Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Connectivity for Process Analytical Systems: Confusion or Opportunity Peter van Vuuren ExxonMobil Chemical Engineering and Manufacturing Services Baytown, Texas January 22, 2001

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Analyzer Computing System Hierarchy Analyzer Computing System Hierarchy Topics Proprietary vs. Open Connectivity Solutions Proprietary vs. Open Connectivity Solutions Level 0/1 Challenges Level 0/1 Challenges Level 1/2 Challenges :Data Domains Level 1/2 Challenges :Data Domains The Process Analytics Community 1M$? The Process Analytics Community 1M$? Opportunity for Action Opportunity for Action

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Process Control System/Analyzer System Perspective PLANT AREA UNIT FIELD A PIUCB PM AM HM VMS PROCESS CONTROL SYSTEM PLANT AREA UNIT FIELD A CAC AC GCC AMHM AEWS SS SENSOR ANALYZER COMPUTING SYSTEM System within a System

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Analyzer Computing System Hierarchy A Sample System Sensor GC FTIR LEVEL 3 an-LAN LEVEL 2 FLAN Datalink INFORMATION MANAGEMENT (Gateway to External Data) CENTRAL USER INTERFACE AND DATA MANAGEMENT DATA ACQUISITION AND CONTROL FIELD DEVICES (SENSORS, VALVES, DETECTORS, ETC.) LEVEL 4 LAN = PLANT LAN PC -Based Workstation/ User Interface PC-Based Data/Methods Archive and User Interface L0 L1 L2 L3 DCS Validated Measurements Remote Server(s) Remote Workstation(s)

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 DAAC Com Sample Conditioning System Process Stream Field LAN P FT Level 1 Bus AnalyzerController A DAAC Com Analyzer Computing System Hierarchy (Level 0/1) All System Components in Contact with Sample including the Sensors Level 0 Level 1 All Additional Electronic and Computing Components Required to Generate Analytical Result

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Sample Conditioning System All System Components in Contact with Sample including the Sensors Level 0 Level 1 A Process Stream Level 2 Bus = Field LAN P FT Level 1 Sensor Bus AnalyzerController DAAC Com All Additional Electronic and Computing Components Required to Generate Analytical Result Level 2 Level 3 Central User and Operations Interface Applications and Data Management (Archiving) Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Analyzer Computing System Hierarchy (Level 0/1) Level 4 Remote User Interface/Applications Server(s) Workstations Plant LAN

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Challenges/Opportunities Sample Conditioning System A Process Stream Level 2 Bus = Field LAN P FT Level 1 Sensor Bus AnalyzerController DAAC Com All System Components in Contact with Sample including the Sensors Level 0 Level 1 All Additional Electronic and Computing Components Required to Generate Analytical Result Level 2 Level 3 Central User and Operations Interface Applications and Data Management (Archiving) Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Level 4 Remote User Interface/Applications Server(s) Workstations Plant LAN

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Level 2 Level 3 Central User and Operations Interface Applications and Data Management (Archiving) Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Sample Conditioning System A Process Stream Level 2 Bus = Field LAN P FT Level 1 Sensor Bus Analyzer Controller DAAC Com All System Components in Contact with Sample including the Sensors Level 0 Level 1 All Additional Electronic and Computing Components Required to Generate Analytical Result Proprietary vs. Open Connectivity Solutions = Common Solutions Level 4 Remote User Interface/Applications Server(s) Workstations

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Level 0/1 Challenges Opportunities Sample Conditioning System A Process Stream P FT Level 1 Sensor Bus Analyzer Controller DAAC Com All System Components in Contact with Sample including the Sensors Level 0 Level 1 All Additional Electronic and Computing Components Required to Generate Analytical Result Level 2 Level 3 Central User and Operations Interface Applications and Data Management (Archiving) Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Level 4 Remote User Interface/Applications Server(s) Workstations

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 A Process Stream P FT Level 1 Sensor Bus Analyzer Controller DAA Com NeSSI Concept (CPAC Initiative): Small Smart Integrated Sensor and Sampling system Modular Design based on Surface Mount Technology Ensure the Representativenes of Sample (Data Validation) Level 0 Level 1 Level 0/1 Challenges Opportunities

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 A Process Stream P FT Level 1 Sensor Bus AnalyzerController DAA Com Level 1 Sensor Bus: True Plug and Play Installation/Configuration (a la USB?) Should ideally include Analytical Sensor (pH, Cond etc.) Potential for Inherently Safe Designs Level 0 Level 1 Level 0/1 Challenges Opportunities

