+ All Categories
Home > Documents > On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas,...

On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas,...

Date post: 29-Jun-2020
Category:
Upload: others
View: 2 times
Download: 0 times
Share this document with a friend
70
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren Optograf TM Product Manager SpectraSensors/Kaiser Analytics Jan 20, 2011
Transcript
Page 1: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

On-line Process Analyzers -

Quo Vadis?

(about prima donnas, dinosaurs, etc.)

Peter van VuurenOptografTM Product Manager

SpectraSensors/Kaiser AnalyticsJan 20, 2011

Page 2: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

TCO

$Measurement value$“Analyzer Credits” $Bottom-line Value$

Process Analysis Value Proposition

• Safety• Efficiency

(Control/Optimization)• Environmental

• Cost to Buy/Build/Install• Cost to Own

• Profit Center?

• Cost Center?

Page 3: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

We treat our Analyzers nicely, with respect, TLC etc.

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical

TCO Considerations TCO COnsiderations

Page 4: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

A Lot of Infrastructure

(Brute Forcing the Installation)

A/C

Sample Conditioning

Systems

Sample Transport

Lines

AnalyzerShelter

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical

TCO Considerations

Page 5: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Sample Conditioning Systems:

* Custom designed, engineered and built

* Poor standardization

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical

TCO Considerations

Page 6: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Sample Conditioning Systems:

* Custom designed, engineered and built

* Lots of tubing/fittings

* Many man-hours designing/building it

* Lots of discrete components

Cost Issue – Irritates the Bean Counters

* Typically not Smart

(Smart = knowing if p,t,f of sample are

normal, i.e. validating representative

sample)

“Quality of Measurement Issue” -

Credibility of analysis

Picture Courtesy ExxonMobil Chemical

TCO Considerations

Page 7: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Analyzers treated like Prima Donnas

We change the environment to meet their needs

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical

TCO Considerarations

Page 8: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Real Prima Donna Analyzer Prima Donna

His/her Own Dressing Room

+ a big star on the door

Same

Star on the outside door missing

All the necessary facilities to make the room meet all his/her needs:Air conditioning

Air conditioning, own instrument air, hazardous area adaptation etc., vent lines, headers

His/her own bar (food, drinks etc.) Its own sample at the right pressure and temp

Has his/her own entourage:Hairdresser, pedicurist, manicurist etc.

Technicians, analyzer engineers etc.

An Analyzer Prima Donna?

Page 9: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Number

K USD

each

K USD

total PCT

Gas chromatographs 50 30 1500 38

Other analysers 75 10 750

Sample systems 125 10 1250 30

Sample transport 125 5 625

Analyser houses 8 200 1600 27

Data system 1 150 150 3

Installation costs 1 125 125 2

TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV

Lifetime 15 years

Number of equivalent analysers 250

Equivalent analyser per technician 50

Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yr

Technician 5 30 300

Engineer 1 50 100

Spares 300

Consumables 100

TOTAL / yr 800

TOTAL / life 12000

To Buy/Build/Install

To Own

Cost to Build/Install/Own – Major Greenfield Project

Page 10: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

$ = X2

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Total Cost Of Ownership – A More Detailed Look

Cost to Buy/Build &Install Cost to Own/Operate

Page 11: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

"When men got structural steel, they did not use

it to build steel copies of wooden bridges."

Ayn Rand. Atlas Shrugged. 1957.

What to do?

