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© ABB Group March 1, 2010 | Slide 1 Matching NeSSI™ System Solutions to Process Criticality: Realizing the Value Proposition Tracy Dye P.E., IFPAC NeSSI™ Sessions, Winter 2010
© ABB Group March 1, 2010 | Slide 1
Matching NeSSI™ System Solutions to Process Criticality: Realizing the Value Proposition
Tracy Dye P.E., IFPAC NeSSI™ Sessions, Winter 2010
© ABB Group March 1, 2010 | Slide 2
IntroductionNeSSI Technology Status
The word (and some product) continues to get out but …
The challenge of gaining market adoption for Gen 1 and especially Gen 2 technology remains.
The Market drivers still remain …
Retiring technician workforce
Relatively inexperienced replacement technicians
Standard vs costly custom engineering
Readily available, actionable data needed
© ABB Group March 1, 2010 | Slide 3
Analytical Systems integrated via NeSSITM
Technology will provide the infrastructure for anadvanced, reliability centered maintenance systemfrom sample tap to DCS (“pipe to pixel”)
Insurance for high risk factory processes
Environmental
Safety
Off specification product
On demand versus Scheduled Maintenance
Fewer and fewer maintenance personnel available
More efficient use of limited personnel
More conducive to entry level technician experience
IntroductionVision
© ABB Group March 1, 2010 | Slide 4
IntroductionTechnology Adoption Lifecycle
* Moore, Geoffrey (1991), Crossing the Chasm, Marketing and Selling High‐Tech Products to Mainstream Customers, Harper Business Essentials
© ABB Group March 1, 2010 | Slide 5
IntroductionMore Questions Than Answers
Is the overall NeSSI value proposition too broad and not application specific enough?
Is NeSSI a continuous or discontinuous technology?
If discontinuous, are we successfully creating the “bandwagon effect” to cross the chasm?
Is system visualization (Gen 1 driven) needed sooner than later?
Should we just go back to what we were doing before?
Do these systems make sense for certain applications and not for others (sledge hammer on a nail)?
© ABB Group March 1, 2010 | Slide 6
PROCESS RISK(Environmental, Safety, Off Specification Product)
LOW HIGH
NeSSI™ TechnologyProcess Criticality Spectrum
Basic Modular
ModularLocal Indication
Generation 2
IS CommunicationRemote Alarms
Generation 3
Visualization and ControlMicro‐AnalyticalWireless
When we put capital at higher risk, we in turn expect higher returns on that capital
Cost Reduction
© ABB Group March 1, 2010 | Slide 7
Generation 1Compact Design
Per end users, the compact system became somewhat invisible …
Where to start troubleshooting?
How does the system flow?
Need system visualization
© ABB Group March 1, 2010 | Slide 8
3.340 3.340
NO OUT
IN
VENT
OUT
IN
VENT
Air Signal
Air Signal
3.340
Stream SwitchVent
CALSTREAM
NC
STREAM1
1/4"
SS0AV1 AV4
AV5
STREAM1
SAMPLERETURN
Stream SwitchVent
HOKE
GYRO
LOK
1/8"Elbow
1/8" npt
HOKE
GYROLOK
1/8"
Elbo
w 1/8"
npt
HOKE
GYRO
LOK
1/8"Elbow
1/8" npt
FLOW TOANALYZER
FLOW FROMANALYZER
ATMVENT
1/4" NPT
MV
Air Signal
HOKE
GYRO
LOK
1/8"
Elbow
1/8" npt
AV6
ARV
AV1
AV2
AV3
AV4
AV5
AV6
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GYR
OLO
K
1/8"
GY
RO
LOK
1/8"
GYROLOKGYROLOK
GYROLOK
1/8"
¼” O
D
GYR
OLO
K
1/4"
GY
RO
LOK
1/4"
GYR
OLO
K
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/8"
GYR
OLO
K
1/8"
GYROLOK
1/8"
¼” O
D
GYR
OLO
K
GYROLOK
GYR
OLO
K
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GYR
OLO
K
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GYR
OLO
K
1/4"
GY
RO
LOK 1/4"
GY
RO
LOK
GY
RO
LOK
GYROLOK
GY
RO
LOK
GYR
OLO
K
GYR
OLO
K
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GYR
OLO
K
1/8"
GYR
OLO
K
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
HOKE
1/4"GYROLOK
ANALYZERFLOW CONTROL
Generation 1Visual Design
Stream Switching Module
Sample Bypass Module
Atmospheric Reference
Vent Module
Collateral Benefits
• Serviceability
• Maintenance
© ABB Group March 1, 2010 | Slide 9
Generation 1Increasing Complexity
FPDTCD
© ABB Group March 1, 2010 | Slide 10
Generation 1
© ABB Group March 1, 2010 | Slide 11
Generation 1Hot Spare Modules
© ABB Group March 1, 2010 | Slide 12
Generation 1Gains and Remaining Challenges
