1. 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”

2. Presentation Outline NeSSI™ Roadmap
Recap of SAM* Hardware/Software Functionality
Drivers for SAM Development
Features of a SMART Analytical System
*SAM = Sensor Actuator Manager
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3. 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.
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4. Electrical Networked & Smart
NeSSI™ Roadmap
Gen III
Gen II
Gen I
Fluid Components
Electrical Networked & Smart
& Wireless
uAnalytical
END USER VALUE
Today
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5. 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
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6. 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
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7. 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)
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8. 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
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9. 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
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10. 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)
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11. 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”
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12. 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
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13. 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
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14. 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
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15. 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
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16. 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
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17. 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
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18. 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
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19. 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
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20. 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…
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