1. Networked Sampling System (NeSSI-Generation II)
NeSSI-II Network and Sensor Developments
Networked Sampling System
(NeSSI-Generation II)
Development and Field Test by
John Mosher, Bob Nickels – Honeywell Sensing & Control
and
Ulrich Bonne – Honeywell Laboratories 2

2. NeSSI-II Network and Sensor Developments
Outline:
Project Team
Definition and NeSSI functions. Status of NeSSI-I
Challenges for NeSSI-II components:
Networked Components
Easy plug-and-play
Intrinsically Safe
Reliable
Affordable
Demo and field test of NeSSI-II
Sensor Developments 2

3. NeSSI-II Network and Sensor Developments
NeSSI Generation II
Being Developed by a
Supplier Team
Supplier Team:
Steve Doe (256) Parker-Hannifin
Dave Simko (440) Swagelok
Richard Hughes (310) Autoflow
Bob Nickels (815) Honeywell-ACS
John Mosher (209) Honeywell-ACS
Ulrich Bonne (763) Honeywell Labs 2

4. NeSSI-II Network and Sensor Developments
User Team for Potential DoE NeSSI Project
Peter van Vuuren (281) ExxonMobil
Rob DuBois (780) Dow
Joe Andrisani (302) DuPont
Steve Wright (423) Eastman
Bob Reed (215) Merck
Paul Vahey (973) Honeywell-SM
Don Young/Don Nettles (510) ChevronTexaco
Frank Schweighardt ( ) Air Products
George Vickers (630) BP
Paul Barnard (713) EquistarChemicals
Steve Doherty (847) Pharmacia
Carol Zrybko Kraft
Michelle Cohn UOP
Alan Eastman/Randy Heald (918) ConocoPhillips
Center for Process Analytical Chemistry (CPAC)
Mel Koch (206) U.Washington, CPAC 2

5. NeSSI Benefits Compliments of Bruce Johnson, DuPont
| |
| Now | NeSSI |
| Analyzer houses | Analyzer cabinets close to sample |
| | point |
| Long heat traced lines | Short heat traced lines |
| Extensive design to bring sample | Minimal Design |
| to sensor | |
| One at a time assembly | Modular "tinker-toy" type assembly|
| Field repair | Modular replacement of components |
| | or systems, repair in shop or at |
| | vendors |
| Sample may not reach analyzer | Sample flow is validated |
Compliments of Bruce Johnson, DuPont 2

6. Fig. 1. Functions of a Process Sampling System.
Courtesy of ExxonMobil 2

7. Fig. 1a. Traditional Stream Sampling System in a Petrochemical Plant.
No Modular or Standardized Components
Courtesy of P.vanVuuren, ExxonMobil 2

8. Fig. 3. Sampling System for Measurement of H2O and O2 ppm
NeSSI Generation I
Fig. 3. Sampling System for Measurement of H2O and O2 ppm
in a High-Purity Hydrocarbon Stream. Miniaturized Version
Courtesy of D.Simko, Swagelok

9. NeSSI II = SP76 + IS + CAN + SAM
NeSSI Generation II
What is Generation II?
NeSSI II = SP76 + IS + CAN + SAM
SP76 = NeSSI Generation I from SEMI
IS = Intrinsic Safety
CAN = Controller Area Network – DeviceNet
SAM = Sensor Actuator Manager – Open Interface
to Plant-wide Network and/or Analyzer
Reliable, Networked, Modular, Safe, Open, and Affordable!

10. NeSSI II = SP76 + IS + CAN + SAM
NeSSI Generation II IS
NeSSI II = SP76 + IS + CAN + SAM
CAN
SAM
SP76 2

11.  Accelerate development of the prototype system component
NeSSI Generation II
PROJECT ABSTRACT
The Problem: Need for a networked, standardized, int.safe, modular, affordable and reliable process stream sampling and sensor system. Sampling systems now are causes for down-time and questionable process stream samples followed by costly control errors.
Objectives are to:
 Accelerate development of the prototype system component
such as intrinsically safe, digital pressure, temperature and
flow (p, T, F), sensors, smart valves, flow-controllers, and a
sensor/actuator networking capability
 Build, demonstrate, and test 1-2 NeSSI-II units, and
 Provide a platform for incorporating analytical sensors right
into the sampling system. 2

