Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Next Generation Process Analyzer System Connectivity Issues Peter van Vuuren ExxonMobil Chemical Engineering and Manufacturing Services Baytown, Texas January 22, 2001

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Analyzer Computing System Hierarchy A Sample System Sensor GC FTIR LEVEL 3 an-LAN LEVEL 2 FLAN Datalink INFORMATION MANAGEMENT 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) Historian

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Sample Conditioning System Process Stream P FT DAAC Com 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 Field LAN Level 1 Bus SAM

Next Generation Process Analyzer System Connectivity CPAC Spring 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 Analyzer Computing System Hierarchy (Level 0 - 4) Level 4 Remote User Interface/Applications Server(s) Workstations Plant LAN Level 2 Bus = Field LAN Sample Conditioning System All System Components in Contact with Sample including the Sensors Level 0 Level 1 A Process Stream P FT Level 1 Sensor Bus AnalyzerController DAAC Com All Additional Electronic and Computing Components Required to Generate Analytical Result SAM

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Level 2/3 Central User and Operations Interface DCS Gateway Client/Server(s) Analyzer Server Workstations DCS L2 DCS L3 TPS CLM Analyzer Computing System Hierarchy (Level 0 - 4) Level 4 Remote User Interface/Applications Server(s) Workstations Plant LAN Level 2 Bus = Field LAN Sample Conditioning System All System Components in Contact with Sample including the Sensors Level 0 Level 1 A Process Stream P FT Level 1 Sensor Bus AnalyzerController DAAC Com All Additional Electronic and Computing Components Required to Generate Analytical Result SAM

Next Generation Process Analyzer System Connectivity CPAC Spring 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 SAM

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 M easure- ment Domain Level 2 Bus = Field LAN Level 3 Bus = AnLAN DCS Domain O&M 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 Analyzer Controller DAAC Com

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Level 2 Bus = Field LAN Analyzer Controller DAAC Com Level 3 Bus = AnLAN Gateway Server Analyzer Server Physical Layer Ethernet TCP/IP 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 ? ? BIG ANSWER ? ? The Process Analytics Community 1M $? Given the choices of: controller, server and workstation platforms communication protocols HMI interfaces database options (short term and long term) security and controls needs (local & remote access) How do we (as end-users and suppliers) develop and agree on industry guidelines for the analyzer connectivity infrastructure which will ensure plug-and-play compatibility for all analyzers? ? ? BIG QUESTION ? ? CPAC Sponsored Connectivity Initiative

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 The Process Analytics Community 1M $? Exploratory Meeting at Pittcon2001: End-users Shell, Dupont, EMCC Suppliers ABB, AAI, Rosemount, ThermoOnix Panametrics, Servomex Outcome: Confirmed the Need for Industry Wide Effort Group Volunteered to act as “Steering Team” Requested CPAC to Sponsor Effort End-users to Develop Connectivity Functional Specification Next Step: Get CPAC Endorsement for Workgroup Initiate Development of Functional Specification

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 FINI

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Sample Conditioning System Process Stream P FT Level 1 Sensor Bus Level 0 Level 1 Level 2 Level 3 Level 3 Bus = AnLAN DCS Gateway OPC Server(s) Long Term Storage Analyzer Server Workstations DCS L2 DCS L3 TPS CLM A Analyzer Controller DAAC Com Level 4 Server(s) Workstations Plug-and-Play Connectivity

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 The Process Analytics Community 1M $? Food for Thought: Convene a Process Analytics “Connectivity Focus Group” (Sponsored by CPAC or ISA AD?) Representation: End-users/Analyzer VendorsConvene a Process Analytics “Connectivity Focus Group” (Sponsored by CPAC or ISA AD?) Representation: End-users/Analyzer Vendors Develop a consensus about Proprietary vs Open Model (POM) (Learn from FF and OPCF?) - Vendor Issue Agree on the System Functionality Requirements - End-User Issue Understand the possible range of compatible/incompatible solutions (Hardware & Software) Propose a plan to develop a connectivity/infrastructure model (Include industry acceptance) Continue?

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 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

Next Generation Process Analyzer System Connectivity CPAC Spring 2001 Measurement Domain 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: Legacy Systems Redundancy Wireless LAN’s Portable Terminals

Next Generation Process Analyzer System Connectivity CPAC Spring 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 Analyzer Computing System Hierarchy (Level 0 - 4) Level 4 Remote User Interface/Applications Server(s) Workstations Plant LAN Level 2 Bus = Field LAN Sample Conditioning System All System Components in Contact with Sample including the Sensors Level 0 Level 1 A Process Stream P FT Level 1 Sensor Bus AnalyzerController DAAC Com All Additional Electronic and Computing Components Required to Generate Analytical Result SAM