Enabling the Pipe-Centric Sampling & Sensor Paradigm (the - - PowerPoint PPT Presentation

Process RAMAN & NeSSI - Enabling the Pipe-Centric Sampling & Sensor Paradigm

(the evolution of a PA “Steel” Bridge)

• Dr. Peter van Vuuren

2

OptografTM: The New Measurement and Sampling Paradigm

3

Process RAMAN Analyzer = OptografTM

Process Interface AirheadTM RAMAN Probe 150oC/1000 PSI OptografTM Optical Fibers Up to 100 meters Process RAMAN 4 Lasers (= 4Streams) Simultaneous Operation

4

H2S CO N2 CO2 H2

Optogram for a Typical Raw Syngas Stream

CH4 NH3 SF6

Single Probe can do Total Measurement H2, N2 O2 No Valves, Columns, IA Transparent to Moisture

5

"When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged. 1957. How Do we Apply This New Technology?

* Courtesy of NeSSI Colleague Rob Dubois

*

6

Field LAN Process Stream

S S A N

DCS

• &m

user

GP Area Field – Classified Area (Typically ZONE2)

Analyzer House A N

Instrument Room Analyzer Shop Control Room

Traditional SHELTER Centric PA Configuration

7

Number K USD each K USD total PCT Gas chromatographs 50 30 1500 38 Other analysers 75 10 750 Sample systems 125 10 1250 30 Sample transport 125 5 625 Analyser houses 8 200 1600 27 Data system 1 150 150 3 Installation costs 1 125 125 2 TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” Plenary Session Paper, IFPAC2000, Las Vegas, NV

Lifetime 15 years Number of equivalent analysers 250 Equivalent analyser per technician 50 Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yr Technician 5 30 300 Engineer 1 50 100 Spares 300 Consumables 100 TOTAL / yr 800 TOTAL / life 12000

To Build/Install To Own

Requires Expensive Infrastructure Cost

$$ = 2X TBI

8

• Just having an advanced high-tech sophisticated analyzer (such as a Process

FTIR, MS, RAMAN etc.) does not guarantee a reliable process analysis

• In fact, it may fail because its sample quality requirements cannot be

guaranteed by the sampling system required to deliver such a sample

• It is well recognized that the performance of any in-lone process analyzer is

directly linked to the performance of the sampling system (a 70%+ problem)

• Bottom-line is that:

Unless one can ensure the integrity and reliability of the sampling and sample delivery system, the measurement value of any on-line analyzer no matter how simple or advanced cannot be realized

• Conclusion:

PA Performance is a PA System Issue and not an Analyzer issue only

Some Sampling System Myths/Truths

9

OptografTM Wooden Bridge

F PI FI FI Field Sample Conditioning System (typically located at Shelter) Flare Vent Bypass Flow Analyzer Flow Atm Vent Validation Valves

Analyzer Shelter

Analyzer Flow NV Heat Traced Sample Transport Lines

This is the traditional process analysis configuration = SHELTER CENTRIC MODEL Syngas is a Hot, Dirty, Steam Saturated Stream

10

Applying Sample Conditioning

Dynamic Reflux Sampler

(For Hot, Dirty, and Steam Saturated Samples) F PI FI FI Field Flare Vent Bypass Flow Analyzer Flow Atm Vent Validation Valves Analyzer Flow NV

Major Issue: Relatively High Flow Rate ( manage lag times) Sample still need to be transported to Analyzer Limited Cooling Capacity

Heat Traced Sample Transport Lines Analyzer Shelter Sample Conditioning System (typically located at Shelter)

Vortex Cooler/Temp Controller not shown

11

Traditional DRS Sample Conditioning System – Closely Coupled Configuration

Dynamic Reflux Sampler

(For Hot, Dirty, and Saturated Samples) F PI FI FI Sample Conditioning System Closely Coupled with DRS Flare Vent Bypass Flow Analyzer Flow Atm Vent Validation Valves Analyzer Shelter Analyzer Flow NV Heat Traced Sample Tube

12

Simplified Sampling / Location Opportunity?

12 Dynamic Reflux Sampler (For Hot, Dirty, and Saturated Samples) Field Analyzer Shelter Optional Optical Fiber (no heat traced tubing)

13

New Generation Dynamic Reflux Sampler/NeSSI Module

• Integration of Sampling and

Sample Conditioning

• NeSSI system compatible:

Modular design - configuration adaptable to different process conditions

• Low volume allow for low flow with

minimum impact on lag time

• Easier serviceability

3D-NeSSI Flow Substrate for Sample Conditioning

ASTUTE

14

New Generation Dynamic Reflux Sampler/NeSSI Module

• Integration of Sampling and

Sample Conditioning

• NeSSI system compatible:

