Siemens Applied Automation Process Gas Chromatography Ne SSI

Siemens Applied Automation Process Gas Chromatography Ne. SSI Update Siemens Activities CPAC; Ne. SSI: May 2006 Siemens Update. ppt Slide 1; CPAC; May 11, 2006

Siemens Applied Automation Topics Process Gas Chromatography Ø Summary of Siemens activities Ø Review of requirements Ø More detail on Siemens approach Siemens Update. ppt Slide 2; CPAC; May 11, 2006

Siemens Applied Automation Action and Inaction – Benefits and None Process Gas Chromatography Ø The Ne. SSI concept is intended to bring benefits to users by doing a common thing better ► Reduced cost ► Higher availability ► Better performance • Size, utilities, material, labor • Intrinsic reliability, MTBF, MTTR, skill set, parts • Volumes, flow paths, design Ø On any project intended to result in the benefits of doing a thing better: ► ► The costs continue to occur even if you do nothing; The benefits NEVER occur if you do nothing! Ø Sometimes, you need to do something – maybe ANYTHING – even if it’s not perfect – in order to get things going. ► This can be true EVEN if you’re dealing with possible rework later on. Siemens Update. ppt Slide 3; CPAC; May 11, 2006

Siemens Applied Automation Summary of Siemens Activities Process Gas Chromatography Ø Working with a major user to meet the requirements of a specific large analyzer project ► Strong time lines and “field-proven” requirements Ø Committed to development of a Generation 2 approach to “smart sampling system” design ► ► Use of Generation 1 mechanical components and design Development of Generation 2, intrinsically safe serial bus for component interconnection Implementation of Generation 2 SAM functionality; both virtual and physical Creation of a Sampling-System-specific human interface Ø Working cooperatively with 3 major substrate and component vendors to interface components to the Generation 2 bus Ø Continuing to work actively with Ne. SSI work groups on review and establishment of broader standards Siemens Update. ppt Slide 4; CPAC; May 11, 2006

Siemens Applied Automation Requirements Review Process Gas Chromatography Ø The Ne. SSI Vision Ø The needs of a practical sampling system Ø Some details Siemens Update. ppt Slide 5; CPAC; May 11, 2006

Siemens Applied Automation The Analyzer System Today Process Gas Chromatography System Communication Network Air Power Dumb Analyzer er w Po Siemens Update. ppt Ai r w Po Ai r Smart Analyzer Process HMI Slide 6; CPAC; May 11, 2006

Siemens Applied Automation The Ne. SSI Vision Process Gas Chromatography System Communication Network Air Power Dumb Analyzer HMI SAM Siemens Update. ppt er w Po Ai r HMI Smart Analyzer Process SAM HMI Slide 7; CPAC; May 11, 2006

Siemens Applied Automation Pieces Of the Ne. SSI Idea Process Gas Chromatography Ø New mechanical components ► Modular ► Standardized mounting platform ► Interchangeable function Ø New electrical interconnection ► Serial connection – plug in ► Intrinsically safe ► Self-identifying components Ø New smart design features (SAM) ► Helpful HMI ► Programmability ► Standardized, transportable user programming Siemens Update. ppt Slide 8; CPAC; May 11, 2006

Siemens Applied Automation Requirements Process Gas Chromatography Ø Certain key requirements ► Bus length ► Active device count ► Power consumption and distribution issues Ø Operational issues ► Field repair and replacement considerations ► Component ► Support identification issues for interchangeability Ø Other requirements Siemens Update. ppt Slide 9; CPAC; May 11, 2006

Siemens Applied Automation Bus Length Process Gas Chromatography Ø An “obvious” statement: Sampling systems are associated with analyzers Ø Bus length is the amount of cable required to go from a SAM to the sampling system and to continue linking to each of the components in the system Ø So, the key question is, where is the SAM relative to the sampling system? Siemens Update. ppt Slide 10; CPAC; May 11, 2006

