Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Process Analyzer Connectivity Initiative (ConnI) A Status Report Ron O’Reilly Dow Chemical Canada Inc. Fort Saskatchewan, AB Canada Peter van Vuuren ExxonMobil Chemical Baytown, Texas USA

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003Topics  Functional Domain and Connectivity Model for Process Analyzer System - Overview  Measurement Domain  DCS Domain  Model - O&M Domain  Model - Enterprise Model  A Summary

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 ConnI recognizes that a process analyzer is not a stand- alone entity but has only added value if through connectivity it is an integral component of several related system domains: Connectivity Role –Measurement domain: integrated with other analyzers –DCS domain: DCS is its primary customer –Analyzer Operations/Maintenance domain: Support system for reliable operation and effective user interfaces –Enterprise domain: Must allow remote access and support

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Level 3 LAN Enterprise Domain Level 4 Enterprise LAN AnLAN O&M Domain Safety Control/ Optimization Environmental L0 Primary Data Path > Requires Maximum Integrity/Reliability Level 2 LAN = Field LAN L1 L2 Secondary Data Path > Requires High Integrity/Reliability Measurement Data (Validated) Status/Change Info Limited Control Functions DCS Data +: Raw Data/Calibration/SQC Diagnostics/Alarms Configuration Data All Control Functions Hierarchical/Domain* Model for Process Analyzer System - Overview L4 Measurement Domain SAM eSAM Level 1 Sensor Bus (CAN) L3 DCS Domain c-LAN * Functional Domains NOT Computer Domains

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - Measurement Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) Measurement Domain SAM eSAM Level 1 Sensor Bus (CAN) Modular Smart Sampling System(NeSSI) Sample, Condition and Validate Process Sample Multiple Sensors (may be Physical and Analytical) Level 1 Sensor Bus (CAN -based SDS or DeviceNet) Small Footprint Configuration via Flash Memory Existing and Mature Technology - Inexpensive Components CAN-based communications already in use by Major Suppliers Future Goal is Wireless Communications (NeSSI III)

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - Measurement Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) Measurement Domain SAM eSAM Level 1 Sensor Bus (CAN) Sensor/Actuator Manager (SAM) SAM is a Sampling System Controller Manages all Sampling System Functions and Diagnostics Collects and Validate Sensor Information (Analytical Sensor information Converted by Analyzer Controller) Examples of Functions: Responsible for Stream Sequencing (Valve Actuation) Control Sampling System Heating/Cooling Measures all physical Properties of Sample (e.g.. T,P,F) Collects Maintenance & Diagnostic Information (SAM is key to successful Preventative Maintenance System) SAM can be a Stand-alone Level 2 Controller Device communicating via the Level 2 LAN with it’s Host Controller SAM Functionality can be embedded in an Analyzer Controller (e.g. GC Controller) Standardized Communications between Sensors and SAM of critical importance if NeSSI Sampling systems are to be successful Connectivity Issues: CAN-based specification (2002/2003) SAM/Host Analyzer Controller Functional Specification SAM is likely a WIN CE device which can also support OPC Communications between SAM and Host Controller

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - Measurement Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) Measurement Domain SAM eSAM Level 1 Sensor Bus (CAN) Analyzer Controller Responsible for the Measurement and Overall Validation of Result(s) Support and Validation of Sampling System via SAM (Embedded or Remote) Update DCS System via OPC Gateway Server or other Datalink Types (OPC Server may be Embedded) Update Short Term Data Server Support User Interface at Workstations (Multiple User Interfaces from Different Analyzer Controllers must co- exist) Scalable Platforms (WinCE to Windows XP/2000) Connectivity Issues: Protocol for Updating OPC DCS Gateway Server User Interface Communications Protocols Database Server Protocols

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 GC Proposed Connectivity Model for Measurement Domain GC Anlzr Level 2 FLAN (Private IP Addresses) GP Area - Control/Analyzer/RIB Room Fiber -optic link Field Anlzr Level 1 Sensor Bus (CAN) GC Embedded SAM SAM Analyzer Control Sampling Systems SAM FTNIR Raman Spectral Fiber Diversity of Analyzer Devices that makes up the Measurement Domain

