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					  An Integrated Analytical
Process GC and SHS Based
on IS CAN Communication

            IFPAC 2008

   Circor Tech      ABB Analytical
  Patrick Lowery      Tracy Dye

  An integrated process analytical system that
  receives, sends and acts on critical
  multivariate data to monitor, communicate
  and control its status and health via any
  networked client.
NeSSITM Value Proposition

     Improved System Reliability and Serviceability

     Reduced Capital Costs

     Reduced Operational and Maintenance Costs
Innovative, Early Adopter Market

              Achieving the stated vision and
              value     proposition   in   an
              innovative, early adopter market
              dictates the need for a phased,
              risk reduced approach.
                 Gen 2
Phased Market Approach

     Phase 1 – Connectivity
         Hybrid communication system
              Discrete analog outputs for single signal devices
              Discrete digital inputs
              IS CAN networked components for multivariate data
         Basic control
              Temperature, flow, filtration backup, valve switching
         Basic indication
              Sample flow, ΔP, temperature
Phased Market Approach

    Phase 2 – “Self Describing”
        All SHS components have open standard
         description file (EDDL, XML, etc.)
        Real time operational view of SHS on any
         networked client
        Fully integrated process analytical system
IS CAN for the NeSSITM Communication Bus
   “Plug and play” in Div 1/Zone 1 classified areas
   CAN is everywhere in demanding applications (marine, auto,
   Balanced signaling (differential drive) enables superior noise
    rejection (relative to unbalanced single end) especially over cables
   Open and Standard, already built in …
        Data Integrity Mechanisms
        Integral Bus Error Recovery and Self Correction
        Message Prioritization Via Non-Destructive Arbitration
        Mature and Well Defined Application Layers Such As CANopen
        Master to slave or peer to peer communication
             This allows individual devices to contain their own alarms and setpoints
             Allow for the system to interact with other devices in the system without the
Smart SHS Topography

   What is needed to ascertain status of SHS?
       Power
       Pressures
       Flows
       Temperature (both ambient and actual fluid temp)
       System valve status
       Filter “health” (need two signals, either pressure/flow, or
        pressure & differential pressure)

   Example of basic smart sample system
  Smart SHS Topography
          SAMPLE                   PROCESS
          SYSTEM                   CONTROL

                                                         DCS SYSTEM

CABINET                             LOWER LEVEL
                   SAFE CANbus

                   ANALOG I/O &
                   IS BARRIERS,
                   IF NEEDED

                                   (ENTIRE GC CONTROL ON FIBER OPTIC
                         OPTIC     CANopen NETWORK
IS        SAM            CAN
POWER                    CABLE
Smart SHS Topography

                            DIFF PRESSURE
                            AND FLOW
                            ACROSS STREAM

                                                      FAST LOOP
                                                      FLOW, TEMP,
             GC ATM
                         FLOW TO
                                            FILTER HEALTH
                                            (FLOW AND DIFF

                           POWER MONITOR AND
                           DEVICE INVENTORY/
                           HEALTH FROM CAN TO
   There is no industry consortium on the definition of SAM (Sensor
    Actuator Manager)
   The definition of SAM in this system topology is:
        Bridge between C1D1 (Zone 1) and C1D2 (Zone 2) for CAN
        Integrated analog I/O to digitize 4-20mA devices
        Obtains inventory of all CAN networked devices using IEEE virtual
         TEDs concept (i.e. device profiles/ data sheets)
        Monitors total IS can bus power consumption and health
        Has a basic application interface that can pass alarm triggers and set
         points down to devices and pass alarms and data up to GC
        GC is not the sample system master per se, but a data server
        Future upgrade path for CAN device metadata to provide system
         configuration data up to HMI at GC interface
Comparison to Traditional/ Legacy SHS
   Purely mechanical SHS
       Lower initial capital cost, but no data from system
       If system goes down, analyzer goes down, process is diverted
        or fines can occur (in emission monitoring applications)
       EPA requires backfill of worst case data for emission monitoring
        analyzer downtime, average of $15-25k per event
       Higher cost in human “capital” and higher average analyzer
        down time
       One refining case study found an average of 6 hours of
        process down time (per event) from time of DCS alarm to time
        that analyzer/ process chemistry was verified
       6 hours of process downtime = BIG $$$
Comparison to Traditional/ Legacy SHS
   Analog instrumented SHS (GEN 1.5)
       Analog devices (in most but not all cases) are less expensive
       No multi-variate data from single device
       All devices must be discreetly wired and must have
            Discreet IS barrier
            Analog I/O module to PLC or data logger
            PLC or data logger
            Ethernet or other field bus communications module
       Data can be shown that digital bus implementation can reduce
        overall system cost
            ~$300 per sensing point cost savings on pressure/temp sensing
            ~$2000 per sensing point on flow, including cabling/wiring cost
            ~20-30% reduction in needed modular or fitting hardware
            ~40% reduction in wiring/ installation / integration cost
Still challenges ahead
   Although major technical hurdles are being addressed,
    there are still some market challenges ahead
       Further reduction of cabling cost needed along with
        some more choices of chemical compatibility options
       New types of power levels and digital bus
        implementation at IS certifying bodies
       More IS power supply vendors needed
       Further reduction in component costs can be realized
        by economy of scale (although highly expensive gen
        1.5 systems have been economically justified at
        several large refineries)
Still opportunities ahead
   GEN 2, digital bus SHS also provide new opportunities
       Integration of “grab bag” closed-loop sample system
        with continuous GC SHS for validation
            Can differentiate between analyzer problem and SHS
             problem; if analyzer isolated as problem, can automatically
             route sample to sample cylinder for lab analysis
       Can localize heating solutions with tighter control or
        vaporize liquid samples near source to GC, remove
        the need for problematic liquid inject valves
       XML metadata into device profiles for graphical
        representation on HMI displays
       Integration of continuous analyzers along with
        associated SHS onto analyzer network

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