Siemens Applied Automation Local Sample Conditioning Process Gas Chromatography Ø Summary ► ► ► Sample is extracted from process and transported to the sampling system with only minimal modification A relatively small portion of sample is cleaned and conditioned and provided to the analyzer Distance between the analyzer and the sampling system is limited by sample transport considerations Ø Most typical situation that we think of and experience in the field – for both “smart” and “dumb” analyzers Ø Typically – a few feet; a reasonable maximum 10 -20 meters Analyzer House 10’s to 100’s m SS Ax Sample Conditioning System Analyzer (and SAM) SS Ax 1 to 20 m Siemens Update. ppt Slide 11; CPAC; May 11, 2006

Siemens Applied Automation Remote sample conditioning Process Gas Chromatography Ø Summary ► ► ► Sample is extracted from the process and immediately cleaned and conditioned Relatively small quantities of conditioned sample are transported to the analyzer Distance between the analyzer and sample conditioning system is limited by transport considerations Ø Not (today) a common configuration. However, some systems have some remote devices Ø SAM associated with the system might be located adjacent to it 10’s to 100’s m Remote Sample Conditioning System SAM Close coupled; 1 meter Siemens Update. ppt Sample Delivery Analyzer (and SAM) System Network Slide 12; CPAC; May 11, 2006

Siemens Applied Automation In situ analysis Process Gas Chromatography Ø Sample is not removed from the process Ø No sample conditioning exists Siemens Update. ppt Slide 13; CPAC; May 11, 2006

Siemens Applied Automation Component Count Process Gas Chromatography Ø How many active devices must be supported by the Ne. SSI bus? Ø There are differences between older, conventional construction techniques and Ne. SSI construction techniques. In Ne. SSI, the count will be larger! Siemens Update. ppt Slide 14; CPAC; May 11, 2006

Siemens Applied Automation Process Gas Chromatography Reference Sampling System Diagram 1 stream plus auto-calibrate Analyzer Bypass Flow Analyzer Flow F Filter Drain Stream Select Valves Sample Flow Vent Siemens Update. ppt Slide 15; CPAC; May 11, 2006

Siemens Applied Automation Device Count Process Gas Chromatography Analyzer Flow Bypass Flow Filters Stream Select Flow / Pressure Adjust Siemens Update. ppt Slide 16; CPAC; May 11, 2006

Siemens Applied Automation Device Count Process Gas Chromatography Ø Per Stream (5 devices) ► ► Stream select solenoid Bypass flow / pressure adjust Analyzer flow / pressure adjust Filter pressure drop sense (1 or 2) Ø Per System ► ► Temperature control / sense Pressure / air sense Ø Number of streams ► ► Minimum 1 Typical 2 -4 Common 4 -5 Maximum 30 Ø Number of devices ► Up to 200 Siemens Update. ppt Slide 17; CPAC; May 11, 2006

Siemens Applied Automation Device Power and Connection Issues Process Gas Chromatography Ø Intrinsically safe systems ► I. S. communication bus ► I. S. device Power Source Ø Small devices ► Connector space ► Separation space for I. S. requirements Ø Power source ► Preferred: power for communication and device have common source ► Required: power be sourced through I. S. Siemens Update. ppt Slide 18; CPAC; May 11, 2006

Siemens Applied Automation Operational Issues Process Gas Chromatography Ø Repair and replacement must be “in place”. Positive device identification and physical placement must be provided ► Address strapping in hardware ► Address encoding before installation Ø Field repair needs to be supported under live power Ø Systems are not ad hoc. An analyzer is controlling the system and it’s needs and programming do not change ► Device recognition during application engineering phases may be useful Ø Interchangeability requires that the system be able to confirm that a replacement device is of comparable type to device being replaced Siemens Update. ppt Slide 19; CPAC; May 11, 2006

