John Mosher, Bob Nickels

1
NeSSI-II Network and Sensor Developments
Networked Sampling System (NeSSI-Generation
II) Development and Field Test
by John Mosher, Bob Nickels Honeywell
Sensing Control and Ulrich Bonne Honeywell
Laboratories
2
NeSSI-II Network and Sensor Developments
Outline Project Team Definition and NeSSI
functions. Status of NeSSI-I Challenges for
NeSSI-II components Networked Components Easy
plug-and-play Intrinsically Safe Reliable Affor
dable Demo and field test of NeSSI-II Sensor
Developments
3
NeSSI-II Network and Sensor Developments
NeSSI Generation II Being Developed by a Supplier
Team Supplier Team Steve Doe [phone]
Parker-Hannifin Dave Simko [phone]
Swagelok Richard Hughes [phone]
Autoflow Bob Nickels [phone]
Honeywell-ACS John Mosher [phone]
Honeywell-ACS Ulrich Bonne [phone]
Honeywell Labs
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NeSSI-II Network and Sensor Developments
User Team for Potential DoE NeSSI Project Peter
van Vuuren [phone] ExxonMobil Rob
DuBois [phone] Dow Joe Andrisani (302)
695-3156 DuPont Steve Wright [phone]
Eastman Bob Reed [phone] Merck Paul
Vahey [phone] Honeywell-SM Don
Young/Don Nettles [phone]
ChevronTexaco Frank Schweighardt (610-481-6683)
Air Products George Vickers [phone]
BP Paul Barnard [phone]
EquistarChemicals Steve Doherty [phone]
Pharmacia Carol Zrybko Kraft Michelle
Cohn UOP Alan Eastman/Randy Heald (918)
661-3475 ConocoPhillips Center for Process
Analytical Chemistry (CPAC) Mel Koch (206)
616-4869 U.Washington, CPAC
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NeSSI Benefits
------------------------------------------------
------------------------ Now
NeSSI
----------------------------------------------
-------------------------- Analyzer houses
Analyzer cabinets close to
sample
point
----------------------------------------------
-------------------------- Long heat traced
lines Short heat traced lines
-----------------------------------------
------------------------------- Extensive
design to bring sample Minimal Design
to sensor

