Advances in NeSSI TM communications

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1 Advances in NeSSI TM communications An Implementation of the Generation 2 Bus Siemens Activities Silke Ebbing CPAC Rome, March 2008 Siemens NeSSI Update Slide 1; 03/08

2 Portfolio Process Analytics Continuous Gas Analytics Laser Spectrometry Gas Chromatography System Integration Siemens NeSSI Update.ppt Slide 2; SE 03/08

3 How to get a valid measurement??? - Reliable, robust analyzer - Regular validation & calibration - Representative sample Siemens NeSSI Update.ppt Slide 3; SE 03/08

4 Topics Sample Handling Systems for Gas Chromatographs Status quo NeSSI Siemens Implementation of Generation 2 A major project The Maxum connection Cooperation with NeSSI component suppliers Summary of key design requirements Status Siemens NeSSI Update.ppt Slide 4; SE 03/08

sometimes used Valves (stream or bottle selection, atmospheric reference, other) Pressure controllers or sensors Flow

5 Traditional Sample Conditioning Systems Process Gas Chromatography Custom designed and built Discrete components with tubing interconnection Layout in cabinets or on panels Electrical components are minimized; pneumatic devices sometimes used Valves (stream or bottle selection, atmospheric reference, other) Pressure controllers or sensors Flow controllers or sensors Temperature controllers and sensors Interconnection to analyzers Siemens NeSSI Update.ppt Slide 5; SE 03/08

Typical, Conventional Not Smart System Process Gas Chromatography Maxum GC Air tubing bundle to operate valves; electrical pilot valves are mounted inside GC Sample system with mechanical components

6 Typical, Conventional Not Smart System Process Gas Chromatography Maxum GC Air tubing bundle to operate valves; electrical pilot valves are mounted inside GC Sample system with mechanical components inside cabinet Note: High Voltage electrical power in Explosion Proof housings for heat. No automated control or sensing. Some sampling systems mounted separately from GC. Some systems mounted attached to GC. Mechanical regulators, flow indicators and gauges with no electrical interface. Siemens NeSSI Update.ppt Slide 6; SE 03/08

7 Conventional Smart System Very Rarely Provided Maxum GC Air tubing bundle to operate valves; electrical pilot valves are mounted inside GC Sample system with mechanical components inside cabinet Wiring bundle between GC and Sampling System; Discrete I/O electronics inside GC; Wiring conforms to Explosion Proof, non-incendive methods. NOTE: This is rarely done because of the high expense and awkward construction techniques required. All mechanical indicators, sensors and controllers must be replaced with electronics. All electronics must conform to Explosion Proof or non-incendive design. (NOT SHOWN in this photograph!) Siemens NeSSI Update.ppt Slide 7; SE 03/08

8 NeSSI Intended Benefits Reduced size and cost of sampling systems Standard, modular components Improved on-line system availability Fewer tubing fittings, couplings Opportunity for electronic maintenance monitoring Improved on-line performance Smaller components Precise electronic control Siemens NeSSI Update.ppt Slide 8; SE 03/08

concept is published No one has previously developed NeSSI interface electronics Generation 3 Concepts for

9 Status of NeSSI Process Gas Chromatography Generation 1 A mechanical specification is published (SP76.02) Several companies now produce NeSSI standard mechanical components Generation 2 An electrical interface concept is published No one has previously developed NeSSI interface electronics Generation 3 Concepts for integrated sensors and analyzers Various models and prototypes have been shown Siemens NeSSI Update.ppt Slide 9; SE 03/08

Technical Overview NeSSI Modular Mechanical Concept Small, modular components Standardized substrate (or platform ) that the components mount to Substrate can be made in a variety of ways Components

10 Technical Overview NeSSI Modular Mechanical Concept Small, modular components Standardized substrate (or platform ) that the components mount to Substrate can be made in a variety of ways Components can be made in a variety of ways The interface between the substrate and the components is always the same Conventional Sampling System Modular Sample System (Mechanical Concept) Illustration courtesy of CIRCOR Tech. Large mechanical components. Tube and fitting construction. Small modular components. Standard substrate interconnections. (Actual systems typically in a cabinet.) Siemens NeSSI Update.ppt Slide 10; SE 03/08

11 Technical Overview Example NeSSI Systems Modular components Note: In actual systems, the components and substrates are mounted inside a cabinet. Modular interconnection substrates. Siemens NeSSI Update.ppt Slide 11; SE 03/08

12 Technical Overview NeSSI Illustration; Mechanical; exploded view Mechanical Flow Meter Air-operated Valve Mechanical Guage Substrate block Footprint: 3.8cm x 3.8cm Pro-E rendering of Swagelok system; rendering by Siemens component representation approximate. Siemens NeSSI Update.ppt Slide 12; SE 03/08