Page 12: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Or as Rob Would Say

"When analyzer men got NeSSI they did not use

it to build duplicates of legacy

sampling systems”

Rob Dubois

Page 13: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Programmable Substrate Heater

Ethernet LAN

F,T

Sensor/ActuatorManager (SAM)

IS NeSSI bus

Auxiliary Heating/Cooling

Flow Channel SubstrateT

T

DCS o&muser

PDA

P

GP Area

Field –Classified Area

V

Micro- Climate enclosure

NeSSI = Sampling & Communications Platform

Page 14: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Connecting the DOTS

AN

Instrument Room

Analyzer Shop

Control Room

Page 15: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

SS

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Moving the DOTS

Instrument Room

Analyzer Shop

Control Room

AN

AN

Page 16: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Pro

ce

ss S

tre

am

DCS

o&muser

GP Area

Field –Classified Area(Typically ZONE1)

Enabled by:

e.g. NeSSI PlatformMiniaturizationIS Design

ANFiber

RAMANNeSSI

Control Room

Analyzer Shop

NDIR/RAMAN

Enabling Topographical Changes: FUTURE

AN

AN NDIR/RAMAN

Page 17: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Intensive/Major Infrastructure Requirements

Minimal Infrastructure Requirements

Micro-House@ Sampling Point

NeSSI PlatformIntrinsically SafeMicro-Analyzers

Fiber-Optic probes

Macro-Analyzers

Macro-House

Legacy SS

Total Cost of Ownership - Gen III Vision

Courtesy of Dow Chemical, Freeport, Texas

Page 18: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

TCO

$Measurement value$“Analyzer Credits”

TCO

Process Analysis Value Proposition - TCO Optimized

$Bottom-line Value$

$Bottom-line Value$

Perception of Process Analytics: Profit Center

Cost

PROFIT

Page 19: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

If we look down the road:

What should the attributes of the ideal next generation analyzer system be?

Vision for the Future

Page 20: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Sample probe

• In the pipe or at the pipe

• High temp and flows

• Filtering of particulates

• Removal or rejection of condensables

• No or limited sample removal (in/ex situ sampling)

Sample handling

• At line or near line pressure

• Minimal sample conditioning

• No sample transport

• No sample return required

• Ports for calibration/validation

• Pressure and Temperature (and Flow Measurement)

Attributes of the ideal next generation analyzer system?

Page 21: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Analyzer sensor/controller

• Poles to tropics operation

• Does not require an analyzer shelter

• Intrinsically safe or flame proof (miniature)

• No or few moving parts (inherently reliable)

Communications• With DCS

• Serial data links OPC, Modbus TCP/IP

• Future wireless

• With maintenance LAN

• Separate and firewalled from DCS and other plant devices & LANS

• Diagnostics/history/setup

• Remote access/operations (off-site maintenance)

• Wired or Wireless

Attributes of the ideal next generation analyzer system?

Page 22: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• We must change if we want to avoid becoming a dinosaur technology.

• It’s now time to move ahead with Generation III

– A scorecard to set the stage for on-line methodologies is underway.

– microAnalytical is our future - now

Tutorial Conclusion

Page 23: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Thank You

Page 24: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Page 25: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Micro-analytics Design Requirements

• Understand the NeSSI Platform Concept (Enabler)* Provides a Standardized Micro-Infrastructure Environment

for Deploying micro-analytical sensors/Analyzers* At the same time, allows for IP protection

• IS has to be designed in up front

• Design for temperature accommodation/correction* NeSSI platform can be installed anywhere (Zone 0/1/2 GP)

– no costly purge systems

• Design for validation of results (Good Housekeeping Seal)* Use all the analytical process information for validation

• Design for no or little consumables

• Design for mecahnical simplicity – no or few moving parts

• Design for extensive but smart diagnostics

Page 26: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

The Case for a Micro-Analytics Initiative at CPAC

• The NeSSI slogan is apropos: “The best way to predict thefuture is to create it”

• Clearing House for Micro-analytical Design requirementsbased on the NeSSI platform* Developments of new technology typically done in research center

or academic environments* Design guidelines will accelerate product to market time* Can position the USA again as a leader in innovative analytical

product development and commercialization

• Clearing House for Industrial Needs in search of a (micro)-analytical solution

• Provide a forum for facilitation/education/coordination* Annual conference on Micro-analytics (complimentary to Summer

Institute)

• CPAC knows how to drive and manage an initiative

• Open the door to alternative funding sources?