Modular design - configuration adaptable to different process conditions

• Low volume allow for low flow with

minimum impact on lag time

• Easier serviceability

3D-NeSSI Flow Substrate for Sample Conditioning

ASTUTE

AirHeadTM ASTUTE 3D Substrate 15

The “OptoAST” – Integrated Probe and NeSSI 3D Sample Conditioning Unit

Sample Outlet Filter P,T Xmitter Very small volume flow channels for operation at high pressures and low flows Flange can be connected to a DRS (OptoDRS) or to a traditional fixed probe at the sample tap point (OptoAST)

STEEL BRIDGE

OptoAST primarily used on relatively clean and dry gases (NO DRS required)

16

90o 90o

Sample/Validation/Calibration Gas Flow Paths (NeSSI Enables Small Footprint)

Val or Cal Gas Inlet DRS or Direct Probe Inlet

u v x w v w

Sample Outlet

Cal/Val Gas Sample Gas Shared Flow Path

P,T Xmitter Temp Gauge Filter Relief Valve 2-Way Valve

17

OptoAST Configuration

18

OptoAST installed at an Ammonia Plant in Rouen, France: Feed to Steam Reformer Stream

OptoAST Installation

19

Newest Generation of Dynamic Reflux Sampler: “OptoDRS”

Measurement Sensor (Optograf fiber-optic probe) Integrated with NewGen DRS – Ultimate Pipe-Centric Sensor and Sampling Installation Very Low Volume Sampling and Sensor Implementation – secret

• f stable operation by

limiting flow through DRS to maximize cooling capacity of Vortex cooled condenser

20

OptoDRS/AST System Configurations

Clam-shell weather Enclosure Vortex Cooler (~ 15 SCFM Air) Temp Controller (includes Air Shut-off Valve, Temp Probe)

OptoAST

For relatively dry, clean and moderate temp samples etc.

OptoDRS

Difficult to sample streams: particulate matter, condensables, high temp etc.

21

OptoDRS Enclosure and OptoAST Mounting Example

Vortex Cooler and Electronics not Shown

22

CLASSIC Paradigm Prima Donna Model = SHELTER Centric

Process/Measurement Environment is CHANGED TO MEET the analyzer sampling/operating requirements

OLD vs. NEW Process Analytics Paradigm NEW Paradigm = PIPE Centric

(Steel Bridge)

Enablers: Miniaturization NeSSI New Spectroscopic Technologies Remote Access Drivers: Cost to BBI Cost to Own Manpower Consumables

(Wooden Bridge)

Analyzer sampling/operating requirements are ADAPTED TO the Process/Measurement Environment

23

Number K USD each K USD total PCT Gas chromatographs 50 30 1500 38 Other analysers 75 10 750 Sample systems 125 10 1250 30 Sample transport 125 5 625 Analyser houses 8 200 1600 27 Data system 1 150 150 3 Installation costs 1 125 125 2 TOTAL 6000

J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” Plenary Session Paper, IFPAC2000, Las Vegas, NV

Lifetime 15 years Number of equivalent analysers 250 Equivalent analyser per technician 50 Cost of spares per equivalent analyser / yr 1200 USD

Number USD / hr K USD / yr Technician 5 30 300 Engineer 1 50 100 Spares 300 Consumables 100 TOTAL / yr 800 TOTAL / life 12000

To Build/Install To Own

Requires Expensive Infrastructure Cost

$$ = 2X TBI

Key Optograf/OptoDRS/AST Benefits

24

• 1. The Optograf/OptoDRS/AST configuration reduces the cost for process

analytics system where it counts most, i.e. infrastructure costs:

• Minimize sample conditioning – working at line pressure
• Sample transport – minimal and does not need heat traced tubing
• In many parts of the world, a shelter is optional
• 2. The OptoDRS provides more reliable sampling as it conditions hot, dirty and

wet streams by condensing /washing condensables, particulate matter back into the process (no external water removal required)

• 3. The OptoDRS/AST provides for better opportunities to return sample to the

process

• Sample pressure does not need to be reduced to be measured; more lower pressure returning

points would be available as sample return points.

• 4. Analysis update times are reduced as there are virtually no sample lag time
• 5. Safety/Toxicity Benefits
• Hazardous/explosive or toxic samples are contained at the sampling point; no transport to the

analyzer or the analyzer shelter

Fuel Gas Density Measurement

Low Sulfur Diesel - 3 years no maintenance

CGs mounted directly on pipe

• 2 x C2V GCs
• Intertec Insulated

enclosure

LEL Detection

Draeger detector mounted on the pipe. Heated, pivoting clamshell enclosure supplied by Intertec

6 Sided ASTUTE System

50% increase in surface area to house components for the same height

Numerous sensors exist today

Micro viscosity- density sensor H2 sensor Rolsi valve Micro GC Oxygen Sensor Moisture sensor

31

Acknowledgements

ASTUTE: Philippe Coric David Faulkner SpectraSensors David Novak Kaiser Analytics Joe Slater Ron Fairchild

32

Thank You