Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core Engineering.

PROCESS ANALYTICAL SYSTEMS- a vision for the future

Jeff Gunnell and Peter van Vuuren

ExxonMobil Chemical - Core Engineering


COMMONLY HEARD PHRASES

“lump sum, turn key”

“industry-standard design”

“trend-line decrease in cost”

“year on year improvements”

“best practices”


GOALS

Understand the driving forces

Recognise technology trends

Imagine the future

Create change


UNDERSTAND THE DRIVING FORCES

Reduce time from concept to product

Reduce hours for design and development

Reduce cost of build

Reduce cost of ownership

Maximise profitability


TODAY’S ANALYSER SYSTEM



DCS

SAMPLETAKE-OFF



DCS

SAMPLETAKE-OFF

A



DCS LAN

ANALYSER DATA SYSTEM

SAMPLEPRECONDIT .

SAMPLERECOVERY

SAMPLETRANSPORT

SAMPLETAKE-OFF

SAMPLERETURN

VALIDATIONBLEND

SAMPLECONDITIONING

INSTRUMENT AIRELECTRICAL

GASES

DRAINVENT

SAFETY SYSTEMHVAC

A

AH











ANALYSER HOUSE

COMMSXFACE JB

A

SHS

A

SHS

COMMSXFACE

A

SHS

COMMSXFACE

A

SHS

A

DCS LAN

JB

OTHERANALYSER

HOUSESLEVEL 0Field mounted

hardware

LEVEL 1Unit control and

processing

LEVEL 2Distributed control

and processing

LEVEL 3Higher levelprocessing

GATE-WAY

MAINT.


TODAY’S COST OF BUILD

AH 1

A AAAA

AH 2

A AAAA

AH 3

A AAAA

AH 4

A AAAA

AH 5

A AAAA

AH 6

A AAAA

AH 7

A AAAA

AH 8

A AAAA

DCS LAN

ANALYSER DATA SYSTEM



For a major greenfield projectNumber

Gas chromatographs 50Other analysers 75Sample systems 125Sample transport 125Analyser houses 8Data system 1Installation costs 1TOTAL



For a major greenfield projectNumber

K USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000


THE FUTURE

The challenge...

...and the opportunity

Reduce cost of build by 40%



For a major greenfield project

NumberK USDeach

K USDtotal PCT

Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000


TODAY’S COST OF OWNERSHIP

Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD




Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000


THE FUTURE

The challenge...

...and the opportunity

Reduce cost of ownership by 35%




Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000


ENABLING TECHNOLOGIES

Modular sample system componentsdeveloped by the semi-conductor industryISA group working on design standards

Application specific integrated circuitsprovide the smart components

Open communication architecturesprovide the data integration


IMAGINE THE FUTURE

A

T

P

Analyzer Analyzer

ControlleControllerr

Fie

ld

Fie

ld

LA

NLA

N

Level Level 00

Level Level 11

Pro

cess

Pro

cess

Str

eam

Str

eam

F


IMAGINE THE FUTURE

FLAN (Optical Fiber)

Sensor/Signal Bus

IA

Controller

(ASIC)

Original Picture of Gas Delivery System courtesy Valin Corporation;

A

T

PF

Sensor = Moisture Probe


IMAGINE THE FUTURE

A

T

PF

Sensor = RAMAN Probe


IMAGINE THE FUTURE

Integrated analysers and sample systems

Field-mounted and self contained

Smart incorporating diagnostics + control

Open-architecture data systems

Plug-and-play maintenance

Standard designs for generic applications


Integrated analysers and sample systems

analyser vendor provides sample systemone-shop stop

maximise standardisationthere really aren’t that many special cases



Field-mounted and self contained

can work anywherefrom the poles to the tropics

no analyser houses

no long sample transport lines

minimum utilities

Reduce time of design and cost of build


Smart with diagnostics + control

full system info available

remote modification of parameters

control of P, T, Fwith flow control, install across control

valves



Open-architecture data systems

one data highway for all systems

single windowopportunity for remote support

simple to add new analysers

Reduce time of design and cost of build



Plug-and-play maintenance

For failures take a complete system to the fieldplug in the new one, repair the old one

back at the workshop



Standard designs for generic applications

Reduce time from concept to product


Reduce cost of build


Maximise profitability


CREATE CHANGE

Agree a common vision

Standardise sample system components

Standardise data system architecture

Partnerships between stake-holders


COMMERCIAL BREAK

RELATIONSHIPS IN THE PROCESS ANALYSIS INDUSTRY

discussion of how interactions between the stakeholders need to change

Time: Wednesday 26 Jan, a.m.


Date post:	21-Dec-2015
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Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core Engineering.

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