nessi systems: the approach to a best practice jeff gunnell exxonmobil chemical company rob dubois...

NeSSI systems: the approach to a Best Practice

Jeff GunnellExxonMobil Chemical Company

Rob DuboisDow Chemical Company

1. Recap on the objectives for NeSSI

2. Best Practices

3. The score card

3

Objective 1:Modular, miniature, smart process analyser systems

4

Objective 2:A platform for micro-analytical devices

5

Objective 3:An enabler for by-line analysis

6

Objective 4:Common communication architecture

7

It’s all about standard interfaces: the rail concept

8

Some quick definitions

OFF-LINE: samples taken manually in bag, bottle or bomb, analysed elsewhere

ON-LINE: analysers are permanently connected to the process being analysed

IN SITU: sample is analysed where it is

EXTRACTIVE: sample is transported to an analyser

AT-LINE: analysis done by pre-programmed analysers, located near the process : started by people in overalls

LAB: analysis is done by people in white coats

•REMOTE = what people often call “on-line” = analyser distant from process•BY-LINE = sometimes “near-line” = analyser is very close to the process

•IN-LINE e.g. in-stack O2•POINT e.g. combustible gas•OPEN PATH e.g. line of sight IR

9

The elements of a NeSSI system

APPLICATIONS

OFF-LINE– at-line

EXTRACTIVE– remote– by-line

10


“The Professor’s invention for peeling potatoes” by W. Heath Robinson© by courtesy of the estate of Mrs J C Robinson and Pollinger Ltd.

• Proven way of doing something– demonstrated beyond any

doubt that it really works

• Evidence that this is better than any other way

– safer AND/OR

– faster AND/OR

– more reliable AND/OR

– lower costAND/OR

– whatever metrics matter to you

What is a Best Practice?

11


You’ve got to have miles in the bank

“Ladies and gentlemen, here is the result of event No 9, the one mile. First, No 41, R. G. Bannister, of the Amateur Athletic Association and formerly of Exeter and Merton Colleges, with a time that is a new meeting and track record, and which, subject to ratification, will be a new English native, British national, British allcomers, European, British Empire and world record. The time is three . . .”

The rest of the announcement was drowned by the uproar of the crowd.

• Demonstrated in the field• Measured superiority

© The Times, London

12


To create a Best Practice:

• State your goals• Come up with the best design that you can• Test it extensively• Fix the things that didn’t work very well• Test it all over again• Keep doing that until everything meets your goals• Do a reality check - compare with the status quo

13


To create a Best Practice:

• State your goals• Come up with the best design that you can• Test it extensively• Fix the things that didn’t work very well• Test it all over again• Keep doing that until everything meets your goals• Do a reality check - compare with the status quo

14


Goal for analyser systems: Maximise payback

• Reduce cost to build• Reduce cost to own• Increase credits delivered

15


Goal for analyser systems: Maximise payback

Relative USD• Reduce cost to build 1• Reduce cost to own 2 1

• Increase credits delivered 5-10 2

Over a 15 year life

1 Gunnell and van Vuuren IFPAC 2000

2 Based on a typical returns of 30-60%

16


17


In general we expect NeSSI to contribute by:

• Making the mechanical things easier– quicker to design and build

overall lower cost of build

• Making it easier to look after systems– efficient use of technician and engineering time– improved reliability

lower cost of ownership

• Smart diagnostics minimizing downtime– higher availability

increased credits captured

18


Field trials by ExxonMobil Chemical Company

Number in service Stream Vendor CommentsBaytown Olefins Plant 12 gas streams Swagelok Just one instance of pluggingTexas 9 running since 2001 all clean and easy One design error by system integratorSarnia Chemical Plant 12 vapour to diesel Autoflow “No need to touch it”Canada 1 running for 4 years hydrocracker Parker Will use whenever possible in future

Baytown Chemical Plant 6 all liquid 5 SwagelokTexas 1 x 18 months operation benzene to xylene 1 Parker

5 x 15 months operation T amb to 180 degF

19


Field trials by Dow Chemical

Plaquemine, LAFreeport, TX

Fort Saskatchewan, Canada

Terneuzen, Netherlands

Schkopau, Germany

Stade, Germany

20

Gen I Gen II Gen IIICost to build Sensor New tech

SHS Design time -50%Components +10%Manufacturing time -60%

Infrastructure Sample transport -80%Shelters -90%Utilities -50%Data transfer SAM Wireless

Cost to own Services UtilitiesConsummablesSpares

Staff Engineer time Remote

Technician time Samaritan

Credits Availability +? Samaritan


The score card to date

21


NeSSI fluid handling systems: miles in the bank

• We have a proven operating envelope of gases and liquids (up to diesel)

• We have seen the cost of components come down to a premium of about 10%

• We have seen the overall cost of build reduce by about 30%• We have demonstrated technician acceptance• We have demonstrated self contained systems• We have demonstrated SAM jr

22


The Tipping Point“The moment when an idea goes from being just

another word on the street to becoming THE way that everyone thinks.”

NeSSI is making good progress on its approach to becoming a Best Practice

• Decreasing costs• Solid field experience with fluid handling

systems• Commitment to develop electrically

networked systems• DoE project support of -analytical &

wireless

The Tipping Point for NeSSI could be close at hand The Falkirk Wheel

© by courtesy of MG Bennett & Associates, UK

nessi systems: the approach to a best practice jeff gunnell exxonmobil chemical company rob dubois...

Documents