13 Major project enforced Siemens Activities for Gen 2 Project Large petrochemical manufacturer; major plant expansion Several hundred analyzers with sample conditioning systems User desires smart systems implemented with NeSSI Generation 2 technology to maximize on-going system performance Project issues: Risk mitigation; project requires proven techniques to minimize risk Problem No NeSSI bus standard yet existed Significant technical issues to be resolved with available techniques Siemens NeSSI Update.ppt Slide 13; SE 03/08

14 The Siemens Solution Process Gas Chromatography Implement bus using available technology Buffers and barriers for rugged I.S. environment Cooperate with major substrate and component suppliers to provide compatible components Swagelok CIRCOR Tech Parker Hannifin Build demonstration systems for evaluation Complete commercial engineering and certification following go-ahead approval Siemens NeSSI Update.ppt Slide 14; SE 03/08

15 Topics for bus development Process Gas Chromatography Implementation with an existing bus used in Siemens analyzers Existing hardware, software and bus protocol for proven reliability in similar applications Enhanced with standard circuitry for robustness in Intrinsic Safety Tested for conformance with CE and IEC specification for immunity and avoidance of EMI and RFI Siemens provides: Bus technology including circuit design and Intrinsic Safety design parameters Intrinsic Safety implementation technology plus design assistance and certification support Project management and point of overall responsibility for implementation Specialized Human Interface to facilitate field maintenance Component vendors provide: Bus compatible components including component-specific electronics Integration of component-specific electronics and Siemens bus interface electronics Point of responsibility for component I.S. certification Siemens NeSSI Update.ppt Slide 15; SE 03/08

Electrical Concept Implementation Smart Analyzers

Software GC Control Electronics Chromatograph

system components are never directly accessed by

This data is always provided via the analyzer / SAM

16 Electrical Concept Implementation Smart Analyzers Ethernet Communications Network Specialized HMI Software GC Control Electronics Chromatograph Sampling System Note: SAM Embedded in GC Sampling system components are never directly accessed by System Bus above. This data is always provided via the analyzer / SAM which controls the sampling system. Intrinsically Safe NeSSI Gen. 2 Bus Siemens NeSSI Update.ppt Slide 16; SE 03/08

(NAU) with integrated NeSSI Generation 2 Bus Control capability.

17 Electrical Concept Implementation Dumb analyzers Ethernet Communications Network SAM functionality is external to the analyzer Continuous Gas Analyzers with system control and network integration provided by Siemens Network Access Unit (NAU) with integrated NeSSI Generation 2 Bus Control capability. Intrinsically safe, Generation 2 Bus P V A T Sampling systems built with substrates and smart, Generation 2- compatible components. Siemens NeSSI Update.ppt Slide 17; SE 03/08

18 System Concept Implementation Ethernet Network Specialized HMI Software Intrinsically Safe NeSSI Bus SAM Embedded in Controllers Intrinsically Safe NeSSI Bus Sample to Analyzers Siemens NeSSI Update.ppt Slide 18; SE 03/08

19 Technical Overview NeSSI Electrical Concept Intrinsically Safe Bus; provides; - Signal for sensors and valve control - Power for sensors and valve electrical pilots Input: Manifold air for valves Input: Electrical power for high wattage heaters Illustration courtesy of CIRCOR Tech. Actual components mounted inside a cabinet creating a Division 1 or Zone 1 environment. Siemens NeSSI Update.ppt Slide 19; SE 03/08

Maxum Electronic Section Multiple channels of Electronic Carrier Gas Pressure Control Multiple

20 Bus Electrical Implementation Using Existing I/O Link Structure Maxum currently uses an internal serial I/O linking system to manage devices required for the Chromatograph. Maxum Electronic Section Multiple channels of Electronic Carrier Gas Pressure Control Multiple channels of Oven Temperature Control Detector Signal and Control Multiple Solenoid Valve Controls Siemens NeSSI Update.ppt Slide 20; SE 03/08

Maxum GC Electronics P V A T Existing I/O link used for control of GC Inputs and Outputs.