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Sample Conditioning System A Process Stream P FT Level 1 Sensor Bus Analyzer Controller DAAC Com Level 0 Level 1 Level 2 Level 3 Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Level 4 Server(s) Workstations Level 1-2 Challenges

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Level 2 Bus = Field LAN Analyzer Controller DAAC Com Level 3 Bus = AnLAN DCS Domain O&M Domain M easure- ment Domain Primary Data Path > Requires Maximum Integrity/Reliability 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 Level 1-2 Challenges: Domain Interactions L4 = Enterprise Wide Domain L1 L2 L3L4

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Level 2 Bus = Field LAN Analyzer Controller DAAC Com Level 3 Bus = AnLAN DCS L2 DCS Gateway Server(s) L1 L2 L3 Ethernet DCS OPC Client OPC Protocol on Ethernet Measurement Data (Validated) Status/Change Info Limited Control Functions Analyzer OPC Server(s) Level 1-2 Challenges: DCS Domain

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Level 2 Bus = Field LAN Analyzer Controller DAAC Com Level 3 Bus = AnLAN Gateway Server Analyzer Server Physical Layer Ethernet TCP/IP (LonWorks Profibus Modbus Plus DeviceNet Etc.) Scalable Analyzer/COM Platforms WindowsCE NT Kernel Win2000/NT OPC Client Browser Client Workstation Platform Win2000/NT Browser Enabled WS Level 1-2 Challenges: DCS/O&M Domains OPC Protocol on Ethernet Gateway Server Platform Win2000/NT Multiple OPC Servers/Drivers Analyzer Server Platform Win2000/NT Multiple Servers/Drivers Database Application Layer(s) Protocols OPC HTTP FF (HSE)? Proprietary

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Analyzer Controller DAAC Server(s) Workstations Com Level 3 Bus = AnLAN DCS Gateway Client/Server(s) Long Term Storage Analyzer Server DCS L2 DCS L3 TPS CLM Level4 Access expose L2/L3 Analyzer Devices to Enterprise-wide Network L2/L3 must meet Enterprise-wide Security/Controls standards: -Logon authentication (Requires NT Domain Controller – not shown) -Software Isolation (Requires Win2000/NT Terminal Server) L1L4L2 L3 WS Level 2 Bus = Field LAN Level 4/3/2 Challenges: Remote Access & Security and Controls

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 O&M Domain DCS Domain Connectivity: Summary Level 2 Bus = Field LAN Analyzer Controller DAAC Com DCS L2 DCS Gateway Client/Server(s) Level 3 Bus = AnLAN Long Term Storage Analyzer Server Workstations WindowsCE NTKernel Win2000/NT Ethernet TCP/IP - OPC - HTTP - FF? - Proprietary Win2000/NT OPC Protocol on Ethernet Win2000/NT Not discussed: Redundancy Wireless LAN’s Portable Terminals

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 The Process Analytics Community 1M $? Given the choices of: controller, server and workstation platforms communication protocols database options (short term and long term) security and controls needs (local & remote access) How do we develop and agree on industry guidelines for the analyzer connectivity infrastructure which will ensure plug-and-play compatibility for all analyzers? ? ? BIG QUESTION ? ?

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Considerations: The Process Analytics Community 1M $? Convene an Open Process Analytics “Forum” (Sponsored by CPAC or MCEC or ISA AD?) Develop a consensus about Proprietary vs Open Model (POM) (Learn from FF and OPCF?) Confirm challenges to achieve POM goals Establish a Workgroup to address each challenge (should NOT be a formal standardization effort) Issue Guidelines Keep Effort Evergreen

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Call to Action Opportunity is Knocking: You are invited to an ad-hoc meeting on Tuesday 6:30 pm Explore/Test Process Analytics “Forum” Concept: Connectivity (Plug and Play Integration) Modular Sampling System Initiative (More at our Sampling System Session this PM)

Connectivity for PA Systems – Confusion or Opportunity IFPAC 2001 Mark Griffin-ExxonMobil Chemical Larry Washburn-ExxonMobil Chemical Jeff Gunnell-ExxonMobil Chemical Dan Podkulski-ExxonMobil Chemical Norm Kincade-LaPlace Technologies ABB Analytical SAAI Rosemount Analytical Acknowledgements