Process Analytics:

are there dinosaurs among us?

Standards

Myths and mistakes that may

contribute to our extinction
Rob Dubois

Certification
Education & Training
Publishing

Conferences & Exhibits

Rob Dubois
robndubois@shaw.ca

Rob Dubois is a process analytical consultant based out of Sherwood Park, Canada. He has been
an active writer, presenter and visionary behind the use of smart and automated sampling.

Rob co-authored (with Peter van Vuuren and Jeff Gunnell) the NeSSI Generation II
specification which helped lay the groundwork for a dedicated sampling system bus for process
analytical. He has worked with major companies including Dow Chemical, ExxonMobil Chemical
and CF Industries and has been involved with process analytical for over 35 years with roles
ranging from maintenance to sampling design, project engineering and R&D.

Rob is dedicated to process analytical simplification as well as the use of microAnalytical devices.
He has started a company to advance these concepts.

Are we sick of this mantra yet?

80% of process analytical reliability issues are
due to the sample system.
Poor understanding of sample integrity
plugged, leaking, fouled?
Poor understanding of sample temperature
condensing, frozen, two-phase?
Poor understanding of sample pressure
vent header fluctuation, perhaps?

Lets take a pipe to pixel look at myths and

mistakes with process analytical systems

Myth: analyzer rounds are essential

today
Of $6 billion spent each
year on process
analytical, approx. 50% is
spent to maintain*
How many people in your
plant look after analyzers?
Can automation help?
Diogenes searching for a hydrogen leak

*Source: PAI partners

Myth: Size (and weight) dont matter

conventional
Size and weight are not
a critical factor with
current design
High infrastructure costs

Conventional sample system designs can be

quite large and involved.

by-line
Move closer to the
process
Size is important for field
maintenance

The move to by-line analysis requires smaller, lighter

components.
5

Myth: the process interface meet our needs

We do careful design of sample system components to
reduce lag time, yet the 1st process connection can
introduced dead volume
Redesigned each project who owns these things!
Or worse we give an operator a way to stop the flow

Lets get an industry standard, low volume sample

valve and probe specifically designed for Process Analytical
requirements

Myth: its de rigeur to use DB&B* valves

Cultural norm

With automation

Based on historical problems

with leaking and/or bad valves
Adds weight and cost
Bubbler identify leaks
Fugitive emission source
Maintenance issue

Pressure or flow sensor

Close coupled design
Simple on/off valves fine

AT

landry loop

* DB&B = double block & bleed

7

Myth: Monitoring the analyzer is good enough

(Actually the analyzer is only one part of a large system)
Utilities

Validate
DCS

Extract & Pre-Condition

Sample
System
Transport

Analyzer
Post cond. &
disposal

Shelter/House/Enclosure/Container

Services &
Utilities
8

Myth: Div/Zone 2 rating is fine for

enclosures handling hazardous fluids
Enclosures handling hazardous fluids should be de
facto treated as Div/Zone 1
sniff test

Not a myth: Its difficult and expensive to automate an

analytical system in order to meet multi-national
hazardous area requirements. Global harmonization
welcome!!

The penitent

Myth: 4-20 mA & discrete I/O is the

communication choice for sample systems

Its labour, design and cost

intensive for use with a multitude
of geographically distributed
sensors & actuators in hazardous
areas
Emerging

Small, serial bus rated Div/Zone 1

Capable of 20-30 sensors per node
Intrinsically safe NeSSI-bus (CAN, I2C)
System designed with conventional 4-20
mA and discrete I/O in a hydrocarbon
processing facility. (Courtesy of Dow
Chemical. Photo by R. Dubois)

Demonstration of a CAN based sampling

system at ISA EXPO2007. Houston, Texas.
(Photo by R. Dubois)

10

Myth: Automation done in the DCS

Better a local way to handle our signals

Unmet need the SAM* (real distributed, local control)
Form hockey puck size, Div/Zone 1
Function PAC** like; serial I/O
Graphical visualization
Standard applets (e.g. stream switch, system health, etc.)
Danielle R. Dubois

SAM
*SAM = Sensor Actuator Manager
**PAC = Process Automation Controller
Who can solve SAM?

11

Myth: Wireless not on my watch!

Ethernet LAN (anLAN)
(wired today; wireless future)

DCS (Operations)

NeSSI-bus
Wireless*or wired access
V

SAM

Substrate
Programmable Substrate Heater

Auxiliary Heating/Cooling

Secure, remote connectivity

for maintenance is important!
- Wireless may be useful for
this purpose
12

Myth: Thermostats are good enough

conventional
On/off control typ.
Blind & dumb
Dew point problems

The ubiquitous Honeywell thermostat

common to home heating systems. An
explosion proof variation is typically
used with analytical systems.

automated
Graphical visualization
Networked control of heat
tracer, heater, regulator
Dew points and flashes
tightly controlled

Heating systems need to be

tied into a bus system so that
they can be set and viewed
locally or remotely.
(Courtesy of Intertec)

13

Myth: Rotameters, etc. rule (not)

conventional
Rotameters, pressure and
temperature gauges which
require walk-by visual
checking
automated
Temperature, flow and
pressure gauges replaced
with bus-enabled sensors
Graphical visualization
Window test

Rotameter replacement: NeSSI-bus-enabled sensor

can measure fluid flow, pressure and temperature,
and serve in Div/Zone 1. (Courtesy of CircorTech)
14

Myth: No need to automate flow control

conventional
Remote pilot valves
located in a safe area
Eliminate tubing runs

Needle valves still used

to control pressures and
flows

Valve control module,

NeSSI-bus enabled.

automation
Bus-enabled solenoid
valve pilots rated for
hazardous areas
Some progress!

Needle valves replaced

by proportional valve
similar to EPC* in gas
chromatographs
So far no product

(Courtesy of Swagelok)

*EPC = electronic pressure control

15

Myth: Operators need detailed operational

information
Common practice
Status alarm of analyzer & flow perhaps
No mechanism to predict failure

Better
RED: Analytical system bad unreliable data
YELLOW: Analytical system needs maintenance
GREEN: Analytical system good reliable data

Give operators a system reliability indication

watch test

16

Myth: microAnalytical easy to deploy

The realityits tough

Certifications & hazardous classifications

Sample systems & analyzer houses
Reliability
Interferences and sensitivity
Expensive
A conservative end user community
It takes years to penetrate this market

Is there a simpler way?

Menacing complexity! Statue

dedicated to Kafka Prague,
Czech Republic

17

Analytical Engine are we heading in the

right direction?

Miniscule sample used

Integral pressure, temperature control
Integral filtration; particulate rejection
microAnalytical ready
Sample returned to pipe (no venting req.)
Based on a patent awarded to Dow Chemical
Complete analytical solution by-line

18

Myth or not? Process analytical - the

technology of last resort
Unless we become more
reliable and lower cost we
may become extinct
We can improve reliability
incrementally through
automation, but are we just
applying a band-aid?
What then, needs to done to
move our analytical
measurements by-line?
Analyzer installation Buna, Germany ca. 1951
Courtesy of S. Bach

19