21 Bus Electrical Implementation Existing I/O link connected to new module. New module with power drivers and Intrinsic Safety Barriers. NeSSI Generation 2 Bus; Intrinsically safe; carries signal and power for devices. Maxum GC Electronics P V A T Existing I/O link used for control of GC Inputs and Outputs. Existing protocol supports several hundred I/O channels. Pepperl-Fuchs Intrinsically Safe Power supply: 9.5v at 1 Amp. Powers I/O link and components. Use additional power supplies as needed for large numbers of components. Siemens NeSSI Update.ppt Slide 21; SE 03/08

Software and I/O link master protocol by Siemens Component Electrical Implementation Link driver and I.S. barriers by Siemens Chip with I/O link slave software; Intrinsic Safety barriers; and

22 Software and I/O link master protocol by Siemens Component Electrical Implementation Link driver and I.S. barriers by Siemens Chip with I/O link slave software; Intrinsic Safety barriers; and Standardized interface to component electronics by Siemens Proprietary component-specific electronics by component vendor Proprietary mechanical NeSSI component by component vendors Maxum GC Certification of the complete component by component vendor. NeSSI Substrates by component suppliers Siemens NeSSI Update.ppt Slide 22; SE 03/08

Key Physical and Functional Requirements Process

Sampling System Analyzer Sampling System Analyzer

Total cable length <=20m Analyzer House (typical)

analyzer control and reduce cost; <= 2 instances

Bus to support very large number of participating

23 Key Physical and Functional Requirements Process Gas Chromatography Sampling System Analyzer Sampling System Analyzer Sampling System Analyzer Analyzer may be up to 10m from sampling system. Total cable length <=20m Analyzer House (typical) Number of bus instances to be limited to simplify analyzer control and reduce cost; <= 2 instances preferred, excluding power sources. Bus to support very large number of participating component suppliers (unlimited ~ >1000 s) Siemens NeSSI Update.ppt Slide 23; SE 03/08

Key Physical and Functional Requirements Process Gas Chromatography Bus to be I.S.

Design goal for flammability ignition temperature to be T4 (135 C) with minimum at least T3 (200 C).

bus: Start-up, minimum, maximum, abnormal, other powermanagement issues Bus to provide for sensing and

Capability for the standard functions to be implemented in a variety of ways.

24 Key Physical and Functional Requirements Process Gas Chromatography Bus to be I.S.; components to mount in Div. 1 / Zone 1 hazardous area. Design goal for flammability ignition temperature to be T4 (135 C) with minimum at least T3 (200 C). Must support power loading and control of power permitted by I.S. bus: Start-up, minimum, maximum, abnormal, other powermanagement issues Bus to provide for sensing and control of: valves, pressure, flow, temperature. Capability for the standard functions to be implemented in a variety of ways. Component ambient temperature to be >=70 C Any single physical device should be able to represent itself as using multiple device types. Interior of cabinet is considered hazardous due to leakage of flammable gases in a closed area. Mounting area may be hazardous or not. Siemens NeSSI Update.ppt Slide 24; SE 03/08

least 30 separate streams Bus to provide for control of

(eg. heaters) Bus to support replacement of components while

hoc. Device function does not change while live.

Interchangeability requires that the system be able to confirm

25 Key Physical and Functional Requirements Process Gas Chromatography Sampling system to be capable of supporting at least 30 separate streams Bus to provide for control of highpower components that do not draw power from the bus itself (eg. heaters) Bus to support replacement of components while live without interruption of bus operation Systems are not ad hoc. Device function does not change while live. Device recognition during application is useful. Interchangeability requires that the system be able to confirm that a replacement device is of comparable type to device being replaced Siemens NeSSI Update.ppt Slide 25; SE 03/08

Key Physical and Functional Requirements Process Gas Chromatography Distance to analyzer <=20m Components must be scanned every 10 to 30 seconds. Valves must operate within 0.5 sec.

26 Key Physical and Functional Requirements Process Gas Chromatography Distance to analyzer <=20m Components must be scanned every 10 to 30 seconds. Valves must operate within 0.5 sec. At least 4 valves may be active simultaneously Bus must meet Zone 1 and EMI/RFI requirements. Number of components on bus: Typical: 5-15 Common: Maxum: 200 (Note: not all are shown connected in this illustration.) Cabling must connect in available footprint of 3.8cm x 3.8cm Bus must provide signal AND power. Components not large enough to permit 2 cable connections. Power Requirements: Sensors: 10-40ma Controllers: 20-70ma Valve pilots: ma Pro-E rendering of Swagelok system; rendering by Siemens component representation approximate. Siemens NeSSI Update.ppt Slide 26; SE 03/08

27 Status of Siemens Implementation Process Gas Chromatography Analyzer and software Communications Software / Protocol: existing proprietary, complete External bus Buffer / drivers and I.S. barriers: testing complete; production design in progress I.S. certification: preliminary review complete EMI / RFI testing: bus validation tests complete Robustness, bit error rate testing: bus validation tests complete Components Bus interface chip and circuitry: Version 1 operating in test Component interface and software: in test I.S. certification: pending Component functions: in test Compatibility with NeSSI Vision Direct implementation of NeSSI concept; meets all key requirements Architecture consistent with other Bus technologies currently being considered (CAN, Fieldbus, Profibus) Siemens NeSSI Update.ppt Slide 27; SE 03/08

