Evolving Applications that Demonstrate the Value of the NeSSI TM Platform. Sampling System Development for the Field and Laboratory

Transcription

1 Evolving Applications that Demonstrate the Value of the NeSSI TM Platform Sampling System Development for the Field and Laboratory February 2, 2012

2 Process Analytical Systems: The Big Picture Sample Conditioning Sample Extraction Clean Gas DBB Probe Sample Transport Heat Trace Honeywell Alliance (pressure & flow sensing) Key System Performance Information To Analyzer Network Hub Sensor Monitoring DCS/Unit Control Control R-Max Sample Disposal Vent Master Intertec (enclosure & heat) Analyzer Carrier & Cal Gas Delivery Gas Generators

3 The Conventional Approach 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 3 Picture Courtesy ExxonMobil Chemical

4 What Is NeSSI? New Sample/Sensor Initiative Simple Lego-like assembly Easy to re-configure No special tools or skills required Standardized flow components Mix-and-match compatibility between vendors Growing list of components Standardized electrical and communication (Gen II) Plug-and-play integration of multiple devices Simplified interface for programmatic I/O and control Advanced analytics (Gen III) Micro-analyzers Integrated analysis or smart systems

5 NeSSI TM Modular Sampling System Initiative: Technology Roadmap Gen III: Microanalytical Systems Platform for microanalytical, remote wireless, advanced gas & liquid sensors Gen II: Electrically Networked Systems IS Serial Bus, minitransducers, local wireless Gen I: Fluid Handling Systems Mostly Mechanical Components 5

6 Modular Component Suppliers Swagelok Circor 6 Parker - Intraflow TM

7 Modular Hardware Functionality Three Suppliers: Parker, Swagelok and Circor Parker Design Incorporates a Taper connection between substrates Swagelok Design Utilizes a channeled tube design Circor Design models Swagelok but uses welded joint connections Parker Intraflow Swagelok Circor 7

8 Intraflow TM Parker Modular (NeSSI TM ) Systems: Gen I Foundation of Modular Approach ISA/ANSI SP Compliant Same plane flowpaths Same screw size throughout 8 Field connectors (top or end) Mounting Pegboard Slip-fit intrafitting connectors

9 Design Drivers Simplicity Overcomes Limitations IntraFlow Fitting IntraFlow System 9

10 Intraflow TM Substrates/Flowpath Options: The Library is Has Become Much Larger to Accommodate Laboratory and Process Applications (over 100 flow options) IntraFlow Fitting 10

11 Modular Sampling System Tool Box Full range of valves (Library) Full range of pressure control hardware Flow control Volumetric and Mass Flow/Pressure Monitoring (Local/Remote) Temperature Control Convective/Conductive Sample Eductors/Pumps Sample Cylinders Analytical Systems (ph, Cond., O 2, GC, RAMAN, FTIR, etc.) 11

12 "When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged

13 Modular System vs. Conventional Tubing Conventional Flow System 13

14 Modular System Applications: Where and How are They Used? Typical process analyzer sample conditioning applications liquids and gases (HF non-sp76 standard system to accommodate higher viscosity liquids) Fluidic control for laboratory and R&D reaction systems Mixing/blending of standard gases for supplying variable concentration ranges Platform for supplying controlled sample to on-board analytical systems Gen. III Implementation of gas purifying hardware Sample conditioning upstream of bench-top analytical systems 14

15 Intraflow TM Process Sample Conditioning Complete smart sample system integration Mono-ethylene glycol liquid service Flow & pressure sensing Conductive heating Conventional grab sample & system functionalities 15

16 High Pressure Applications 10-Stream Natural Gas BTU Analysis System Coalescing & Membrane Separator Drain Header Restricted Orifice Header Pressure Control Freeze Protection Heating Sample pressure 1,500 3,000psig Common Drain

17 NeSSI and Raman Probe Reactor Application

18 NeSSI Sampling System for Reactor Raman Probe monitor clean bypass

19 NeSSI TM and MicroReactor Performance Analysis 1.2 Normalized Standard Spectra Normalized Intensity (Arb. Units) Raman Shift (cm -1 ) 19 Courtesy of Brian Marquardt U.S. Food and Drug Administration

