NeSSI - New Sampling Sensor Initiative by John Mosher, Bob Nickels – Honeywell Sensing & Control and Ulrich Bonne – Honeywell Laboratories NeSSI-II Network

NeSSI - New Sampling Sensor Initiative

byJohn Mosher, Bob Nickels – Honeywell Sensing & Control

andUlrich Bonne – Honeywell Laboratories

NeSSI-II Network and Sensor Developments

Networked Sampling SystemNetworked Sampling System(NeSSI-Generation II)(NeSSI-Generation II)

Development and Field TestDevelopment and Field Test



Outline:Project TeamDefinition and NeSSI functions. Status of NeSSI-IChallenges for NeSSI-II components: Networked Components

Easy plug-and-playIntrinsically SafeReliableAffordable

Demo and field test of NeSSI-IISensor Developments


NeSSI Generation IIBeing Developed by a

Supplier Team

Supplier Team:

Steve Doe (256) 435-2130 Parker-HannifinDave Simko (440) 349-5934 SwagelokRichard Hughes (310) 515-2866 AutoflowBob Nickels (815) 235-5735 Honeywell-ACSJohn Mosher (209) 330-4004 Honeywell-ACSUlrich Bonne (763) 954-2758 Honeywell Labs



User Team for Potential DoE NeSSI ProjectPeter van Vuuren (281) 834-2988 ExxonMobilRob DuBois (780) 998-5630 DowJoe Andrisani (302) 695-3156 DuPontSteve Wright (423) 229-4060 EastmanBob Reed (215) 652-1691 MerckPaul Vahey (973) 455-5977 Honeywell-SMDon Young/Don Nettles (510) 242-3298 ChevronTexacoFrank Schweighardt (610-481-6683) Air ProductsGeorge Vickers (630) 420-3701 BPPaul Barnard (713) 336-5351 EquistarChemicals Steve Doherty (847) 982-7465 PharmaciaCarol Zrybko KraftMichelle Cohn UOPAlan Eastman/Randy Heald (918) 661-3475 ConocoPhillips

Center for Process Analytical Chemistry (CPAC)Mel Koch (206) 616-4869 U.Washington, CPAC



NeSSI Benefits

|------------------------------------+------------------------------------|

| 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


Fig. 1. Functions of a Process Sampling System.

Courtesy of ExxonMobil


Fig. 1a. Traditional Stream

Sampling System in a

Petrochemical Plant.

No Modular or Standardized

Components

Courtesy of P.vanVuuren,

ExxonMobil


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

NeSSI Generation I


NeSSI Generation II

What is Generation II?

NeSSI II = SP76 + IS + CAN + SAMNeSSI II = SP76 + IS + CAN + SAM

SP76 = NeSSI Generation I from SEMIIS = Intrinsic SafetyCAN = Controller Area Network – DeviceNetSAM = Sensor Actuator Manager – Open Interface

to Plant-wide Network and/or Analyzer

Reliable, Networked, Modular, Safe, Open, and Affordable!


NeSSI Generation II

SP76

IS

CANSAM

NeSSI II = SP76 + IS + CAN + SAMNeSSI II = SP76 + IS + CAN + SAM


PROJECT ABSTRACTThe 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.

NeSSI Generation II


ABSTRACT (cont’d.)Benefits Enabled by Full NeSSI Implementation: Reduce down time, energy use & operating & sampling cost: U.S.: 0.1-0.2 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 testingDeliverables: 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


Table 1. NeSSI Generation I versus IITable 1. NeSSI Generation I versus II

FeatureSignalProtection MethodsClassificationSensorsIntelligenceControl PhilosophyRegulating Comp.Passive Comp.ActuatorsHeatingWiringCommunications

Generation I4-20 mAPurge, X-proofDiv.2 (seldom f.)

Non-substrateLimitedCentralizedSelf-containedMechanicalStand-aloneExternalConduit/CableIndividual

Generation IISerial BusMostly ISDiv.1 (often flamm)(mini)SubstrateProcessor on boardDistributed (SAM)PID control loopsElectro-mechanicalSubstrate, combiSubstrate integratedIS Plug and PlayNetworked

From Rob Dubois, Dow, May’02


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


Feature Generation I Generation II Generation IIISignal Type 4-20 mA; discrete Serial bus Serial bus

Wireless; Opt.FiberProtection 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-SubstrateAnalyzer Locat Off-Substrate On/Off-Substr. MicroAnalyticalIntelligence 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/PIDPassive Comp. Pure Mechanical Electro-Mechan. Int. Electro-Mechan.Valves Manual or Pneum., Off On-Substr.Combi On-Substr.CombiHeating External Substr.-Integrated Substr.-Integrated Wiring Pwr/Sig X-proof conduit/cable IS Plug & Play IS Plug & Play Communication Individual Hard-Wired Networked NetworkedCost High Moderate Moderate to low.