12. Benefits Enabled by Full NeSSI Implementation:
ABSTRACT (cont’d.)
Benefits Enabled by Full NeSSI Implementation:
 Reduce down time, energy use & operating & sampling cost:
U.S.: Q/y or $10-20 billion
 Bring these savings to the end-users at an earlier date, and
 Reduce the business risk to the Supplier and End-User
End-Users are members from across the processing industries: chemical,
petrochemical, power generation, refining, food, beverage and dairy, pulp & paper
Schedule:  One year for design, build and lab-test
 One year for installation and field testing
Deliverables:  Interim and Final Reports (no hardware) on
design of sensor hard- and software, NeSSI
test results, benefits and recommendations
Management of the Program: Honeywell + Consortium 2

13. Table 1. NeSSI Generation I versus II
From Rob Dubois, Dow, May’02

14. Diagram of NeSSI-Gen2-POCA (Proof of Concept Assembly) to Check Networking and Control of Flow, Pressure and Temperature. (Courtesy of R.DuBois, DowChemical)

15. Comparison of NeSSI Generation Designs
Feature Generation I Generation II Generation III
Signal Type mA; discrete Serial bus Serial bus
Wireless; Opt.Fiber
Protection Purging, X-proof Low-Power IS Low-Power IS
Enclos.Classif. Div.2(Seldom Flam.) Div.1(Often Flam.) Div.1 (Often Flam.)
Sensor Locat’n Off-Substrate On-Substrate Mini-Substrate
Analyzer Locat Off-Substrate On/Off-Substr. MicroAnalytical
Intelligence Limited Processor OB Processor OB
Ctrol.Philosophy Centralized Distrib’d (SAM) Distributed (SAM)
Regulat’g Comp. Self-Contained On-Substr.w/PID On-Substr. w/PID
Passive Comp. Pure Mechanical Electro-Mechan Int. Electro-Mechan.
Valves Manual or Pneum., Off On-Substr.Combi On-Substr.Combi
Heating External Substr.-Integrated Substr.-Integrated
Wiring Pwr/Sig X-proof conduit/cable IS Plug & Play IS Plug & Play
Communication Individual Hard-Wired Networked Networked
Cost High Moderate Moderate to low. 2

16. CAN Communications - Issues and Background
Issues/Questions:
1. Is it feasible to embed all required device electronics,
microcontroller, and CAN communications into a NeSSI
SP x 1.5” footprint?
2. Is a CAN network capable of operating through an IS barrier?
Selection of CAN as a communications enabler for NeSSI
High Level Protocol
SDS, DeviceNet, CANOpen - all publicly available & proven
Data Link Layer
Master/slave, peer-to-peer, multicast messaging
All data types supported
Diagnostics
Carrier Sense Multiple Access with Collision Resolution
16-bit CRC error checking, intell.network mgmt.capability
Physical Layer
Trunkline/multidrop with branches
Separate twisted pairs for signal and device power distribution
Up to 64 nodes, up to 500 meters trunk length
Intrinsic Safety
Application Layer
Presentation Layer
Session Layer
Transport Layer
Network Layer
Data Link Layer
Physical Layer
ISO OSI
7-Layer Model

17. Adaptation of Honeywell Temperature, Pressure, & Flow Sensors to NeSSI design standards.
Microbridge flow sensor interfaced to a typical miniature CAN microcontroller and 12 mm connector.
A similar interfacing
approach will be used in this project to connect existing sensors and actuators to
the CAN network.
12 mm
by Bob Nickels, Honeywell 2

18. CAN Communication - Feasibility and Intrinsic Safety Evaluation
DESCRIPTION OF TESTING:
Lab tests utilized SDS protocol and devices
A standard Zener Intrinsic Safety Barrier was used in series with both CAN communication signals. Component values were varied down to 4.3 volt Zeners and up to 100 ohms of series current-limiting resistance
20 CAN devices were connected over trunk lines varying from 5 to 250 meters
Devices were configured to generate bus traffic as high as 20% bandwidth utilization to simulate worst-case conditions.
A CAN network analyzer was connected to monitor traffic and detect errors
TEST RESULTS:
After over 72 hours of operation, a total of 87 million messages had been sent with only two CAN error frames. This is well within normal expectations for a CAN bus.
CONCLUSION: (tentative)
It appears that industrial CAN networks are entirely suitable for applications such as NeSSI when used with a properly-designed IS barrier.