20 NeSSI TM :Reactor Monitoring and Control Product monitoring Upstream reactor control and monitoring 20

21 Micro Reactor Fluid Control with Intraflow TM 21 Courtesy of Brian Marquardt UW APL

22 Sampling, Vaporization and Injection Integrated Advantage of NeSSI: Pre-heated carrier gas Helium Remote Stream Isolation Parker Vaporizing Regulator 6-port VICI Valve and Actuator To GC 22

23 NeSSI TM Reactor Sampling/Calibration Pump 1 Reactor Feed 1 Product Stream Reactor Feed 2 Real-time Calibration waste prod Pump 2 Analyzer Suite Application of sampling systems and analytics to optimize and control reactor

24 Small-Scale Lab Fermenter Applications Pump for liquid recirculation Parker Intraflow TM for Fluidic Control and Sensor Interface 1 Liter Fermentation Vessel 24

25 BioTech Applications: On-line Fermenter Monitoring Hardware used to transport, control and manage fluidic delivery to the analytical system Calibration media also mounted to hardware and engineered to deliver calibration gas to GC 25

26 Integration of Sophisticated Analytics to Modular Sampling Systems 26 RAMAN Probe

27 Analytical Probe-Based Measurement on ISA SP76 Platforms 27 H 2 Measurement

28 Parker Intraflow TM A Platform for Experimentation R&D Sensors for Experimentation Simple fluid control hardware implemented easily Complete flexibility for changing flow and pressure Custom R&D Sensor 28 Courtesy of Brian Marquardt UW APL

29 NeSSI TM SP76 and Transportable Analytical Applications 29 MicroGC (Falcon Analytical) with Intraflow TM Sample Conditioning System Mobile Unit with Support Equipment Mounted Courtesy of Carl Rechsteiner - Chevron

30 NeSSI TM Lab Calibration/Dilution System with On-board Analytics 30 Real-time monitoring of pressure, flow and component concentration Courtesy of Brian Marquardt UW APL

31 Conventional Sample Extraction Modularized Easy removal of heat exchanger Patent Pending

32 Intraflow Vaporizing Regulator CFD modeling of the vaporizer indicates that room temp water vaporizes at around 80% through the heat exchanger Number of Tetrahedral Elements =.42 million Pressure Inlet: 25 psi Pressure outlet : 5 psi Temperature input to aluminum block: 190 o C All other external walls are considered as adiabatic walls Fluid: Water Solver: Segregated 3D steady solver with SIMPLE pressurevelocity coupling with standard k-e turbulence model. Location of Post Processing Plane C C

33 Calibration from NeSSI TM -Permeation Tube System Conceptual Design Alternative Prototype Testing 33

34 Flow Rate Results: Ethanol Permeation Tube Trial 20 x Ethanol CO 2 Absorbance (Arbitrary Units) 10 5 As Flow Rate Increases the Signal Decrease H 2 O 10 ml/min 60 ml/min Wavenumber (cm -1 )

35 Temperature Range Test: Ethanol Permeation Tube Trial 5 x H 2 O Ethanol CO 2 Absorbance (Arbitrary Units) As Temp Decreases the Signal Decreases 85 C 65 C Wavenumber (cm -1 )

36 Sample Introduction Flexibility for microanalytics is Available Inject valves for GC or LC 36

37 Dilution/Mixing Systems Analytics GC, FTIR, O 2, etc. Expensive Blended Gas Cylinder (H 2 S, CH 4, CO, CO 2, etc.) $$$$ Pure gas cylinders $ Gas Calibration System Yields blended gas cylinder results

38 The NeSSI TM Platform Accommodates Sampling At The Process Extraction Point H 2 Sensor microgc 38 Courtesy of E.I.F Astute System with C2V Micro GC and H2Scan hydrogen analyzer (

