Jeff Gunnell and Peter van Vuuren - University of...
Transcript of Jeff Gunnell and Peter van Vuuren - University of...
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Jeff Gunnell and Peter van Vuuren
ExxonMobil Chemical - Core Engineering
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
COMMONLY HEARD PHRASES
“lump sum, turn key”
“industry-standard design”
“trend-line decrease in cost”
“year on year improvements”
“best practices”
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
GOALS
Understand the driving forcesRecognise technology trends
Imagine the future
Create change
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
STAKEHOLDERS
Petrochemical companiesEngineering contractorsSystem integratorsAnalyser vendorsComponent vendorsAnalyser research groups
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
UNDERSTAND THE DRIVING FORCES
Reduce time from concept to productReduce hours for design and development
Reduce cost of buildReduce cost of ownership
Maximise profitability
![Page 6: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/6.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS
SAMPLETAKE-OFF
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS
SAMPLETAKE-OFF
A
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
DCS LAN
ANALYSER DATA SYSTEM
SAMPLEPRECONDIT.
SAMPLERECOVERY
SAMPLETRANSPORT
SAMPLETAKE-OFF
SAMPLERETURN
VALIDATIONBLEND
SAMPLECONDITIONING
INSTRUMENT AIRELECTRICAL
GASES
DRAINVENT
SAFETY SYSTEMHVAC
A
AH
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
![Page 11: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/11.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
![Page 12: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/12.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
![Page 13: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/13.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
![Page 14: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/14.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S ANALYSER SYSTEM
ANALYSER HOUSE
COMMSXFACE JB
A
SHS
A
SHS
COMMSXFACE
A
SHS
COMMSXFACE
A
SHS
A
DCS LAN
JB
OTHERANALYSER
HOUSESLEVEL 0Field mounted
hardware
LEVEL 1Unit control and
processing
LEVEL 2Distributed control
and processing
LEVEL 3Higher levelprocessing
GATE-WAY MAINT.
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
AH 1
A AAAA
AH 2
A AAAA
AH 3
A AAAA
AH 4
A AAAA
AH 5
A AAAA
AH 6
A AAAA
AH 7
A AAAA
AH 8
A AAAA
DCS LAN
ANALYSER DATA SYSTEM
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
Gas chromatographs 50Other analysers 75Sample systems 125Sample transport 125Analyser houses 8Data system 1Installation costs 1TOTAL
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
K USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
THE FUTURE
The challenge...
...and the opportunity
Reduce cost of build by 40%
![Page 19: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/19.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF BUILD
For a major greenfield projectNumber
K USDeach
K USDtotal PCT
Gas chromatographs 50 30 1500 38Other analysers 75 10 750Sample systems 125 10 1250 30Sample transport 125 5 625Analyser houses 8 200 1600 27Data system 1 150 150 3Installation costs 1 125 125 2TOTAL 6000
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
THE FUTURE
The challenge...
...and the opportunity
Reduce cost of ownership by 35%
![Page 23: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/23.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
TODAY’S COST OF OWNERSHIP
Lifetime 15 yearsNumber of equivalent analysers 250Equivalent analyser per technician 50Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yrTechnician 5 30 300Engineer 1 50 100Spares 300Consumables 100TOTAL / yr 800TOTAL / life 12000
![Page 24: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/24.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
ENABLING TECHNOLOGIES
� Modular sample system components�developed by the semi-conductor industry�ISA group working on design standards
� Application specific integrated circuits�provide the smart components
� Open communication architectures�provide the data integration
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
A
T
PAnalyzer Analyzer
ControllerController
Fiel
d LA
NFi
eld
LAN
Level 0Level 0 Level 1Level 1
Pro
cess
Str
eam
Pro
cess
Str
eam
F
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
FLAN (Optical Fiber)
Sensor/Signal Bus
IA
Controller
(ASIC)
Original Picture of Gas Delivery System courtesy Valin Corporation;
A
T
PF
Sensor = Moisture Probe
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
A
T
PF
Sensor = RAMAN Probe
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
IMAGINE THE FUTURE
Integrated analysers and sample systemsField-mounted and self containedSmart incorporating diagnostics + controlOpen-architecture data systemsPlug-and-play maintenanceStandard designs for generic applications
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Integrated analysers and sample systems
� analyser vendor provides sample system�one-shop stop
� maximise standardisation�there really aren’t that many special cases
Reduce hours for design and development
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Field-mounted and self contained
� can work anywhere�from the poles to the tropics
� no analyser houses� no long sample transport lines� minimum utilitiesReduce time of design and cost of build
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Smart with diagnostics + control
� full system info available� remote modification of parameters� control of P, T, F
�with flow control, install across control valves
Reduce cost of ownership
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Open-architecture data systems
� one data highway for all systems� single window
�opportunity for remote support
� simple to add new analysersReduce time of design and cost of build
Reduce cost of ownership
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Plug-and-play maintenance
� For failures take a complete system to the field�plug in the new one, repair the old one
back at the workshop
Reduce cost of ownership
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
Standard designs for generic applications
Reduce time from concept to productReduce hours for design and development
Reduce cost of buildReduce cost of ownership
Maximise profitability
![Page 35: Jeff Gunnell and Peter van Vuuren - University of Washingtondepts.washington.edu/cpac/NeSSI/2_IFPAC_2000/VisionPaper...Jeff Gunnell and Peter van Vuuren ExxonMobil Chemical - Core](https://reader036.fdocuments.in/reader036/viewer/2022071406/60fbedb4931536704d518004/html5/thumbnails/35.jpg)
PROCESS ANALYTICAL SYSTEMS- a vision for the future
CREATE CHANGE
Agree a common visionStandardise sample system componentsStandardise data system architecturePartnerships between stake-holders
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PROCESS ANALYTICAL SYSTEMS- a vision for the future
COMMERCIAL BREAK
RELATIONSHIPS IN THE PROCESS ANALYSIS INDUSTRY
discussion of how interactions between the stakeholders need to change
Time: Wednesday 26 Jan, a.m.
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PROCESS ANALYTICAL SYSTEMS- a vision for the future