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Define the Physical Layers for Level 1/2/3 * Level 1 : CAN bus *Level 2/3:Ethernet TCP/IP (Industrial)Define the Physical Layers for Level 1/2/3 * Level 1 : CAN bus *Level 2/3:Ethernet TCP/IP (Industrial) Identify Compatible High-level Communication Protocols (peaceful co-existence on same workstations, servers etc.) *OPC *HTTP *Fieldbus etc.Identify Compatible High-level Communication Protocols (peaceful co-existence on same workstations, servers etc.) *OPC *HTTP *Fieldbus etc. Define Functional requirements for Data Server, Workstations and Long Term HistorianDefine Functional requirements for Data Server, Workstations and Long Term Historian Define Requirements for Analyzer-DCS Data Link Interface *Draft Specification posted on CPAC ConnI websiteDefine Requirements for Analyzer-DCS Data Link Interface *Draft Specification posted on CPAC ConnI website ConnI Goals

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - DCS Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) DCS Domain FTNIR DCS OPC Server Embedded DCS OPC Client (EDC) Embedded Analyzer OPC Server (AES) OPC Client Bridge (CB) Analyzer Gateway OPC Server (AGS) Long Term Historian Not showing Operator Consoles

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - DCS Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) DCS Domain FTNIR Not showing Operator Consoles CB EDC AGSAES How do we “stitch these together? * Ethernet & TCP/IP What information do we exchange? * Draft OPC DCS/Analyzer Datalink * Soliciting Comments * Soliciting Endorsements * Testing Underway or Planned with Several Process Control and Process Analyzer Vendors

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - DCS Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) DCS Domain FTNIR Not showing Operator Consoles CB EDC AGSAES DCS Analyzer OPC Client DCS Analyzer OPC Client: * Setup and Configuration based on Analyzer OPC Server Database * Should be based on OPC Standard 2.0 * DCS Client linked to DCS Specific OPC Server * Communication with OPC Analyzer Server via Ethernet TCP/IP Configuration of OPC Client should be based on using standard OPC 2.0 Configuration Software e.g., “subscribing” to the individual analyzer OPC data elements such as “Analyzer Status” The DCS Client can be implemented as: * Embedded DCS Client (integrated with the DCS OPC Server and supported by the DCS Supplier) * Client Bridge i.e., “Double Headed Client” - Presents itself as a Client to the Analyzer OPC Server - Presents itself as a Client to the DCS OPC Analyzer Server - Typically provided/supported by a Third Party

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - DCS Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) DCS Domain FTNIR Not showing Operator Consoles CB EDC AGSAES Analyzer OPC Server Implemented either as a “Gateway” (AGS) or Embedded Server (AES) TCP/IP - OPC is currently the protocol of choice for communications between computers in the DCS World - in process of adapting it as the basis for an Analyzer/DCS Datalink Progress: Preliminary Specification Developed: * Client/Server Topologies * Addressing Scheme * OPC Server Content Summarized Later Status/Plans: * Draft specification posted on CPAC ConnI website 2Q02 * Complete Specification in 1Q03 as part of ConnI effort * Testing to continue 3Q02 - 2Q03 (Several Control System/Analyzer Vendors) * Solicit endorsements from end-users, analyzers suppliers and DCS vendors

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - DCS Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) DCS Domain FTNIR Not showing Operator Consoles CB EDC AGSAES DCS/Analyzer OPC Datalink Specification Draft Specification posted for comments on CPAC ConnI website Complete Final Specification in 1Q03 as part of ConnI effort Continue testing with several Process Control/Process Analyzer Vendors Solicit endorsements from other analyzer and DCS vendors Specification Addresses Three Key Functions: * Client/Server Topologies * Addressing Scheme * OPC Server Content/Failure Recovery

