Is the breakthrough in smart sampling technology at hand? An update of progress & missing links on the road to NeSSI Gen II Rob Dubois CPAC Workshop, Seattle,

Is the breakthrough in smart sampling

technology at hand? An update of progress & missing links on the road to NeSSI Gen II

Rob Dubois

CPAC Workshop, Seattle, WA, May 11, 2006

“the best way to predict the future is to create it”

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Presentation Outline

• The Roadmap and Generations• Progress and missing links• Example of an enabler• How do get the WOW factor• Summary and questions

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NeSSI™ Roadmap

Gen III

Gen II

Gen I

Fluid Components

Electrical Networked & Smart

uAnalytical

END USER VALUE

2008-20122004-08

2000-04

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JEB Stuart

Were we circling Washington?

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Progress on 7 elements of Gen II

• (1) Smart transducers• (2) Programmable heated substrate base• (3) Combi valve• (4) Multi-Drop IS serial bus• (5) temp. controlled microClimate

enclosure• (6) Sensor Actuator Manager (SAM)• (7) PDA – graphical user interface

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(1) Progress: Transducers

• Flow– Thermal – cons: current

load, wiring complexity, robustness?

– DP with orifice – cons: pressure drop, size, cost?

– Rotameter switch/tx cons: cost and size

– need new technologies• Pressure & Temperature• Analytical (early stages)• Objective:

– single block, multi-drop– combine transmit and

local indication into one package

Courtesy of FCI

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Flow Devices - Today

Courtesy of Dow Chemical

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What’s different about this analytical system?

Courtesy of Dow Chemical

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Pressure and Flow by Differential Pressure/Orifice

Courtesy of UOP

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(2) Progress - Smart Heaters

• Approved for ATEX/CSA Zone 1

• First identified in 2003 now deployed in several locations

• Missing link is the connectivity to smart devices or stand-alone Courtesy of Intertec

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Smart Heaters – the value

• Increase Reliability– early detection of heater failure (prevent freezing and

condensation/2-phase systems)– networking allows remote monitoring and setpoint change

• Technology Enabler– precision temp. controls supports the use of microanalytical

on a substrate – enables ramping and zoning– in combination with a precise flow meter allows use of

permeation calibration devices eliminating gas cylinders• Enhanced Capabilities

– higher temperature operation by controlling heater surface below the T-zone temp. - an alternative to air bath systems

• Cost Savings– conduction heat is more efficient than air heating– allows smaller package by compact hotplate design

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Smart heaters in action(…also good size comparison)

All pictures courtesy of Dow Chemical

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(3) Combi-Valve Proposed

• Modulating & On-Off Valves – challenges

• size• power budget• cost• networking• technology to

make modulating is tough

– Proportional Valve is missing link

A

Air Actuator

Inst

Air

ValveVent

Vent

Comm.

D/ASolenoid

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Simple On-Off Valve Driver

• Current solution– on/off solenoid

manifolds– needs “safe” area

for installation– various buses Courtesy of SMC

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(4) Progress: Multi-Drop Intrinsically Safe Bus

• The inability to align to a standard has prevented us from moving ahead– component makers “in limbo”

• Good Features: plug and play, IS, low cost, low power, small, small range, std. connector

• Is this still the missing link?

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(5) Enclosure Progress: Clamshell Design – Flexible

Connections

Courtesy of ExxonMobil

Still a needfor convectionheating….

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(6/7) SAM and the PDA

• Concentrates sensor/actuator signals – without this capability we will be

doomed to dumb systems– running signals from each sensor &

actuator to a facilities DCS system is not cost effective

– handheld PDA useful for local monitoring & simple control

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VP

A

F Sensor/Actuator

Manager (SAM)

NeSSI™-bus (e.g. IS-CiA)

Fluid Handling System

r-SAM

(PC) dcs

SmartAnalyzer

Heater

Ethernet

by supplier

I. smart

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VP

A

F Sensor/Actuator

Manager (SAM)

NeSSI™-bus (e.g. IS-CiA)

Fluid Handling System

r-SAM

(PC)dcs

Simple & legacyAnalyzer

Heater

Ethernet

4-20 mA

discrete

by supplier

Sol Vlv

II. simple

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VP

A

F Sensor/Actuator

Manager (SAM)

NeSSI™-bus (e.g. IS-CiA)

Fluid Handling System

r-SAM (PC)

dcs

Heater

Ethernet

microAnalyzer

Sol. Vlv

by supplier

III. micro

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Oh, the humanity…legacy wiring

Modular system with intrinsically safe discrete wiring – Dow Chemical (hydrogen service)

NeSSI-box wiring analogue and digital wiring – Dow Chemical

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Enabler: Small flows allow wider use of catalytic sample disposal systems

• cost savings enabled by by-line analysis and low volume modular systems– eliminate vents

• environmental protection– a temperature sensor can

monitor catalyst depletion or heater failure and alarm that unit is failing

• performance enhancement– atmospheric reference

with no environmental impact – no analyzer backpressure issues

TRACErase is Courtesy of

MerTech

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How do I achieve the WOW factor?

• Function Intensification• Reduce weight and space• Easily reconfigurable• Simplify the design and spec process

– one stop shopping, integration and check-out• Plug and Play communication• Minimize certification issues• Sensor/Actuator signal concentration/control loops• SMART (automated) – but configurable and easy (fun?)

to use for the analyzer technician (e.g. intuitive menu structure and graphics)

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Who will climb Mount Fuji?

What do we need to do to fill the missing links?