Process Gas Chromatography Ne. SSI Bus System Support Requirements Siemens Applied Automation Ø Up to 30 process streams in a sampling system plus 2 calibration streams. Ø Up to 200 active devices in a Ne. SSI Sampling System. (Additional “nonactive” devices as needed) Ø Up to 1/2 of the active devices may be of any one type (example, pressure sense”) Ø Capability for support of standard functions: ► ► pressure, temperature, flow monitoring (absolute measurement and/or binary alarm level) pressure and flow absolute control temperature control of substrate, sample cabinet, flowing stream fluid automatic valve control to switch on / off or to divert process streams (block or 3 way) Ø Capability for the standard functions to be implemented in a variety of ways Ø All components should be interconnected on as few instances of the Ne. SSI bus as possible for cost reasons. If more than one instance is required, both shall be capable of being seamlessly controlled by a single analyzer or controller (PLC) operating as a Ne. SSI “SAM”. Siemens Update. ppt Slide 20; CPAC; May 11, 2006

Siemens Applied Automation System Bus Requirements (continued) Process Gas Chromatography Ø Analyzer may be mounted up to 10 meters away from sampling system Ø Opportunity for large number of component manufacturers to participate with large number of component types per manufacturer. Ø Sampling System HMI / visualization tool shall be capable of identifying an installed component type, manufacturer and model number for purposes of facilitating maintenance or replacement Ø Any single physical device should be able to represent itself using as multiple device types. Ø Interruptible while live – user can replace components while system is still operating Ø Intrinsically Safe for installation in Zone 1 (Type Ib) ; Division 1 Ø Must support power loading and control of power permitted by I. S. bus Start-up, minimum, maximum, abnormal, other powermanagement issues Siemens Update. ppt Slide 21; CPAC; May 11, 2006

Process Gas Chromatography Component Specs Required Entity Parameters Siemens Applied Automation Ø Power profile (for power budgeting) ► Start up ► Maximum ► Steady State ► Minimum Ø Stored power potential contributed to the system Ø Capacitive, inductive and resistive loading on the IS system ► Active Load ► Passive Load Siemens Update. ppt Slide 22; CPAC; May 11, 2006

Siemens Applied Automation Siemens Approach Process Gas Chromatography Ø Utilize existing device bus and protocol Ø Utilize available commercial methods to achieve I. S. compatibility and establish bus robustness Ø Provide bus interface method with software to interested component (device) suppliers and support for component interface design Ø Provide simple method of interface to the bus for other non-Siemens controllers Siemens Update. ppt Slide 23; CPAC; May 11, 2006

Siemens Applied Automation Siemens GC Electronics Process Gas Chromatography Siemens Update. ppt Slide 24; CPAC; May 11, 2006

Siemens Applied Automation Siemens Implementation of Ne. SSI Bus Process Gas Chromatography Bus Access Controller Chip (chip spec and burn image by Siemens; assembly by component manufacturer) Siemens GC I. S. Power Supply Component interface electronics (by component manufacturer) Bus buffer Intrinsically Safe Ne. SSI Bus I. S. Barrier Mechanical component (by others) Siemens Update. ppt Slide 25; CPAC; May 11, 2006

Siemens Applied Automation Project Implementation Process Gas Chromatography s Maxum edition II Win. CC Visualization Bridge module Siemens Update. ppt Modbus link Slide 26; CPAC; May 11, 2006

Siemens Applied Automation Future Plans and the Future Standard Process Gas Chromatography Ø Siemens is planning to implement a large scale Ne. SSI Generation 2 system using available technology Ø Other existing buses may still evolve into the long term standard for Ne. SSI ► Fieldbus ► CAN / Profibus Open ► Other Ø Siemens plans to participate actively in development of standards for the Ne. SSI bus Siemens Update. ppt Slide 27; CPAC; May 11, 2006

Siemens Applied Automation Conclusions Process Gas Chromatography Ø Users should implement now ► Use “closest available” from their preferred supplier ► Be sure “closest available” is in the same direction as Ne. SSI is going ► Don’t worry if “closest available” does not exactly match in the future ► Plan to field retrofit IF desirable and needed Ø Siemens ► Plans to support this approach using our available busses now ► Plans to continue to support the Ne. SSI efforts toward full standardization Siemens Update. ppt Slide 28; CPAC; May 11, 2006