Page 27: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Acknowledgements

• All the Believers (all of you and many others)

• My ex-colleagues at ExxonMobil

• CPAC (adopted NeSSI as a new IURC “business model”)

• Special Tribute/Thank You to Rob Dubois

Page 28: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Analytical Clusters Concept > Going Micro All the Way

Pictures Courtesy of Dow Chemical Freeport, TX

Analytical Cluster = A Process Stream Requiring Multiple Analyte Measurements

Examples: On-line Propylene CertificationCEMS (Stack Analysis)Cooling WaterWaste Water Treatment/Effluents

Byline Analytical Cluster = Multiple Analyte Measurements done on a Single NeSSI Platform

Macro-House Micro-House

Macro-Analyzers Micro-Analyzers

Page 29: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Programmable Substrate Heater

Ethernet LAN

AnalyzerController

V

A

P F

SAM

NeSSI bus

Auxiliary Heating/Cooling

SubstrateT

T

Standard

Sampling

Interface

dcs o&muser

Standard

Connectivity

Interface

NeSSI “Sandwich/Rail” Platform Concept

next

PDA

Development

Focus can be

on Sensors !

Page 30: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

TCO

$Measurement value$“Analyzer Credits”

Process Analysis Value Proposition - TCO Optimized

$Bottom-line Value$

TCO $Bottom-line Value$

Page 31: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Number

K USD

each

K USD

total PCT

Gas chromatographs 50 30 1500 38

Other analysers 75 10 750

Sample systems 125 10 1250 30

Sample transport 125 5 625

Analyser houses 8 200 1600 27

Data system 1 150 150 3

Installation costs 1 125 125 2

TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV

Lifetime 15 years

Number of equivalent analysers 250

Equivalent analyser per technician 50

Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yr

Technician 5 30 300

Engineer 1 50 100

Spares 300

Consumables 100

TOTAL / yr 800

TOTAL / life 12000

To Build/Install

To Own

Cost to Build/Install/Own – Major Greenfield Project

Page 32: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Total Cost Of Ownership – A More Detailed Look

Cost to Buy Cost to Own/Operate

Rational/Big Picture

Zone

Rational/Big Picture

View

Sticker Shock Zone

Sticker Shock Zone

Page 33: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Topic

+

TCO

Page 34: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

TCO

$Measurement value$“Analyzer Credits” $Bottom-line Value$

Process Analysis Value Proposition

• Safety• Efficiency• Environmental

Page 35: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

What is Wrong with these Pictures

A Lot of Infrastructure

(Brute Forcing the Installation)

A/C

Sample Conditioning

Systems

Sample Transport

Lines

AnalyzerShelter

Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical

Page 36: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

$ = X2

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Total Cost Of Ownership – A More Detailed Look

Cost to Buy Cost to Own/Operate

Page 37: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Process Analytics Installation – Existing Analyzer Replacement

4 – 20 mA

Modbus

Replace Analyzer with RAMAN/SSS(maximize existing infrastructure)

Page 38: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Optography

“Chromatography” with Laser Light

Page 39: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Cost to Build/Install/Own – Major Greenfield Project

Number

K USD

each

K USD

total PCT

Gas chromatographs 50 30 1500 38

Other analysers 75 10 750

Sample systems 125 10 1250 30

Sample transport 125 5 625

Analyser houses 8 200 1600 27

Data system 1 150 150 3

Installation costs 1 125 125 2

TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV

Lifetime 15 years

Number of equivalent analysers 250

Equivalent analyser per technician 50

Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yr

Technician 5 30 300

Engineer 1 50 100

Spares 300

Consumables 100

TOTAL / yr 800

TOTAL / life 12000

To Build/Install

To Own

Page 40: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

NeSSI Topography

Field LAN

Pro

ce

ss S

tre

am

SS

AN

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

XX

X

X

X

Page 41: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Intensive/Major Infrastructure Requirements

