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
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)
3
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?
4
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
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
6
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
7
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
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
9
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
10
Project Segmentation
Gen III
Gen II
Gen I Mechanical (mostly)
Electrical/Smart (Diagnostic)
MicroAnalyticalValue
11
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
12
Elastomer Seals are desired in HP Industries
Courtesy of the Swagelok Co
Manufacturers…
• Parker-Hannifin
• Autoflow
• CIRCOR
• Kinetics
• Swagelok
• Fujikin
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.
Imagine the Future after
15
Vision: The End of the Analyzer House System
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
17
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
18
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
19
1. Heated, Programmable Substrate
AC PowerAC Power
Conduction Heating- cartridge heater(s)
- over-temperature cut-off
Furn. by
substrate mfg.
Heating Fluids
(alternative)
20
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
21
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
22
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
23
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
24
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
25
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
?☺
26
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
☺
27
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
28
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
29
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
30
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
31
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
32
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
33
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.
34
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
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
36
Keys to development
37
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)
38
Communicate…globally!
z Internationaly Europe, Japan,
Canada, USA
z Consortiay CPAC, CPACT
z Upcomingy ISA - AD 2002
39
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…
40
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
41
New Developments
42
NeSSI Analyzers - here today
Courtesy of Panametrics & Swagelok Courtesy of Rosemount Analytical
Courtesy of Rosemount AnalyticalCourtesy of Panametrics & Swagelok
Oxygen
H2O
pH
Conductivity
43
Just announced...
Courtesy of Applied Analytics
MIR ATR
44
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
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
46
Petrochemical installs...
Coutesy of a
gulf coast
petrochemical facility
Courtesy of an east coast petrochemical facility
and Parker-Hannifin
47
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)
48
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
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.)
50
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
51
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
52
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
53
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.
54
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.