GainsReduction in engineering time and cost
Reducing in the assembly costs
Reduction in the overall ownership costs
Maintenance and Serviceability
Remaining Challenges! System not so compact
! Added tubing and fittings
! Low economies of scale inhibit material cost savings
! Standardization
! Component Interchangeability on mechanical substrate
© ABB Group March 1, 2010 | Slide 13
PROCESS RISK(Environmental, Safety, Off Specification Product)
LOW HIGH
NeSSI™ Process Criticality Spectrum
Basic Modular
ModularLocal Indication
Generation 2
IS CommunicationRemote Alarms
Generation 3
Visualization and ControlMicro‐AnalyticalWireless
Actionable Data
© ABB Group March 1, 2010 | Slide 14
Generation 2Actionable Data, Mechanical Visualization and Control
3.3403.340
NO OUT
IN
VENT
OUT
IN
VENT
Air Signal
Air Signal
Stream SwitchVent
CALSTREAM
Air Signal
FT DPTTT
PT
ARV
SS0AV1 AV4
AV5
AV6
STREAM1
SAMPLERETURN
Stream SwitchVent
INSTRUMENTAIR
ATMVENT
HOKE
GYRO
LOK
1/8"Elbow
1/8" npt
HOKE
GYROLOK
1/8"
Elbo
w
1/8"
npt
HOKE
GY
RO
LOK
1/8"Elbow
1/8" npt
HOKEG
YROLO
K
1/8"Elbow
1/8" npt
FLOW TOANALYZER
FLOW FROMANALYZER
MV
c
ncno
c
ncno
c
ncno
c
ncno
c
ncno
c
ncno
V1
V2
V3
V4
V5
V6
IAVENT
FT DPTTT
PT
NC
NV
STREAM1
1/4"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GYROLOKGYROLOK
GYROLOK
1/8"
¼” O
D
GY
RO
LOK
GYROLOK
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GY
RO
LOK
1/4"
GYROLOK
GY
RO
LOK
1/4"
GY
RO
LOK 1/4"
HOKE
1/4"GYROLOK
GY
RO
LOK
GYROLOK
1/4"
GYROLOK
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GY
RO
LOK
1/8"
GYROLOK
1/4"GYROLOK
GYROLOK
1/8"
¼” O
D
GY
RO
LOK
GYROLOK
GY
RO
LOK
Bypass Flow Indicator
Representative Sample
Analyzer Sample Flow Indicator
Valid Analyzer Data
∆P Measurement
Filter Blockage
Digital IS CAN Solenoids
Stream Switch Status
© ABB Group March 1, 2010 | Slide 15
One Gateway/SAM and 6 DVMs eliminated 36 expensive pneumatic tubing runs
The Gateway/SAM allows for expanding to digital flow indicators in the future.
System VisualizationOptions
Schematic and Network ViewTop Level View
Schematic and Modular Hardware
Fluid Schematic Only
System Visualization:• System level status/ alarms
(visual)
• Color coded visual (same as HMI on GC)
• Bore down into functional area of interest to see data
• See detailed data and settings at component level
45P1 Alarm Point High
25P1 Alarm Point Low
100Flow Alarm Point High
40Flow Alarm Point Low
30Temp Alarm Point High
20Temp Alarm Point Low
Inlet Pressure (psig)
Analyzer Flow (ccm)
Fluid Temp (degC)
Analyzer Backpressure (psig)
20P2 Alarm Point High
10P2 Alarm Point Low
0.920
1.519
FT DPTTT
PT
MV
MV
GYR
OLO
K
Node Address:
011
Full Scale Range (ccm)
150
© ABB Group March 1, 2010 | Slide 17
Generation 2Gen 2 Gains and Remaining Challenges
GainsActionable Data
Sample and Bypass Flow
Stream Solenoid Status
Filter Health
Digital Visualization Makes Compact Design Possible
Remote valve control significantly reduces tubing costs
Remaining Challenges! Standardization
! Still no agreement on communication bus
! Definition of SAM
! Low economies of scale inhibit material cost savings
© ABB Group March 1, 2010 | Slide 18
NeSSITM TechnologyMatching Solutions to Process Criticality
CostValue
1.0
2.2
ConventionalBasic Modular
Smart
3.5Pure analog monitored solution
1.2
PROCESS RISK(Environmental, Safety, Off Specification Product)
LOW HIGH
© ABB Group March 1, 2010 | Slide 19
ConclusionMatching NeSSITM Technology Solutions to Process Criticality
The challenge of gaining market adoption for Gen 1 and especially Gen 2 technology remains (Crossing the Chasm)
System visualization is needed sooner than later (Gen 2 not Gen 3)
Paybacks are there for Generation 2 Systems
EPA Fines ($10K to $12K per event)
Off Spec Product ($$$)
Cost Reduction (elimination of expensive tubing runs)
Employee Safety (Priceless)
Technician Time ($200K annually)
Focus: What problem(s) are we trying to solve with the technology?
Cost reduction? Standard engineering? Ease of Maintenance?
Avoiding costly off spec product, EPA fines and employee accidents?
Making more efficient use of limited technician time?
Gen 1 and Gen 2 are scalable and modular enough to match value with cost
© ABB Group March 1, 2010 | Slide 20