Minimal Infrastructure Requirements

Micro-House@ Sampling Point

NeSSI PlatformIntrinsically SafeMicro-Analyzers

Fiber-Optic probes

Macro-Analyzers

Macro-House

Legacy SS

Page 42: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Page 43: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Programmable Substrate Heater

Fiber-Optic Sensors with NeSSI as Enabler

Ethernet LAN

F,T

Sensor/ActuatorManager (SAM)

IS NeSSI bus

Auxiliary Heating/Cooling

Flow Channel SubstrateT

T

DCS o&muser

PDA

P

GP Area

Field –Classified Area

VO2

R

Micro- Climate enclosure

TDL, CRDS,

NIR…

RAMAN

Page 44: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Process Analytical Infrastructure Topography

Field LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Page 45: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

AN

DCS

o&muser

GP Area

Field –Classified Area(Typically ZONE2)

Analyzer House

Field –Classified Area(Typically ZONE2)

Micro-Climate Enclosure

Ne S SI

SAM

Process Analytical Infrastructure Topography

Page 46: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Process Analytical Infrastructure Topography

Page 47: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

NeSSI Enabled Spectroscopy Process Analytics Topography

Pro

ce

ss S

tre

am

DCS

o&muser

GP Area

Field –Classified Area(Typically ZONE2)

Micro-Climate Enclosure

AN

AN

FiberRAMAN

NIRFiber

Ne S SI

SAM

Control Room

Instrument Room

Analyzer Shop

Page 48: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate

• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensorspreferably at the Sampling Point (By-line Mode)

• Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode

A TCO Optimization Strategy

Page 49: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Programmable Substrate Heater

NeSSI & Next Generation Micro Analyzers

Ethernet LAN

F,T

Sensor/ActuatorManager (SAM)

IS NeSSI bus

Auxiliary Heating/Cooling

Flow Channel SubstrateT

T

DCS o&muser

PDA

P

GP Area

Field –Classified Area

V

Micro- Climate enclosure

Micro- GasAnalyzer(UV, MIR, MS, GC, …

Page 50: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Topics for RAMAN Gas Analysis or Optical Chromatography

1. Role of Process Analytical Measurements

2. RAMAN Phenomenon

3. Optograms/Applications

4. Performance

5. Optography vs. Chromatography

6. Hardware

7. “Greening” of the User Interface

8. TCO Considerations

Page 51: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Role of Process Analysis

1. Enable Safe Operations

2. Implement Mandated Environmental Monitoring

3. Efficiency (Control & Optimization)

* Quality of Data (Data Validation)

* Reliability of Data (98+ Service Factor)

4. Total Cost of Ownership

* Cost to Buy/Build/Install

* Cost to Own (Manpower, Operating Costs)

Page 52: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

A Lot of Infrastructure

(Brute Forcing the Installation)

A/C

Sample Conditioning

Systems

Sample Transport

Lines

AnalyzerShelter

Picture Courtesy ExxonMobil Chemical

TCO Considerations

Page 53: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

TCO Benefits of RAMAN/Smart Sampling System

TCO Benefits of RAMAN/Smart Sampling System:• Reliability

* Push Validation down to Sampling System Level(75+% Analyzer Problems > Sampling System)

* More Reliable Analyzer Hardware

• Reduce Sample System Hardware Costs* Minimize Sample Transport Costs

• Reduce Shelter Requirements * Remote probes

• No Consumables

Page 54: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Pro

ce

ss S

tre

am

DCS

o&muser

GP Area

Field –Classified Area(Typically ZONE2)

Micro-Climate Enclosure

AN

AN

FiberRAMAN

NIRFiber

Cell/SSS

SAM

Control Room

Instrument Room

Analyzer Shop

NDIR/RAMAN

NIR Photometers

Enabling Topographical Changes: New/Greenfield Projects

Page 55: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

AN

Instrument Room

Analyzer Shop

Control Room

Process Analytics Installation – New/Greenfields Projects

Page 56: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Simplified Topographical Diagram of a Process Analytics installation

4 – 20 mA

Modbus

Page 57: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Total Cost Of Ownership – A More Detailed Look