39 NeSSI TM : Clean Sampling? Courtesy of Brian Marquardt UW APL

40 Sterilization Method Sterilized Sterile Water Rinse ~ 500mL 120 C for 15 min Filled Sterile growth media is pumped by head pressure of compressed gas Incubated 37 C for 72 hours Swabbed Substrates sampled onto bacterial streak plates Courtesy of Brian Marquardt UW APL

41 Growth Study End piece (Start Flow) 2. Valve substrate 1 3. Substrate 3 4. Top mount 3 5. Substrate 4 6. Substrate 5 7. Valve substrate 6 8. End piece (End Flow) contaminated Courtesy of Brian Marquardt UW APL Note: Contamination only found in starting and ending components. Most likely due to insufficient sterilization of the sealing caps placed during incubation.

42 What may be Concluded? Demonstrated sterilization of NeSSI components Possibly contaminated by residual cells trapped in threads of end caps Steam sterilization is a valid method of sterilization for NeSSI components O-rings and tubing are compatible with autoclave conditions Ensures a sterile flow path without exposing external parts to hot and humid conditions Next step Top mount components Sterilization of top mount components will be dependent on the materials and flow path of the components themselves Next step Full integration to NeSSI System Integrate rinse stream and boiler system to NeSSI fast loop sampling system Create digital control system for automatic sterilization

43 NeSSI TM Modular Sampling System Initiative Gen III: Microanalytical Systems Platform for microanalytical, remote wireless, advanced gas & liquid sensors Gen II: Electrically Networked Systems IS Serial Bus, minitransducers, local wireless Gen I: Fluid Handling Systems Mostly Mechanical Components 43

44 Sensors for NeSSI Pressure Transmitters: Dwyer (Series 626) Ashcroft (Series A2X, A4) GE Sensing (PTX1200,DPS4000) Brooks Instruments (SS2 series) SensorsONE (PD33X,DMP331i) Mensor (series 6000) StellarTech (GTX2511) Flow Controllers: Porter Instruments (3261) Brooks model (SLA5850) Horiba (STEC) (SEC-G100) Sierra Instruments MKS Instruments Alicat Scientific (316L MCS/MCRS) Flow Meters: Porter Instruments (3261) Brooks (SLA5850) FCI (FS10A (FM, FS)) Sierra Instruments MKS Instruments Alicat Scientific (M Series) 44 Signal Output: 4-20mA 4-20mA 4-20mA, RS485, CanBus 4-20mA 4-20mA, RS-485, USB RS-485 RS-232, RS485, CanBus Signal Output: 0-10vdc, 4-20mA 0-5vdc,4-20mA, RS485, DeviceNet, Profibus 0-5vdc, DeviceNet 0-5vdc, DeviceNet 0-5vdc, DeviceNet 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus Signal Output: 4-20mA 0-5vdc,4-20mA, RS485, DeviceNet, Profibus 4-20mA 4-20mA 4-20mA 0-5vdc, 4-20mA, RS-232, RS-485, DeviceNet, Profibus Area Classification: Intrinsically Safe Intrinsically safe, Class I Div. II Class I Div. II, Class I Div. I, IS, GP Class I Div. II GP and IS GP Class I Div I & II Area Classification: Class I Div. II Class I Div. II GP GP GP Class I Div. II, ATEX Area Classification: Class I Div. II Class I Div. II Class I Div. II GP GP Class I Div. II, ATEX

45 Parker: Sensor, Analyzer, Valve Actuation Management SAM Valve On/Off Indication Valve Control Gen II Model Architecture 45 Ethernet Comm.

46 46 Future Modular Sampling Hardware Developments for the Lab and Process Markets? Mixing Systems Liquid and Gas Dynamic/Static Permeation/Calibration Hardware Inject Valve Integration for Microanalytics Solvent Delivery System Modified Interface Hardware for RAMAN, FTIR, ph and other probe-based analytics Alternative Material Applications - PEEK

47 Acknowledgments Brian Marquadt, Charlie Branham, Wes Thompson, Michael Roberto, Lauren Hughs and Thomas Dearing Applied Physics Laboratory University of Washington Kin Tek Laboratories CPAC University of Washington 47

48 48

49 49 Thank You!!