 • Purpose: – maintain temperature above dewpoint – provide special zone heating for permeation calibrations – supports micro. Analytical & microreactor applications • temperature controlled via the Ne. SSI™-bus and SAM. • Ex d explosion proof heater 24

7. Micro. Climate Enclosure Div/Zone 1 GP. A-D 120/240 VAC rnd/May 6, 2004 • Purpose: – safe environment for analytical systems – allow usage in various climatic conditions for by-line applications – temp. control via Ne. SSI™-bus & SAM. – Ex d X-Proof Heater NEMA or IP Rated Enclosure 25

Need to design & certify electrical components to global requirements. . . • UL or FM (USA) • CSA (Canada) • ATEX Directive (Europe) • GOST (Russia) rnd/May 6, 2004 26

What will a Gen II system look like? o&m user Ethernet LAN dcs Ne. SSI™-bus V F P A T Substrate Programmable Substrate Heater T rnd/May 6, 2004 SAM PDA Auxiliary Heating/Cooling 27

Summary & Conclusion • Ne. SSI™ Gen II ready for development – working spec/prototype design complete – alpha prototypes demonstrated • DOE program – 12 systems to be built – End Users provide field test locations • What can your involvement be? rnd/May 6, 2004 28