jeff gunnell and peter van vuuren - university of...

PROCESS ANALYTICAL SYSTEMS- a vision for the future

Jeff Gunnell and Peter van Vuuren

ExxonMobil Chemical - Core Engineering


COMMONLY HEARD PHRASES

“lump sum, turn key”

“industry-standard design”

“trend-line decrease in cost”

“year on year improvements”

“best practices”


GOALS

Understand the driving forcesRecognise technology trends

Imagine the future

Create change


STAKEHOLDERS

Petrochemical companiesEngineering contractorsSystem integratorsAnalyser vendorsComponent vendorsAnalyser research groups


UNDERSTAND THE DRIVING FORCES

Reduce time from concept to productReduce hours for design and development

Reduce cost of buildReduce cost of ownership

Maximise profitability


TODAY’S ANALYSER SYSTEM



DCS

SAMPLETAKE-OFF



DCS

SAMPLETAKE-OFF

A



DCS LAN

ANALYSER DATA SYSTEM

SAMPLEPRECONDIT.

SAMPLERECOVERY

SAMPLETRANSPORT

SAMPLETAKE-OFF

SAMPLERETURN

VALIDATIONBLEND

SAMPLECONDITIONING

INSTRUMENT AIRELECTRICAL

GASES

DRAINVENT

SAFETY SYSTEMHVAC

A

AH



ANALYSER HOUSE

COMMSXFACE JB

A

SHS

A

SHS

COMMSXFACE

A

SHS

COMMSXFACE

A

SHS

A

DCS LAN

JB

OTHERANALYSER

HOUSESLEVEL 0Field mounted

hardware

LEVEL 1Unit control and

processing

LEVEL 2Distributed control

and processing

LEVEL 3Higher levelprocessing

GATE-WAY MAINT.


TODAY’S COST OF BUILD

AH 1

A AAAA

AH 2

A AAAA

AH 3

A AAAA

AH 4

A AAAA

AH 5

A AAAA

AH 6

A AAAA

AH 7

A AAAA

AH 8

A AAAA

DCS LAN

ANALYSER DATA SYSTEM



For a major greenfield projectNumber

Gas chromatographs 50Other analysers 75Sample systems 125Sample transport 125Analyser houses 8Data system 1Installation costs 1TOTAL




K USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000


THE FUTURE

The challenge...

...and the opportunity

Reduce cost of build by 40%




K USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000


TODAY’S COST OF OWNERSHIP

Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD




Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000


THE FUTURE

The challenge...

...and the opportunity

Reduce cost of ownership by 35%




Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000


ENABLING TECHNOLOGIES

� Modular sample system components�developed by the semi-conductor industry�ISA group working on design standards

� Application specific integrated circuits�provide the smart components

� Open communication architectures�provide the data integration


IMAGINE THE FUTURE

A

T

PAnalyzer Analyzer

ControllerController

Fiel

d LA

NFi

eld

LAN

Level 0Level 0 Level 1Level 1

Pro

cess

Str

eam

Pro

cess

Str

eam

F


IMAGINE THE FUTURE

FLAN (Optical Fiber)

Sensor/Signal Bus

IA

Controller

(ASIC)

Original Picture of Gas Delivery System courtesy Valin Corporation;

A

T

PF

Sensor = Moisture Probe


IMAGINE THE FUTURE

A

T

PF

Sensor = RAMAN Probe


IMAGINE THE FUTURE

Integrated analysers and sample systemsField-mounted and self containedSmart incorporating diagnostics + controlOpen-architecture data systemsPlug-and-play maintenanceStandard designs for generic applications


Integrated analysers and sample systems

� analyser vendor provides sample system�one-shop stop

� maximise standardisation�there really aren’t that many special cases

Reduce hours for design and development


Field-mounted and self contained

� can work anywhere�from the poles to the tropics

� no analyser houses� no long sample transport lines� minimum utilitiesReduce time of design and cost of build


Smart with diagnostics + control

� full system info available� remote modification of parameters� control of P, T, F

�with flow control, install across control valves

Reduce cost of ownership


Open-architecture data systems

� one data highway for all systems� single window

�opportunity for remote support

� simple to add new analysersReduce time of design and cost of build



Plug-and-play maintenance

� For failures take a complete system to the field�plug in the new one, repair the old one

back at the workshop



Standard designs for generic applications

Reduce time from concept to productReduce hours for design and development

Reduce cost of buildReduce cost of ownership

Maximise profitability


CREATE CHANGE

Agree a common visionStandardise sample system componentsStandardise data system architecturePartnerships between stake-holders


COMMERCIAL BREAK

RELATIONSHIPS IN THE PROCESS ANALYSIS INDUSTRY

discussion of how interactions between the stakeholders need to change

Time: Wednesday 26 Jan, a.m.

jeff gunnell and peter van vuuren - university of...

Documents