19. Adaptation of Honeywell S1 Series Pressure Sensor to NeSSI design standards.
Current Status:
Sensor Design and SP76 housing qualified
Intrinsically Safe (IS).
CAN controller and transceiver chipsets
identified.
DeviceNet protocol selected and pretested
in selected chipset.
Preliminary CAN IS mode testing done.
First POCA units being built for February
delivery to Dow and ExxonMobil.
Next Steps:
Design and build PCBs incorporating selected sensing and communication chipsets/circuits.
Design and build PCBs into SP76 Housings and qualify full product as IS.
Establish and incorporate DeviceNet connector architecture for NeSSI applications.
Test Assemblies in full DeviceNet network.
Identify DeviceNet IS network restrictions and rules.
Propose establishment of DeviceNet IS Special Interest Group (SIG) to
ODVA (Open DeviceNet Vendors Association). 2

20. Preliminary Investigation of SAM Controller Choices.
 MKS Instruments RMUd:
DeviceNet in/Ethernet out
4” x 4” x 2”
USB and Serial Ports
32 bit RISC Power PC Processor
2-16MB ROM, 32-64MB SDRAM
Linux OS w/ JavaVirtual Machine
HMI Development Software Included
AutomationDirect 205: 
DeviceNet in/Ethernet out
3” x 4” x 6”
Expandable local I/O, Serial Ports
Windows CE OS
Flowchart Programming
Visio HMI/Control Software 2

21. NeSSI-II Sensor Developments… Cont’d
Compatibility with SP76 Footprint:
Pressure and Temperature
Flow (Gases and Liquids)
Self-Normalizing Flow Sensor
Thermal Conductivity for Process Monitoring
PHASED MicroAnalyzer 2

22. Thermal Microbridge Flow Sensors for NeSSI-II2

23. Thermal Microbridge Flow Sensors for NeSSI-II2

24. Smart, IS, Miniature, p, T, F Sensors for NeSSI Adaptation
Smart, IS, Miniature, p, T, F Sensors for NeSSI Adaptation. (Courtesy of Honeywell)
Smart,
T-Compens.
TC Sensor
Smart,
T-Compens.
Flow Sensor 2

25. PHASED, a GC MicroAnalyzer2

26. Multi-Stage Pre-concentration
Cross section of PHASED structure
Side Views of PHASED structure and Operation
Multi-stage release of analyte increases its concentration:
~100-fold with 1st stage
~100 x n-fold after n stages To
Separator 2

27. NeSSI Benefits, Nominal Ethylene Plant
Output: 1-2 billion pounds ethylene / year.
Savings enabled by smart, modular sampling (NeSSI I-III):
430$k/y due to building and ownership cost savings, over
15 year life, of 2.4 and 4$M, respectively (per P.VanVuuren et al)
100K$/y to 2+M$/y plant operational savings, due to
conservative assumption of only a 1% improvement in
process control (afford more measurements, and achieve
greater efficiencies, less waste and less down time)
Significance:
1-2% total savings by processing industries
Total US energy use & GDP: 1017 Btu/year & $1013/year
Assume US Process Industry uses 10% of total
NeSSI: 1-2% of 1016 Btu/y ( quads/y) or $10-20B/y. 2

28. NeSSI-II Network and Sensor Developments
CONCLUSIONS
Loaded CAN bus network error rate of 2: 87,000, is smaller than expected
Sensors compatible with NeSSI-II are around the corner: PT, FT,
IS certifications of P, F sensors were obtained before and need to be renewed
NeSSI-compatible microanalyzers are under development
Energy and cost savings are projected to be significant: B$/y after NeSSI saturation of all industrial processes
Team approach enhances risk of success 2

29. Acronyms CAN Controller Area Network ConnI Connectivity Initiative
CPAC Center for Process Analytical Chemistry
DoE-OIT Department of Energy, Office of Industrial Technologies
EDS Electronic Data Sheet
F Flow
GC Gas chromatography
GUI Graphical User Interface
HMI Human-Machine Interface
IFPAC International Forum for Process Analytical Chemistry
IR Infra-red
IS Intrinsically safe
NeSSI New Sampling/Sensor Initiative
NRE Non-Recurring Engineering labor
ODVA Open DeviceNet Vendors Association
OLE Object Linking and Embedding
OPC OLE for Process Control based on Microsoft's OLE/COM technology
OSI Open System Interconnect
p Pressure
PC Personal computer
PDA Personal Digital Assistant
SAM Sensor-Actuator Manager
SDS Smart Distributed System
SIG Special Interest Group
T Temperature
TEDS Transducer Electronic Data Sheet
V Valve 2

30. Thank You! NeSSI-II Network and Sensor Developments
Contact Information:
John Mosher (209) Honeywell ACS
Bob Nickels (815) Honeywell ACS
Ulrich Bonne (763) Honeywell Labs 2