Rob Dubois CPAC Workshop, Seattle, WA, May 5, 2005 Crossing the Rubicon SAM and the use of distributed control for SMART Analytical Systems Rob Dubois CPAC Workshop, Seattle, WA, May 5, 2005 “the best way to predict the future is to create it”

Presentation Outline NeSSI™ Roadmap Recap of SAM* Hardware/Software Functionality Drivers for SAM Development Features of a SMART Analytical System *SAM = Sensor Actuator Manager 4/14/2019

Crossing the Rubicon Small, powerful field mounted micro computers allow “true” distributed control In analytical, moving from a centrally controlled model to a distributed one is akin to crossing the Rubicon – once forded it opens up a new world of possibilities Julius Caesar 49 B.C. 4/14/2019

Electrical Networked & Smart NeSSI™ Roadmap Gen III Gen II Gen I Fluid Components Electrical Networked & Smart & Wireless uAnalytical 2006-2010 2004-07 END USER VALUE Today 4/14/2019

dcs SMART Fluid Handling System SYSTEM ANLAN initially copper or fiber optic ultimately capability to do wireless NeSSI™-bus P A V F Sensor/Actuator Manager (SAM) microAnalytical SMART SYSTEM Fluid Handling System 4/14/2019

Sensor Actuator Manager (SAM) Hardware Ports PDA Wireless Local Maintenance Port e.g. Bluetooth Ethernet Gateway - OPC/HTTP/Fieldbus HSE Host Port (IS) Fieldbus “NeSSI-bus” Sensors & Actuators Ethernet Gateway - Legacy Analyzers - Complex Analyzers - Conventional I/O Host Port (NIS) Fieldbus “NeSSI-bus” Sensors & Actuators Wireless Gateway - non-critical applications - analyzer setup/maintenance 4/14/2019

Sensor Actuator Manager (SAM) - Soft Functions “Private” Development Space Custom Software for microAnalytical developers 3rd Party Software Applets -Analytical & Sample System Monitoring and Control Analyzer Utility management Analyzer Validation routines Analyzer System Health Asset management Industry Accepted Operating System Dictionary of industry standard interface parameters (e.g. GC’s) 4/14/2019

SAM: Improve Reliability Allows the use of more automation - sensors and actuators Networks are the key. (Foundation Fieldbus) V P A F NeSSI™-bus Fluid Handling System 4/14/2019

SAM: Simplify Design/Lower Costs By and large we have not been able to provide cost effective control, monitoring and diagnostic functionality for our analytical systems Analyzers have become smart - the sampling system remain archaic Today we use a hodge-podge of analyzer I/O, PLC’s, DCS, data bases and proprietary systems 4/14/2019

SAM: Increase Functionality Attempts to standardize smart analytical functions have been sub-optimal “software applets” Available from 3rd party developers Peacefully coexist on an industry standard SAM operating system Micro Controller Sensor/Actuator Manager (SAM) 4/14/2019

SAM: Simplify Maintenance Eliminate most routine maintenance Sensors allow Predictive maintenance Provide simple graphical tools Bring simple control functionality to the field level Wireless interaction “the new crescent wrench” 4/14/2019

SAM: microAnalytical Interface Substrate On/Off and Modulating valves Flow Sensor w/ Temp, Pressure w/ Temp Moisture in Dry Gas PHASED Micro GC Mod Valve D/A Network Press/ Temp A/D 4/14/2019

SAM: A Way to Standardize Connectivity to Host Systems Desire for industry standard (platform agnostic) communication between any DCS system and any analytical system Connectivity path? OPC over TCP/IP Ethernet One wire concept Opportunity to adopt wireless for non-critical applications; transmit data intensive info (chromatograms & spectra) Sensor/Actuator Manager (SAM) dcs ANLAN initially copper or fiber optic ultimately wireless 4/14/2019

What is a Smart Sampling System? Self-adjusts an analytical system for optimal performance under variable process conditions Tracks Reliability and Operation Metrics Provides an intuitive Graphical User Interface 4/14/2019

Is Self-adjusting… (examples) Adjusts sample pressure sensor using a modulating valve Adjusts Analyzer Sample and Bypass flows Controls pressure around a fluctuating process control valve to maintain a constant flow Controls pressure on atmospheric vent systems on the outlet of an analytical sensor Allows temperature control of sample vaporizer, sample system heater, enclosure heater, air purifiers, analyzer emission controls, heat-tracing, etc. Swings sample filters based on differential pressure Adjusts the speed of a pumped system 4/14/2019

Is Self-adjusting… (examples) Self-purges /back flushes a fouled system on an as need or regular basis Swings gas cylinders based on pressures Provides safety trips – based on pressure, temperature, flow (leak), etc. Shuts off the sampling system / analysis when the process stream is taken out of service Analytical interaction modules - ranges, optical filter selection, path length selection “Soft” startup and shutdown after process events 4/14/2019

Tracks Reliability and Operation Metrics (examples) Calculates operational cycles, for example, valve operations (millions of ops) filter in service time (days) Tabulates mass flow of… sample utility gases e.g. helium, nitrogen, air calibration gases converts volumetric concentrations to mass units Tabulates intrinsic safe power load Tracks temperature, pressure, flow patterns Provides statistics on percent uptime Provides drift information on all parameters 4/14/2019

Tracks Reliability and Operation Metrics (examples) Tracks control chart for zero / span benchmark Tracks control chart for zero / span calibration Maintenance log Data storage and recovery (e.g. CEMS applications) Equipment data e.g. serial number, software version, etc. Spare parts lists Equipment parts lists Auto reorder points for consumable parts 4/14/2019

Graphical User Interface Graphical User Interface (GUI) of all system operation parameters is provided to… Plant Operations Plant Maintenance Remote Users (with security!) Graphical display of fluid flow paths GUI is maintenance configurable for local set-points, alarms, process variables, applet functions 4/14/2019

Summary SAM = A simple, but powerful, distributed control manager providing connectivity to various sensors, actuators and host systems. SAM = A SMART analytical system SAM = a home for microAnalytical Let’s cross the Rubicon, together… 4/14/2019