Comparison of NeSSI Generation Designs


CAN Communications - Issues and BackgroundCAN Communications - Issues and Background

Issues/Questions:1. Is it feasible to embed all required device electronics, microcontroller, and CAN communications into a NeSSI SP-76 1.5 x 1.5” footprint? 2. Is a CAN network capable of operating through an IS barrier?

Selection of CAN as a communications enabler for NeSSIHigh Level Protocol

SDS, DeviceNet, CANOpen - all publicly available & proven Data Link Layer

Master/slave, peer-to-peer, multicast messagingAll data types supportedDiagnosticsCarrier Sense Multiple Access with Collision Resolution 16-bit CRC error checking, intell.network mgmt.capability

Physical LayerTrunkline/multidrop with branchesSeparate twisted pairs for signal and device power distributionUp to 64 nodes, up to 500 meters trunk lengthIntrinsic Safety

Application Layer

Presentation Layer

Session Layer

Transport Layer

Network Layer

Data Link Layer

Physical Layer

ISO OSI 7-Layer Model


Microbridge flow sensor interfaced to a typical miniature CAN microcontroller and 12 mm connector. A similar interfacingapproach will be used in this project to connect existing sensors and actuators tothe CAN network.

by Bob Nickels, Honeywell

Adaptation of Honeywell Temperature, Pressure, & Flow Sensors to NeSSI design standards.

12 mm


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.

CAN Communication - Feasibility and Intrinsic Safety EvaluationCAN Communication - Feasibility and Intrinsic Safety Evaluation


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).


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


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


Thermal Microbridge Flow Sensors for NeSSI-II


Thermal Microbridge Flow Sensors for NeSSI-II


Smart,

T-Compens.

TC Sensor

Smart,

T-Compens.

Flow Sensor

Smart, IS, Miniature, p, T, F Sensors for NeSSI Adaptation. (Courtesy of Honeywell)


PHASED, a GC MicroAnalyzer


Multi-Stage Pre-concentrationMulti-Stage Pre-concentration

To

Separator

Multi-stage release of analyte increases its concentration:

~100-fold with 1st stage

~100 x n-fold after n stages

Cross section of PHASED structure

Side Views of PHASED structure and Operation


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 (0.1-0.2 quads/y) or $10-20B/y.



CONCLUSIONS• Loaded CAN bus network error rate of 2: 87,000,000

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: 10-20 B$/y after NeSSI saturation of all industrial processes

• Team approach enhances risk of success


AcronymsAcronymsCAN Controller Area NetworkConnI Connectivity InitiativeCPAC Center for Process Analytical ChemistryDoE-OIT Department of Energy, Office of Industrial TechnologiesEDS Electronic Data SheetF FlowGC Gas chromatographyGUI Graphical User InterfaceHMI Human-Machine InterfaceIFPAC International Forum for Process Analytical ChemistryIR Infra-redIS Intrinsically safeNeSSI New Sampling/Sensor InitiativeNRE Non-Recurring Engineering labor ODVA Open DeviceNet Vendors AssociationOLE Object Linking and EmbeddingOPC OLE for Process Control based on Microsoft's OLE/COM technologyOSI Open System Interconnectp PressurePC Personal computerPDA Personal Digital AssistantSAM Sensor-Actuator ManagerSDS Smart Distributed System SIG Special Interest Group T TemperatureTEDS Transducer Electronic Data SheetV Valve



Thank You!Contact Information:

John Mosher (209) 330-4004 Honeywell ACSBob Nickels (815) 235-5735 Honeywell ACSUlrich Bonne (763) 954-2758 Honeywell Labs

Documents

NeSSI - New Sampling Sensor Initiative by John Mosher, Bob Nickels – Honeywell Sensing & Control and Ulrich Bonne – Honeywell Laboratories NeSSI-II Network