----------------------------------------------
-------------------------- One at a time
assembly Modular "tinker-toy" type
assembly --------------------------------------
---------------------------------- Field
repair Modular
replacement of components
or systems, repair in shop or
at
vendors
----------------------------------------------
-------------------------- Sample may not
reach analyzer Sample flow is validated
---------------------------------------
---------------------------------
Compliments of Bruce Johnson, DuPont
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Fig. 1. Functions of a Process Sampling
System. Courtesy of ExxonMobil
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Fig. 1a. Traditional Stream Sampling System in a
Petrochemical Plant. No Modular or
Standardized Components Courtesy of P.vanVuuren,
ExxonMobil
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NeSSI Generation I
Fig. 3. Sampling System for Measurement of H2O
and O2 ppm in a High-Purity
Hydrocarbon Stream. Miniaturized Version
Courtesy of D.Simko,
Swagelok
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NeSSI Generation II
What is Generation II? NeSSI II SP76 IS
CAN SAM SP76 NeSSI Generation I from
SEMI IS Intrinsic Safety CAN Controller
Area Network DeviceNet SAM Sensor Actuator
Manager Open Interface to Plant-wide Network
and/or Analyzer Reliable, Networked, Modular,
Safe, Open, and Affordable!
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NeSSI Generation II
IS
NeSSI II SP76 IS CAN SAM
CAN
SAM
SP76
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NeSSI Generation II
PROJECT ABSTRACT The Problem Need for a
networked, standardized, int.safe, modular,
affordable and reliable process stream sampling
and sensor system. Sampling systems now are
causes for down-time and questionable process
stream samples followed by costly control
errors. Objectives are to ? Accelerate
development of the prototype system component
such as intrinsically safe, digital pressure,
temperature and flow (p, T, F), sensors,
smart valves, flow-controllers, and a
sensor/actuator networking capability ? Build,
demonstrate, and test 1-2 NeSSI-II units, and ?
Provide a platform for incorporating analytical
sensors right into the sampling system.
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ABSTRACT (contd.) Benefits Enabled by Full NeSSI
Implementation ? Reduce down time, energy use
operating sampling cost
U.S. 0.1-0.2 Q/y or 10-20 billion ?
Bring these savings to the end-users at an
earlier date, and ? Reduce the business risk to
the Supplier and End-User End-Users are
members from across the processing industries
chemical, petrochemical, power generation,
refining, food, beverage and dairy, pulp
paper Schedule ? One year for design, build
and lab-test ? One year for
installation and field testing Deliverables ?
Interim and Final Reports (no hardware) on
design of sensor hard- and
software, NeSSI test
results, benefits and recommendations
Management of the Program Honeywell
Consortium
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Table 1. NeSSI Generation I versus II
From Rob Dubois, Dow, May02
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Diagram of NeSSI-Gen2-POCA (Proof of Concept
Assembly) to Check Networking and Control of
Flow, Pressure and Temperature. (Courtesy of
R.DuBois, DowChemical)
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Comparison of NeSSI Generation Designs
Feature Generation I Generation II
Generation III Signal Type 4-20 mA discrete
Serial bus Serial bus Wireless
Opt.Fiber Protection Purging, X-proof
Low-Power IS Low-Power IS
Enclos.Classif. Div.2(Seldom Flam.) Div.1(Often
Flam.) Div.1 (Often Flam.) Sensor Locatn
Off-Substrate On-Substrate
Mini-Substrate Analyzer Locat Off-Substrate On/O
ff-Substr. MicroAnalytical Intelligence
Limited ?Processor OB ?Processor OB
Ctrol.Philosophy Centralized Distribd (SAM)
Distributed (SAM) Regulatg Comp.
Self-Contained On-Substr.w/PID On-Substr.
w/PID Passive Comp. Pure Mechanical Electro-Mech
an. Int. Electro-Mechan. Valves Manual or
Pneum., Off On-Substr.Combi
On-Substr.Combi Heating External Substr.-Integ
rated Substr.-Integrated Wiring Pwr/Sig
X-proof conduit/cable IS Plug Play IS Plug
Play Communication Individual
Hard-Wired Networked Networked Cost
High Moderate Moderate to low.
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CAN Communications - Issues and Background
Issues/Questions 1. Is it feasible to embed
all required device electronics,
microcontroller, and CAN communications into a
NeSSI SP-76 1.5 x 1.5 footprint? 2.
Is a CAN network capable of operating through an
IS barrier? Selection of CAN as a communications
enabler for NeSSI High Level Protocol SDS,
DeviceNet, CANOpen - all publicly available
proven Data Link Layer Master/slave,
peer-to-peer, multicast messaging All data types
supported Diagnostics Carrier Sense Multiple
Access with Collision Resolution 16-bit CRC
error checking, intell.network mgmt.capability Phy
sical Layer Trunkline/multidrop with
branches Separate twisted pairs for signal and
device power distribution Up to 64 nodes, up to
500 meters trunk length Intrinsic Safety
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Adaptation of Honeywell Temperature, Pressure,
Flow Sensors to NeSSI design standards.
Microbridge flow sensor interfaced to a typical
miniature CAN microcontroller and 12 mm
connector. A similar interfacing approach will
be used in this project to connect existing
sensors and actuators to the CAN network.
12 mm
by Bob Nickels, Honeywell
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CAN Communication - Feasibility and Intrinsic
Safety Evaluation

• DESCRIPTION OF TESTING
• Lab tests utilized SDS protocol and devices
• A standard Zener Intrinsic Safety Barrier was
  used in series with both CAN communication
  signals. Component values were varied down to
  4.3 volt Zeners and up to 100 ohms of series
  current-limiting resistance
• 20 CAN devices were connected over trunk lines
  varying from 5 to 250 meters
• Devices were configured to generate bus traffic
  as high as 20 bandwidth utilization to simulate
  worst-case conditions.
• A CAN network analyzer was connected to monitor
  traffic and detect errors
• TEST RESULTS
• After over 72 hours of operation, a total of 87
  million messages had been sent with only two CAN
  error frames. This is well within normal
  expectations for a CAN bus.
• CONCLUSION (tentative)
• It appears that industrial CAN networks are
  entirely suitable for applications such as NeSSI
  when used with a properly-designed IS barrier.

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Adaptation of Honeywell S1 Series Pressure Sensor
to NeSSI design standards.

• Current Status
• Sensor Design and SP76 housing qualified
• Intrinsically Safe (IS).
• CAN controller and transceiver chipsets
• identified.
• DeviceNet protocol selected and pretested
• in selected chipset.
• Preliminary CAN IS mode testing done.
• First POCA units being built for February
• delivery to Dow and ExxonMobil.