Cost to Buy Cost to Own/Operate

Rational/Big Picture

Zone

Rational/Big Picture

View

Sticker Shock Zone

Sticker Shock Zone

Page 58: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Field LAN

Pro

ce

ss S

tre

am

SS

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Connecting the DOTS

Instrument Room

Analyzer Shop

Control Room

AN

AN

Page 59: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Spectroscopic Options

On-line RAMAN/NDIR Spectroscopy0.5% - 100%

• Trace Level TDLAS/DA1% - 0.1 PPM

• UltraTrace Spectroscopy as PPBMeasurement Alternative100 PPB - 1 PPB

Spectroscopy as a Vehicle for TCO Optimization

Why Spectroscopy?

Inherently reliable technique(no of few moving parts)

• No or minimal consumables(no carrier gases, instrument air)

• Remote SamplingUncouple the sampling interface from the analyzer proper

Page 60: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Page 61: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Page 62: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Pro

ce

ss S

tre

am

DCS

o&muser

GP Area

Field –Classified Area(Typically ZONE2)

Micro-Climate Enclosure

AN

AN

FiberRAMAN

NIRFiber

Ne S SI

SAM

Control Room

Instrument Room

Analyzer Shop

P

NeSSI Enabled Spectroscopy/MA Process Analytics Topography

Page 63: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

TCO Benefits of RAMAN/Smart Sampling System

TCO Benefits of RAMAN/Smart Sampling System:• Reliability

* Push Validation down to Sampling System Level(75+% Analyzer Problems > Sampling System)

* More Reliable Analyzer Hardware

• Reduce Sample System Hardware Costs* Minimize Sample Transport Costs

• Reduce Shelter Requirements * Remote probes

• No Consumables

Page 64: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Today’s Process Analytics Topographical View = PAT

Field LAN

Pro

ce

ss S

tre

am

SS

AN

DCS

o&muser

GP AreaField –Classified Area(Typically ZONE2)

Analyzer House

Page 65: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

• Analyzer $/ SpareParts

• Sampling Systems

• Shelters/Panels

• Data System

• Sample Tap / Transport Lines

• Utilities (IA, Carrier Gases etc.)

• Power

• Cabling

• Shelters/Panels

• Hookups :Utilities, Power, Cabling, Sampling Systems

• Start-up &Commissioning

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Page 66: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Intensive/Major Infrastructure Requirements

Minimal Infrastructure Requirements

Macro-Analyzers

Macro-House

Legacy SS

Total Cost of Ownership - Gen III Vision

Courtesy of Dow Chemical, Freeport, Texas

• EQAT (Manpower)

• Consumables* Standards* Support Gases

• Spare Parts

• Off-line TimeMissed Opportunity

• Process UpsetLoss of Production

Page 67: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Sample Handling:

• At line or close to line pressure• Minimal Sample Conditioning• No sample transport• No sample return required• Ports for calibration/validation• Pressure and Temperature (and Flow

Measurement)

Sample Handling

Page 68: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Analyzer Sensor/Controller:

• Poles to tropics• Does not require an analyzer shelter• Intrinsically safe• No moving parts (inherently reliable)

Analyzer Sensor/Controller

Page 69: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

Sampling Probe:

• In the pipe or at the pipe• High temp and flows• Filtering of particulates• Removal of condensables• No sample take-off

(in/ex situ sampling)

Probe

Page 70: On-line Process Analyzers - Quo Vadis?...On-line Process Analyzers - Quo Vadis? (about prima donnas, dinosaurs, etc.) Peter van Vuuren OptografTM Product Manager SpectraSensors/Kaiser

Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore

1. Communications to DCS

• Serial data links OPC, Modbus TCIP• Future compatibility with wireless

2. Diagnostic LAN

• Separate and Firewalled from DCS and other plant devices/LANS

• Virtual Interface• Full diagnostics/history• Remote access/operations (off-site

maintenance)

Communications


Recommended