by John Mosher, Bob Nickels – Honeywell Sensing & Control and

Sensing & Control

1NeSSI - New Sampling Sensor Initiative

byJohn Mosher, Bob Nickels – Honeywell Sensing & Control

andUlrich Bonne – Honeywell Laboratories

NeSSI II - A Platform for NeSSI II - A Platform for Micro-Analytical Devices Micro-Analytical Devices

CPAC Spring Meeting – May 2003CPAC Spring Meeting – May 2003

Sensing & Control


Why NeSSI?Why NeSSI?

“It's estimated that 70-80% of analyzer outages can be traced to the sample system.”

T. McMahon, Control Magazine, August 2001

Sample systems limit the Sample systems limit the effectiveness of process analytical effectiveness of process analytical technology:technology:

• Complex

• Expensive

• Sparingly deployed

• High maintenance

• Large, bulky, “dumb” devices

• Major cause of unplanned downtime

Sensing & Control


Evolution of the NeSSI ProjectEvolution of the NeSSI Project

Miniature/Modular (enabled by Mechanical Standard)

Electrical/Smart (enabled by Communication Standard)

MicroAnalytical(enabled by Technology Advances)

Gen IIICirca 200?

End UserValue

Gen IICirca 2003

Gen I2002

At the Pipe(enabled by Intrinsic Safety)

Honeywell Proof Of Concept Apparatus

( under development at S&C, Feb. 03)

Sensing & Control


NeSSI ObjectivesNeSSI Objectives

• Promote the concept of...– at the pipe field-mounted analytical systems

• Facilitate the acceptance/implementation of...– modular & miniature process analytical technology

• Lay the groundwork for...– smart technology open connectivity & communications

• Provide a technology bridge to the process for...– microanalytical “lab-on-a-chip” - PHASED

•GE-Panametrics Oxygen sensor probe on NeSSI

User-Driven, Multi-vendor Supported

• PHASED Multi-Gas Analyzer (Micro Gas Chromatograph) under development at Honeywell Labs

U.S. Patent No:

6,393,894

Sensing & Control


Traditional Sample System: NeSSI Sample System:

Gen I - Miniature/Modular ConceptGen I - Miniature/Modular Concept

ANSI/ISA 76.00.02-2002ANSI/ISA 76.00.02-2002Modular Component Interfaces for Surface-Mounted Modular Component Interfaces for Surface-Mounted

Fluid Distribution Components Fluid Distribution Components Part 1: Elastomeric SealsPart 1: Elastomeric Seals

Approved August 2002Approved August 2002

Sensing & Control


Gen II - Smart/Electrical TechnologyGen II - Smart/Electrical Technology

• Open communications protocol standard based on CAN

• Intrinsically Safe

• SAM = Sensor Actuator Manager – Embedded Controller, Profile Manager Communications Gateway

NeSSI Gen II

Level 2 LAN = Field LAN

Level 3 LAN

INFORMATION D0MAINPROCESS CONTROL

DOMAIN

ENTERPRISE DOMAIN

MEASUREMENT DOMAIN

SAM

eSAM

Level 1 SensorBus (CAN)

Level 4 Enterprise LAN

SAM

CANbus

Programmable Substrate Heater

VP

A

F

Auxiliary Heating/Cooling

SubstrateT

T

NeSSI II = ANSI/ISA76 + IS + CAN + SAMNeSSI II = ANSI/ISA76 + IS + CAN + SAM

Sensing & Control


Physical Interface “Rail” – ANSI/SP76Physical Interface “Rail” – ANSI/SP76

Communications Interface “Rail” – DeviceNet ISCommunications Interface “Rail” – DeviceNet IS

The Area Between the Enabling “Rails” is WhereThe Area Between the Enabling “Rails” is WhereSensor and Instrument Vendors Add Value andSensor and Instrument Vendors Add Value andCommercialize Intellectual Property.Commercialize Intellectual Property.

