Advances in Sample Conditioning Systems
Hardware and Communications Development
Gerald Vos
Chemical Market Manager
April 21, 2008
• IntraFlowTM Hardware Updates
- First, a Flashback to 2003
- Vaporizing Regulator Development
- Computational Fluid Dynamics and Thermal
Modeling
• Communications Development
- Parker “Pilot Pro” Solenoid/Bus
Communications System
2
Remember 2003?
3
Lessons Learned Since 2003
1. We’re all human
2. Champions change the face of any game
4
Lessons Learned Since 2003
3. End User NeSSI Champions
Can Create a Tipping Point
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Conventional Vaporizing Regulator
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IntraFlow™ Vaporizing Regulator
Patent Pending
Patent Pending
7
IntraFlow™ Vaporizing Regulator
• Utilizes Intertec Heater & IR4000 Reg (2.25” footprint)
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IntraFlow™ Vaporizing Regulator
• Easy removal of heat exchanger for exchanger
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Patent Pending
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 oC
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
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°C
IntraFlow™ Vaporizing Regulator
Nonheated
zone
• IR Thermal Imaging
of System Indicates
Areas Where
Insulation is Needed
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Sample Stream Switch Valve
Inlet heat
zone
Gauge down
stream of reg
Reg- w/ insulation
Parker Approach to NeSSi GEN II
Communications Systems
Pilot ProTM
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Pilot Pro: The Next Iteration in Parker
Sample Conditioning Systems
• What is it?
- Integrated solenoid valve and sensor
administration module
• Where is it implemented?
- Designed for installation in legacy or new
sample conditioning applications
• Key Features?
- Utilizes off-the-shelf hardware with custom
components (ATEX Zone 2, FM C1D2)
13
Plant Communications Architectural Scheme
Control Room
DCS Com
DCS Interface
Work
Statio
n
DCS Interface
Process
Process flow
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Communication
Parker
Sample
System
Pilot
Pro
DCS Proprietary
com Interface
Gateway
Analyzer
Siemens - I2C Com
ABB - Can Open Com
Emerson - Field Bus Com
Flare
Basic SCS Communications Architecture
Zone 2
Zone 1
120VAC Supply
15
‘Smart’ Sample System Communications Initial
Approach
PLC Based Data Interrogation
Allows Limited Flexibility
Provides Interface to Multiple
Transmission Protocols
HMI Gives Technician Local and
Remote System Evaluation
16
Current Gen II Architecture
4-20mA
PLC
Ethernet to
Technician
Workstation
It’s about generation and distribution of the information!
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Parker Solenoid Valve and Communications Interface
NEMA 4X Enclosure
Zone 2 Solenoid Valves
IS Barriers
Communications Interface
Power Supply
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* Patent Pending
Pilot ProTM: Solenoid Valve Module and Transfer
Chamber
Produced by KV Automation
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Parker – KV Solenoid Valve Manifold
Transfer plates indicate valve operation (NC/NO)
Manifold Notes:
Maximum of 8 valves
Valve can be turned ‘off’ by inverting
transfer plate
Manifold spaces not used are isolated
by blanking plates
Aluminum construction
Size – Approximately 9” x 7” x 3”
Press-fit connectors for manifold and
transfer chamber assembly
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by KV Automation
Unique Pneumatic Circuitry
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Pilot ProTM – KV Automation Solenoid Valves
KVEX 11143-624D
ATEX Zone 2 Certified
IP65 Rated for 600C
40psig – 125psig
3/2 and 5/2 NC/NO Options
Multiple Coil Options for Hazardous
Duty Service
O-ring Seal Interface with Manifold
Custom Manifolding Options
Valve body may be rotated for
specialized mounting options
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Pilot ProTM: Electrical Hardware
• ‘Off-the-shelf’ Zone 2 Power Supplies
• Custom Honeywell Communications
Interface
• Application of PLC Accommodated
• IS Barrier compartment (sized to
accommodate different IS barriers)
• Hardware rated for 600C Ambient
Operation
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Pilot ProTM: Engineered for Multiple Mounting Options
Pneumatic Feed Through
Electrical Feed Through
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Flexible Positioning
Power Input
Analyzer or DCS Communication
Pilot ProTM: Conventional Applications
Conventional ‘Smart’ Sample System
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>
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Power Input
Analyzer or DCS Communication
Pilot ProTM: Modular Applications
Pilot ProTM: Product Review
Production model will allow variable door
mounting options
Variable construction materials will be available
(316SS, Aluminum, etc.)
Window inserted for viewing hardware and
LEDs
Production option without valve manifold
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The Next Step?
• Complete prototype testing
• Evaluation of tests
• Implement changes based on testing and
customer input
Product Release !!
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What are Current Field Applications and Outlook?
Imperial Oil
Lanxess
Equistar
OMV
Dow
PetroCanada
Eastman
Formosa
BP
UOP
France (Total, Cegelec, BP, others)
Exxon Baton Rouge
Air Products
Sterling
Exxon Baytown
Oxy Vinyls
Dupont
Hemlock Semiconductor
Restek
Johnson Matthey
Linde
Scanraff
Rose Technologies
Dalkia
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Multiple Systems
Modular Systems Outlook
• Sales have increased more than 100%
since FY 2006
• Key OEM partnerships provide increased
sales revenue
• We see more interest from markets
outside of Chem/Petrochem
• Expect continued growth
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What can be in the box ?
31
Astute in corporation with EIF
Astute
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Connection to the Process
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Easy to disassemble
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IntraFlow™ Smart SHS
w/ remote flow & pressure indication, CTC-Human
Machine Interface, solenoid pilot valve package
Sample
Extraction
Sample Transport
Thank You!
Sample of HMI Screens; pressure &
flow, alarms, maintenance & more!
Environmentally
Compliant Sample
Return or Disposal
Carrier & Cal Gas Delivery
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Analyzer (by others)
Gas Generators