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Smart/Modular Sample Handling Systemand Field Mounted Analyzers
S. Staphanos J. Gajewski
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Rosemount Analytical Inc.n Is an operating component of Emerson Electricn Is a part of Emerson’s Fisher-Rosemount groupn Consists of three divisions:
— Tekmar-Dohrmann Cincinnati, OH Laboratory— Uniloc Irvine, CA pH/Conductivity— Process Analytic Division Orrville, OH Combustion Control
Process RamanCEMS
Anaheim, CA Process GCProcess Gas Analyzers
Hasselroth, Germany Process Gas Analyzers
Approximately three years ago, weperformed an assessment of futurerequirements and trends forprocess measurement and analysis
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Conclusion: Analytical Measurement TrendsLaboratory Measurements
Complex Analyzers in Shelters
Sampled Measurements
Single Component Analysis
Analog Data
“Dumb” Analyzers
Data Available Locally
Custom SHS
On-line Analyzers
Simplified Analytical Transmittersin the Field
In-situ Measurements
Multi-component Analysis
Digital Communications
Smart Analytical Transmitters withon-board control and diagnostics
Data available anywhere viaInternet Enabled Instruments
Modular/Smart SHS
These conclusions were incorporatedinto our new product development
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New Analyzers Resulting from the Assessment
• These Analyzers fulfill the trends thatwere identified.
• An additional requirement is “Smart &Modular” sample handling systems.
Oxygen Transmitter O2/Combustibles
CATProcess Laser Raman
GCX
Moving process analysis to thepoint of measurement
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Illustrative Example: GCX Transmitter
Sample Tap inProcess Unit
GCX Transmitter w/sample system $30K
Heated Sample line foruse with Traditional GC
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Illustrative Example: Heated Sample Line Run
Approximately 300 feet($25 / foot min.)
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Illustrative Example: Traditional Gas Chromatograph
Analyzer Shelter$75K min.
Utilities$4-6K / yr
Sample Handling System$5K - $10K
“Battleship” GC$ 30K
Sample Transported viaHeated Sample Line
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Gas Chromatograph TransmitterIncreasedSafety Box
ElectronicsEnclosure /Display Interface
OvenAssembly
Integral SHSEnclosure
PipeMount
Bracket GCX Enclosure• Explosion-proof enclosure• Dual compartment housing,
isolates electronics
GCX Oven Design• High thermal stability, tight
temperature control minimizespower requirements and givesaccurate analysis
• Minimum power requirements• Improved accuracy and reliability,
typically 2x• Supports multiple detectors,
valves, and columnconfigurations dramaticallyexpand applications versatility
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GC Transmitter Offers Better Control
50
10
8
6
4
2
1510 20
GCX control is 2-16times better thanconventional GCbased control
Total Delay Time (minutes)(Analysis Time & Sample line Delays)
Rel
ativ
e C
on
tro
l Err
or
Conv.GC
GCTransmitter
Source: Greg Shinskey
• Fast columns andmethods
• No sample timedelay
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Illustrative Example - Response to a Disturbance
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
0 5 10 15 20 25 30 35 40 45 50
Minutes
SP A
ND
PV
IN P
PM
(C2H
2)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
Setpoint
GCX Control
CompetitiveGC Control
Disturbance
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Operating Characteristics of a Smart/ModularSample Handling System
Field Mountable Integrated or close coupled to the field analyzer, reduced time lag for sample transport
Simplified Improved serviceability and redundancy Modular Minimize the number of unique parts for
service and maintenance Smart Self diagnostics, alarms, automatic fault
correction (i.e. plugged filter) life cycletracking (i.e. valve life)Capable of advanced sample conditioning
Controlled Temp. More repeatable and accurate analysis
Rosemount Analytical is committedto developing and deploying theSmart/Modular SHS
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Technical Requirement of Smart/Modular SHS
n Components— Micro Electronic Flow Controller— Micro Flow Sensor(s)— Micro Electronic Pressure Reducer
n Electronics/Software— SHS should be controlled by the analyzer— Self diagnostics capability
n Material of Construction— Compatible with the process stream composition and temperature
required— Standardized/building block
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Challenges
n Components - Material tends to be 316 stainless. Analyzersuppliers must identify components of Hastelley C, Moneland other materials to provide full Hastelloy
n Temperature Limitations - Most commercially availablecomponents for Smart/Modular SHS have an upper range of65 c.
n Market Acceptance - At this time the nonrecurring costs for aSmart/Modular SHS is greater than a conventional SHS.Manufacturers need to reduce costs and assist customers inconsidering life cycle costs
Rosemount Analytical has an engineering groupactively involved in this activity
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Summary
n Simplified transmitter style analyzers have value to users— Improved control— Reduced nonrecurring costs— Reduced life cycle costs
n Smart and Modular Sample handling Systems are a logical“next step” to analyzer transmitters
n Most of the technology exists for Smart/Modular SHS
n Analytical companies, such as Rosemount, need to partnerwith end users for successful development