28 Siemens Process Analytics Questions? Siemens NeSSI Update.ppt Slide 28; SE 03/08

29 Backup Siemens NeSSI Update.ppt Slide 29; SE 03/08

30 What Is NeSSI? Process Gas Chromatography New Sampling System Initiative User group committee Hosted by CPAC Center for Process Analytical Chemistry; University of Washington; Seattle End users and vendors Meeting for about 8 year Rationale of NeSSI Goals Process analyzers require sample conditioning systems Sampling systems account for a high portion of total system maintenance There has been no development or significant improvement in process sampling systems in many years A group of end users began meeting 8 years ago to address this topic Publish related specifications Encourage and enable standardization and enhanced designs Siemens NeSSI Update.ppt Slide 30; SE 03/08

31 NeSSI Committee (New Sampling System Initiative) Major customer participants Dow ExxonMobil ConocoPhillips Shell BP Others Major analyzer supplier participants Siemens ABB Emerson-Rosemount Major component supplier participants Swagelok CIRCOR Tech Parker / Hannifin Siemens NeSSI Update.ppt Slide 31; SE 03/08

32 The Traditional Analyzer System Process Gas Chromatography System Communication Network Air Power Dumb Analyzer Sampling System Controller HMI Air Power Discrete Electrical and / or pneumatic connections. HMI Smart Analyzer Process Process Siemens NeSSI Update.ppt Slide 32; SE 03/08

33 The NeSSI Vision NeSSI Electrical Concept System Communication Network Air Power Dumb Analyzer SAM HMI Air Power HMI Smart Analyzer Serial electrical bus. Process Process Siemens NeSSI Update.ppt Slide 33; SE 03/08

34 Key Bus Design Requirements The Old Way Stream Select Bypass Flow Filters Flow / Pressure Adjust Analyzer Flow Siemens NeSSI Update.ppt Slide 34; SE 03/08

transmitters 2 flow transmitters (optioned) Active Bus Sample Shut Off and Atmospheric Reference

35 Representative Test System Design An Introduction to NeSSI Bus Design Requirements Speed Loop Return Active Bus Components: 3 selector valves Sample Shut off valve Atmospheric reference valve 2 pressure transmitters 2 flow transmitters (optioned) Active Bus Sample Shut Off and Atmospheric Reference Analyzer Valve Loop Process Stream Inlet Two Standard Bottle Inlets Siemens NeSSI Update.ppt Slide 35; SE 03/08

36 FISCO Power Delivery Power Zündgrenzkurven Delivery Curves nach from W39 W IIB IK (ma) IIC FISCO=-Bereich U 0 (V) Siemens NeSSI Update.ppt Slide 36; SE 03/08

37 Cabling Issues Cable size, bend radius, height Connection methods and system design Jacket materials Cost Siemens NeSSI Update.ppt Slide 37; SE 03/08

38 Representative 4-wire Bus Design Ax Driver Barrier IS PS Components Signal Power Siemens NeSSI Update.ppt Slide 38; SE 03/08

39 Design Topics and Issues Bus Software Component Physical Issues EMI / RFI and Robust Design I.S. Design Issues Cabling Siemens NeSSI Update.ppt Slide 39; SE 03/08

40 Technical Overview Maxum GC Electronics Interior Location of electrical boards required to provide discrete analog and digital I/O to interface sensors. To sampling system (Locations for additional pilot valves if required.) Pilot valves to control air-operated valves in GC and Sampling System. Siemens NeSSI Update.ppt Slide 40; SE 03/08

41 Maxum Detail ProE Illustration of Module on location in Maxum GC. Bus Driver Module Siemens NeSSI Update.ppt Slide 41; SE 03/08

42 Maxum and NAU Detail P&F I.S. Power Supply Bus Interface Module (prototype) in Maxum Network Access Unit Example component electronics - bus interface Siemens NeSSI Update.ppt Slide 42; SE 03/08

Network Issues Affecting Future NeSSI Generations. IFPAC Forum; January 2012 Bob Farmer Siemens Industry, Inc.

Network Issues Affecting Future NeSSI Generations IFPAC Forum; January 2012 Bob Farmer Siemens Industry, Inc. NeSSI 3rd Gen Networks.pptx; January 2012; Slide 1 Author Bob Farmer Gas Chromatograph Product