• Next Steps
• Design and build PCBs incorporating selected
  sensing and communication chipsets/circuits.
• Design and build PCBs into SP76 Housings and
  qualify full product as IS.
• Establish and incorporate DeviceNet connector
  architecture for NeSSI applications.
• Test Assemblies in full DeviceNet network.
• Identify DeviceNet IS network restrictions and
  rules.
• Propose establishment of DeviceNet IS Special
  Interest Group (SIG) to
• ODVA (Open DeviceNet Vendors Association).

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Preliminary Investigation of SAM Controller
Choices.

• ? MKS Instruments RMUd
• DeviceNet in/Ethernet out
• 4 x 4 x 2
• USB and Serial Ports
• 32 bit RISC Power PC Processor
• 2-16MB ROM, 32-64MB SDRAM
• Linux OS w/ JavaVirtual Machine
• HMI Development Software Included

• AutomationDirect 205 ?
• DeviceNet in/Ethernet out
• 3 x 4 x 6
• Expandable local I/O, Serial Ports
• Windows CE OS
• Flowchart Programming
• Visio HMI/Control Software

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NeSSI-II Sensor Developments Contd
Compatibility with SP76 Footprint Pressure and
Temperature Flow (Gases and Liquids) Self-Normaliz
ing Flow Sensor Thermal Conductivity for Process
Monitoring PHASED MicroAnalyzer
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Thermal Microbridge Flow Sensors for NeSSI-II
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Thermal Microbridge Flow Sensors for NeSSI-II
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Smart, IS, Miniature, p, T, F Sensors for NeSSI
Adaptation. (Courtesy of Honeywell)
Smart, T-Compens. TC Sensor
Smart, T-Compens. Flow Sensor
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PHASED, a GC MicroAnalyzer
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Multi-Stage Pre-concentration
Side Views of PHASED structure and Operation
Multi-stage release of analyte increases its
concentration 100-fold with 1st stage 100 x
n-fold after n stages
To Separator
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NeSSI Benefits, Nominal Ethylene Plant

• Output 1-2 billion pounds ethylene / year.
• Savings enabled by smart, modular sampling (NeSSI
  I-III)
• 430k/y due to building and ownership cost
  savings, over
• 15 year life, of 2.4 and 4M, respectively
  (per P.VanVuuren et al)
• 100K/y to 2M/y plant operational savings, due
  to
• conservative assumption of only a 1
  improvement in
• process control (afford more measurements, and
  achieve
• greater efficiencies, less waste and less down
  time)
• Significance
• 1-2 total savings by processing industries
• Total US energy use GDP 1017 Btu/year
  1013/year
• Assume US Process Industry uses 10 of total
• NeSSI 1-2 of 1016 Btu/y (0.1-0.2 quads/y) or
  10-20B/y.

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NeSSI-II Network and Sensor Developments

• CONCLUSIONS
• Loaded CAN bus network error rate of 2
  87,000,000 is
  smaller than expected
• Sensors compatible with NeSSI-II are around the
  corner PT, FT,
• IS certifications of P, F sensors were obtained
  before and need to be renewed
• NeSSI-compatible microanalyzers are under
  development
• Energy and cost savings are projected to be
  significant 10-20 B/y after NeSSI saturation of
  all industrial processes
• Team approach enhances risk of success

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Acronyms
CAN Controller Area Network ConnI Connectivity
Initiative CPAC Center for Process Analytical
Chemistry DoE-OIT Department of Energy, Office
of Industrial Technologies EDS Electronic Data
Sheet F Flow GC Gas chromatography GUI Graphica
l User Interface HMI Human-Machine
Interface IFPAC International Forum for Process
Analytical Chemistry IR Infra-red IS Intrinsica
lly safe NeSSI New Sampling/Sensor
Initiative NRE Non-Recurring Engineering labor
ODVA Open DeviceNet Vendors Association OLE Ob
ject Linking and Embedding OPC OLE for Process
Control based on Microsoft's OLE/COM
technology OSI Open System Interconnect p Pressu
re PC Personal computer PDA Personal Digital
Assistant SAM Sensor-Actuator Manager SDS Smart
Distributed System SIG Special Interest Group
T Temperature TEDS Transducer Electronic Data
Sheet V Valve
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NeSSI-II Network and Sensor Developments
Thank You! Contact Information John
Mosher [phone] Honeywell ACS Bob
Nickels [phone] Honeywell ACS Ulrich
Bonne [phone] Honeywell Labs