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January 20, 2011 IFPAC Paper I-244

Gary C. Astle

Real World Experiences with NeSSI Sample Systems

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Overview of Discussion

The Laws of Chemistry & Physics still apply Modular Substrate (it’s not all the same) Sample System Examples

CEMS (Continuous Emissions Monitoring) Petrochemical Analysis Ambient Air Monitoring Subpart JA Emissions Monitoring

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The Laws of Chemistry & Physics Still Apply

Industrial Sampling Systems Discussion Group NeSSI – Industry Standard or Novelty Approach!?!

25 Comments over 2 months (High level of Activity)

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The Laws of Chemistry & Physics Still Apply

Best for gas service (not Liquids) Particulate sensitive Prone to plugging (small size) Leaks, limited O-Ring life Can’t follow the flow, hard to troubleshoot Leaking stream selection valves Cost is 2x to 2.5x that of conventional Too small Cost of ownership

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NeSSI Modular Substrate

ANSI/ISA 76.00.02-2002, IEC 62339-1:2006(E)

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NeSSI Modular Substrate

The specification is very open 4 bolt holes & 5 gas ports on a 1.5” plate

Not all NeSSI is the same (by a long shot) Pressure ratings vary tremendously Process flow path design is different for all vendors Flow is almost always constrained by the top level

components and not the substrate (i.e.: Valve Cv) Stream selection valve technology varies widely by

manufacturer Completed system size can be very compact or very spread

out (hybrid) based on customer preference

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NeSSI Myths

Best for gas service (not liquids) 35% of CIRCOR Tech systems are sold into liquid

applications Our first NeSSI system was for diesel fuel, low sulfur

analysis This system is still in service today (7 years old)

Liquid systems generally involve the following;

Fast loop with a Swirlklean™ filter for particulate removal Armored rotometer for flow monitoring Block valves to block the fast loop Growing trend toward Nitrogen purge capabilities on systems

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Liquid Fast Loop

Nitrogen Purge

Analyzer Sample

Nitrogen to NeSSI

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NeSSI Myths

Particulate Sensitive Gas Chromatographs have a 2-5 micron particle spec Top level components are generally the devices impacted by

particulates (i.e.: Bourdon tubes in pressure gauges, valves) CIRCOR Tech NeSSI orifice size is 0.110”

Bigger than 1/8” tubing; smaller than ¼” tubing

All sample systems make use of particulate filters of varying sizes, designs & manufacturers

Viscosity is inevitably the parameter of greatest concern to NeSSI (or any sample system)

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NeSSI Myths

Leaks, limited O-Ring life Leaks are a function of process flow design Leaks are a function of pressure rating Leaks are a function of process & O-Ring interaction

Flow design, pressure rating & connectors are a

design issue driven by each NeSSI vendor It can also be a material compatibility issue O-Ring replacements on CIRCOR Tech systems are

a non-routine occurrence

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NeSSI Myths

Can’t follow the flow, hard to troubleshoot Flow path visibility is a vendor design issue, not a NeSSI

issue A blank plate is an excellent troubleshooting tool Liquid leak detector works Helium leak detectors work System design will come back to help or haunt you in

troubleshooting situations Ability to block & purge sections of sample system Density of sample system design

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NeSSI Myths

Leaking stream selection valves Every NeSSI vendor uses a conventional stream selection

valve (Double Block & Bleed) adapted to NeSSI Dynamic O-Rings require routine replacement & can leak

(failure to contain the process within the valve) Valve design is the key factor; NeSSI is completely irrelevant

to the valve reliability issue

CIRCOR Tech uses diaphragm valve technology, not dynamic O-Rings No routine maintenance Never leaks process outside the system

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NeSSI Myths

Cost is 2x to 2.5x that of conventional Projects won in a competitive environment the last year

include; 3 Stream Chemical Refining Process 100+ Stream Ambient Air Monitoring System Multiple Subpart JA total Sulfur Systems Several Natural Gas BTU measurements

Apples to Apples comparison is always best System Integrators often don’t understand NeSSI

When in doubt, build in contingency

Bigger systems tend to favor NeSSI systems in cost Components do cost more; labor is the leverage

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NeSSI Myths

Too small While NeSSI is small; system layout & design is the

overriding factor in system size. Vendor dependent!

CIRCOR Tech uses no size/dimension constraints in our system designs Traditional NeSSI (Highly Compact) Hybrid NeSSI (NeSSI in a “stick” configuration Same functionality, different footprints

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CT76 4 STREAM COMPACT

4 STREAMS

VAPOR

AUTOCAL

MAN CAL

ARV

SSO

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CT76 MODULAR STICK DESIGN

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Hybrid System

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Hybrid System

18

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Conventional+ NeSSI System

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NeSSI Myths

Cost of Ownership Major projects are run by a Project Manager. His constraints

are to implement the project according to specification; on time and within budget. "Cost of Ownership" is not his concern. Capital costs are the major influence. In nearly all the (many) projects I have seen, spare parts, maintenance cost, etc. are NOT taken into account. Assembly is by the low bidder. Low bidders don't buy NeSSI.

This is a cultural issue, until businesses start thinking about the “total cost” the best decision will often be missed.

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Real World Examples

21

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Ambient Air Sampling System

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Ambient Air Sampling System

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Ambient Air Sampling System

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3-in-1 SHS, Isobutylene Application

Tri-fold swing out door: HMI to locally view system status and perform diagnostics both with and without sample cabinet being open

Two zone system: one upper heated vapor system with temperature interlock, one lower liquid system, non heated

Modular SP76 technology enables space savings to fit 3 independent sample systems into one system footprint on shelter Common “stick” design methodology allows for easy visualization and troubleshooting Both visual and electronic pressure and flow sensors available in case of loss of power or bus communications

ProfiNET™ enabled PLC manages: Gathering data from two moisture analyzers (one analog, one Modbus input/output) Gathering data and alarms from digital bus conditioning components Sensing digital relays from a GC and controlling system valves HMI commands/visualization and alarms/ data to DCS system

Three Analyzers are supported with this SHS configuration: •Siemens GC •Ametek Moisture •GE Panametrics Moisture

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Questions

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Real World Experiences�with NeSSI Sample SystemsOverview of DiscussionThe Laws of Chemistry & Physics Still ApplyThe Laws of Chemistry & Physics Still ApplyNeSSI Modular SubstrateNeSSI Modular SubstrateNeSSI MythsLiquid Fast LoopNeSSI MythsNeSSI MythsNeSSI MythsNeSSI MythsNeSSI MythsNeSSI MythsCT76 4 STREAM COMPACTCT76 MODULAR STICK DESIGNHybrid SystemHybrid SystemConventional+ NeSSI SystemNeSSI MythsReal World ExamplesAmbient Air Sampling SystemAmbient Air Sampling SystemAmbient Air Sampling System3-in-1 SHS, Isobutylene ApplicationQuestions