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 InitializationDataStatus ChangeFault Recovery Specification allows for Bidirectional control: DCS Console Operator can Request Status Change e.g. * Start/Stop an Analyzer * Enable/Bypass a Stream * Change the Sequence of Streams to be Analyzed OPC Datalink Specification -Analyzer Operations as Event Driven Functions OPC Datalink Specification - Analyzer Operations as Event Driven Functions

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 TYPE 1a Single Controller Single CAP Single Detector/Probe/Stream Single Component TYPE 1b Single Controller Single CAP Single Detector/Probe/Stream Multiple Components TYPE 2a Single Controller Single CAP Multiple Detectors/Probes/Streams Single Component TYPE 2b Single Controller Single CAP Multiple Detectors/Probes/Streams Multiple Components TYPE 3 Single Controller Multiple CAP Multiple Detectors/Probes/Streams Single/Multiple Components 1 Controller CAP Detector/Probe Streams = STRM Components = COMP n 1 GC Regular GC Master/Slave FTIR RAMAN Mass Spec Configuration Types pH Conductivity Oxygen Autotitrator Photometer Simple GC Panametrics Examples Summary of Possible Analyzer Controller and Stream Configurations GC Master/Master FTIR RAMAN

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Proposed OPC Datalink Specification - Address Hierarchy

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - O&M Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) O&M Domain AnLAN Analyzer Workstation Primary Maintenance/Operations Window into Process Analyzer System Key Functions: * Upload and Download of Analyzer Configuration/Methods * Access of Real-time Diagnostic/Analyzer Analyzer * Access of Diagnostic/Analyzer Analyzer Server * Access and Configuration of SQC Data/Run-time Server Specification Work to begin in 2003

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - O&M Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) O&M Domain AnLAN Analyzer Server Short Term ( ~ 1 month(?)) Data Archive * Raw Data for all assigned Analyzers * Operational Data Storage (Methods/Configurations etc.) * Primary Database for Workstation Access * Serves as Front-end to Long-term Data Archive Connectivity/Specification Issues: * Database Type(s)- ODBC vs. Others * Co-existence of Analyzer Data from Different Vendors * Communications Protocol for Data Exchange between Analyzer and Server Specification Work to begin in 2003

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Hierarchical/Domain Model for Process Analyzer System - O&M Domain DCS O&M Measurement SAM eSAM Ent Level 1 Bus (CAN) O&M Domain AnLAN Analyzer/DCS Long Term Data Archive May be located in O&M Domain or DCS Domain (see DCS Domain functions) If located and supported in the O&M Domain, typically would only store Analyzer Data May require translation software to Update Long Term Archive from Short Term Analyzer Archive (See Analyzer O&M Domain)

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Proposed Connectivity Model - DCS Datalink Client/Server Topologies Anlzr Level 2 FLAN (Private IP Addresses) LEVEL 3/4 Router DCS Level 2 LAN (TDC=LCN) PDC Historian Server/ Workstations DCS OPC Server Embedded DCS OPC Client (EDC) OPC Client Bridge (CB) Analyzer Gateway OPC Server (AGS) FTNIR Raman Work- station Plant LAN IntraNet Embedded Analyzer OPC Server (AES) One of many ways a system can be stitched together E.g. Cisco 2950 VLAN Switch/Router

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 Draft OPC DCS/Analyzer Datalink specification published for comments * Testing Planned or Underway with Several Process Control/Process Analyzer Vendors Solicitation of Endorsements/comments/changes from analyzer suppliers/DCS vendors and end-users underway Overall Architecture well in place - Generic Functional Specification aimed for 2003 Functional specification for NeSSI Sensor bus and SAM (part of NeSSI Gen II specification) to be published soon (NeSSI Website) Prototype Proof of Concept Apparatus (POCA) systems being developed by Honeywell * Based on IS CANbus * Will allow for testing of SAM functionality ConnI Status Report: Summary

Process Analyzer System Connectivity (= ConnI) IFPAC2003: January 24, 2003 FINI