NeSSI II/III – Platform DevelopmentNeSSI II/III – Platform Development

Sensing & Control


Substrate Substrate

Typical NeSSI Device combines state-of-the-art combi- sensor technology with Intelligence and network interface in one small, surface-mount package.

On/Off and On/Off and Modulating valvesModulating valves

Flow Sensor w/ Flow Sensor w/ Temp, Pressure Temp, Pressure w/ Tempw/ Temp

NeSSI II/III – Product DevelopmentNeSSI II/III – Product Development

Substrate

Moisture in Moisture in Dry GassesDry Gasses

PHASED PHASED Micro Micro GCGC

Other Analytical:Other Analytical:pH, pH, OO22, , Ion,Ion,Conductivity, Conductivity, NOx,NOx,Turbidity,Turbidity,??????Mod

Valve

D/A

Network

Press/Temp

A/D

Network

Sensing & Control


Microbridge flow sensor interfaced to a typical miniature CAN microcontroller and 8 mm connector. A similar interfacingapproach will be used in this project to connect existing sensors and actuators tothe CAN network.

by Bob Nickels, Honeywell

8 mm

Adaptation of Honeywell Temp, Pressure, Flow SensorsAdaptation of Honeywell Temp, Pressure, Flow Sensors

Sensing & Control


Current Status:• Sensor Design and SP76 housing qualified Intrinsically Safe (IS).• CAN controller and transceiver chipsets identified.• DeviceNet protocol selected and pre-tested in selected chipset.• M8 connector tested for DeviceNet on POCA.• Preliminary CAN IS mode testing done.• First POCA units delivered 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.• Test Assemblies in full DeviceNet network.• Identify DeviceNet IS network restrictions and rules.• Propose establishment of DeviceNet IS Special Interest Group (SIG) to ODVA.

Honeywell Proof-of-Concept-Assembly (POCA)Honeywell Proof-of-Concept-Assembly (POCA)

Sensing & Control


NeSSI II/III Cost ComparisonNeSSI II/III Cost Comparison

System Configuration:System Configuration:Above Average Complexity, 4 Gas Streams: 2 Process, 1 Span, 1 Calibration.Above Average Complexity, 4 Gas Streams: 2 Process, 1 Span, 1 Calibration.Extra, Blank Locations for Additional Instrumentation, including PHASED GC.Extra, Blank Locations for Additional Instrumentation, including PHASED GC.

Traditional SSTraditional SS NeSSI Gen 1 w/ControlNeSSI Gen 1 w/Control NeSSI Gen 2/3 NeSSI Gen 2/3

$20,000 $36,000 $40,000 est.

Traditional Sampling System:Gauges, Manual Valves, Rotometers, Gas-Purged Enclosure, No Information, Process Variable Disconnect, Custom One-of-a-Kind

NeSSI Gen 1 w/Control:Smaller Footprint, Modular Gas Path, Gauges, 4-20mA Input/Output DevicesPLC Control, Process Variables Connected, Huge Gas Purged Enclosure,Custom One-of-a-Kind.

NeSSI Gen 2/3:Much Smaller Footprint, Networked I/O Devices, Local & Remote Control,Process Variables Integrated, Intrinsically Safe, Software Menu Designed,SAM Controlled, GC Onboard, PDA Enabled, Standard Enclosure Located

Near Flow.

Sensing & Control


Intelligence + Communications = Improved ProductivityIntelligence + Communications = Improved Productivity

The Value of Good, Fast Information:The Value of Good, Fast Information:

• Monitoring of key parameters

• Verify constant flow of analyte

• Control pressure, temperature

• Self-validation, both continuous and periodic (embedded control, integrated diagnostics, self-calibration)

• Intelligent statistical tools identify abnormal events

• Operators notified when trouble is anticipated (predictive diagnostics)

• Data presented in a user-friendly way to the right person, anywhere

• Self-correcting systems to avoid downtime

Wireless enablers for operator productivity

Sensing & Control


SAM Design A:• DeviceNet in/Ethernet out• 4” x 4” x 2”• USB and Serial Ports• Linux OS w/ JavaVirtual Machine

SAM Design B: • DeviceNet in/Ethernet out• 3” x 4” x 6”• Expandable local I/O, Serial Ports• Windows CE OS• Webserver OPC Connectivity

Honeywell Experion PKS C200 Controller • DeviceNet in/Ethernet or ControlNet out• Direct Connectivity to Honeywell Architectures

Preliminary Investigation of SAM Controller ChoicesPreliminary Investigation of SAM Controller Choices

|CPU|Enet|Dnet| I/O|

Sensing & Control


Sensor - Level 1 LAN (DeviceNet)

Gas Analyzer

SensorActuatorManager

V TPA

Sample System I/O Subsystem

Sample System

LocalHMIStation

Control & Information - Level 3 LAN (Ethernet)

OPCGateway

SensorActuatorManager

V TPA

DeviceNet

Sample System

NeSSI Generation 1

Control Room

Analyzer Shed

NeSSI Generation 2/3

At-LineSample Point

Class 1 Div 2

Class 1 Div 1

Class 1 Div 2 WirelessHandheld

HMI

GasAnalyzer

Field

NeSSI Integration into Information SystemsNeSSI Integration into Information Systems

Class 1 Div 1

Field - Level 2 LAN (Ethernet)

Field - Level 2 LAN (Wired or Wireless)

Sensing & Control


Industry Organizations:Industry Organizations:

Honeywell Products and Services:Honeywell Products and Services:

Sensing & ControlSensing & Control - Pressure, Temperature, Flow- Pressure, Temperature, Flow Moisture, Turbitity, ???Moisture, Turbitity, ???Industrial Measurement & ControlIndustrial Measurement & Control - pH, O2, H- pH, O2, H220, Conductivity0, Conductivity NOx, Ion, Moisture, ???NOx, Ion, Moisture, ???Honeywell LabsHoneywell Labs - PHASED, Microanalyzers- PHASED, MicroanalyzersIndustry SolutionsIndustry Solutions - Sales, Service, and Support- Sales, Service, and Support

Center for Process and Analytical ChemistryCenter for Process and Analytical Chemistry

NeSSI - New Sampling Sensor InitiativeNeSSI - New Sampling Sensor Initiative

Open DeviceNet Vendors AssociationOpen DeviceNet Vendors Association

NeSSI II – Market DevelopmentNeSSI II – Market Development

Sensing & Control


Analyzer OEMs

UnsophisticatedEnd Users

Analyzer OEMs

HoneywellSensing & Control

Honeywell Indust.Measure & Control

Other AnalyticalDevice

Manufacturers

Substrate/ValveManufacturers

DeviceNet &Controller

ManufacturersPressure, Temp, Flow, Moisture

pH, O2, H2O,PHASED, More

Parker, Swagelok,Celerity, Others

GE Panametrics,Circor, Rosemount,Others

Many

Gas Box Assemble,Test Companies

Honeywell Services &Industrial Solutions

Sophisticated End Users &Application-Specific OEMs

Celerity, UCT,Others

ABB, Siemens,Many Others

Other Integrators/Installers Also

Customers

Products

Components

Solutions

ABB, Siemens,Many Others

NeSSI II/III – Commercialization StrategyNeSSI II/III – Commercialization Strategy

Sensing & Control


[email protected] (209) 339-4004 [email protected] (815)[email protected] (763)954-2758

NeSSI II - A Platform for NeSSI II - A Platform for Micro-Analytical Devices Micro-Analytical Devices

CPAC Spring Meeting – May 2003CPAC Spring Meeting – May 2003

Thank You!Thank You!

Documents

by John Mosher, Bob Nickels – Honeywell Sensing & Control and