Process RAMAN & NeSSI - Enabling the Pipe-Centric Sampling & Sensor Paradigm (the evolution of a PA “Steel” Bridge) Dr. Peter van Vuuren
Optograf TM : The New Measurement and Sampling Paradigm 2
Process RAMAN Analyzer = Optograf TM Optograf TM Optical Fibers Up to 100 meters Process Interface Process RAMAN Airhead TM RAMAN Probe 4 Lasers (= 4Streams) 150 o C/1000 PSI Simultaneous Operation 3
Optogram for a Typical Raw Syngas Stream Single Probe can do Total Measurement H2, N2 O2 No Valves, Columns, IA H2 Transparent to Moisture CO SF6 CO2 H2S CH4 NH3 N2 4
How Do we Apply This New Technology? * "When men got structural steel, they did not use it to build steel copies of wooden bridges." Ayn Rand. Atlas Shrugged . 1957. * Courtesy of NeSSI Colleague Rob Dubois 5
Traditional SHELTER Centric PA Configuration GP Area Field – Classified Area (Typically ZONE2) DCS Analyzer House Control Room Process Stream A N Instrument Room S A S N Field LAN o&m Analyzer user Shop 6
Requires Expensive Infrastructure Cost K USD K USD To Build/Install each total Number PCT Gas chromatographs 50 30 1500 38 750 Other analysers 75 10 1250 Sample systems 125 10 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 To Own 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 = 2X TBI TOTAL / life 12000 J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” Plenary Session Paper, IFPAC2000, Las Vegas, NV 7
Some Sampling System Myths/Truths 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 8
Optograf TM Wooden Bridge Flare Vent Analyzer Flow Syngas is a Hot, Dirty, FI Steam Saturated Stream Bypass PI FI Flow Analyzer Flow F NV Heat Traced Sample Transport Lines Atm Validation Vent Valves Analyzer Sample Conditioning System Shelter (typically located at Shelter) Field This is the traditional process analysis configuration = SHELTER CENTRIC MODEL 9
Applying Sample Conditioning Dynamic Reflux Sampler Flare (For Hot, Dirty, and Steam Vent Saturated Samples) Analyzer Flow FI Bypass PI FI Flow Analyzer Flow F NV Heat Traced Sample Transport Lines Atm Validation Vent Valves Sample Conditioning System Vortex Cooler/Temp Analyzer (typically located at Shelter) Controller not shown Shelter Field Major Issue: Relatively High Flow Rate ( manage lag times) Sample still need to be transported to Analyzer Limited Cooling Capacity 10
Traditional DRS Sample Conditioning System – Closely Coupled Configuration Dynamic Reflux Sampler (For Hot, Dirty, and Saturated Flare Samples) Vent Analyzer Flow FI Bypass PI FI Flow Analyzer Flow F NV Heat Traced Atm Validation Sample Vent Valves Tube Analyzer Shelter Sample Conditioning System Closely Coupled with DRS 11
Simplified Sampling / Location Opportunity? Dynamic Reflux Sampler (For Hot, Dirty, and Saturated Samples) Optical Fiber (no heat traced tubing) Field Analyzer Shelter Optional 12 12
New Generation Dynamic Reflux Sampler/NeSSI Module ASTUTE 3D-NeSSI Flow Substrate for Sample Conditioning • 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 13
New Generation Dynamic Reflux Sampler/NeSSI Module ASTUTE 3D-NeSSI Flow Substrate for Sample Conditioning • 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 14
The “OptoAST” – Integrated Probe and NeSSI 3D Sample Conditioning Unit OptoAST primarily used on relatively clean and dry gases (NO DRS required) STEEL BRIDGE AirHead TM Very small volume flow channels for operation at high pressures and low flows Sample Outlet ASTUTE 3D Substrate P,T Xmitter Filter Flange can be connected to a DRS (OptoDRS) or to a traditional fixed probe at the sample tap point (OptoAST) 15
Sample/Validation/Calibration Gas Flow Paths (NeSSI Enables Small Footprint) Cal/Val Gas Sample Gas Shared Flow Path 90 o 90 o u v w v Sample x w Outlet Val or Cal Gas Inlet Relief P,T Valve Xmitter 2-Way Valve Temp Gauge Filter DRS or Direct Probe Inlet 16
OptoAST Configuration 17
OptoAST Installation OptoAST installed at an Ammonia Plant in Rouen, France: Feed to Steam Reformer Stream 18
Newest Generation of Dynamic Reflux Sampler: “OptoDRS” Very Low Volume Sampling and Sensor Implementation – secret of stable operation by limiting flow through DRS to maximize cooling capacity of Vortex cooled condenser Measurement Sensor (Optograf fiber-optic probe) Integrated with NewGen DRS – Ultimate Pipe-Centric Sensor and Sampling Installation 19
OptoDRS/AST System Configurations Clam-shell weather Enclosure Temp Controller (includes Air Shut-off Valve, Temp Probe) Vortex Cooler OptoAST (~ 15 SCFM Air) For relatively dry, OptoDRS clean and moderate temp Difficult to sample samples etc. streams: particulate matter, condensables, high temp etc. 20
OptoDRS Enclosure and OptoAST Mounting Example Vortex Cooler and Electronics not Shown 21
OLD vs. NEW Process Analytics Paradigm NEW Paradigm = PIPE Centric (Steel Bridge) Drivers: Enablers: Cost to BBI Miniaturization Cost to Own NeSSI Manpower New Spectroscopic Technologies Consumables Remote Access CLASSIC Paradigm Prima Donna Model = SHELTER Centric (Wooden Bridge) Process/Measurement Environment is CHANGED TO Analyzer sampling/operating requirements are ADAPTED TO the Process/Measurement Environment MEET the analyzer sampling/operating requirements 22
Requires Expensive Infrastructure Cost K USD K USD To Build/Install each total Number PCT Gas chromatographs 50 30 1500 38 750 Other analysers 75 10 1250 Sample systems 125 10 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 To Own 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 = 2X TBI TOTAL / life 12000 J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE” Plenary Session Paper, IFPAC2000, Las Vegas, NV 23
Key Optograf/OptoDRS/AST Benefits 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 24
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 Moisture viscosity- sensor density sensor Oxygen H2 sensor Sensor Micro GC Rolsi valve
Acknowledgements ASTUTE: Philippe Coric David Faulkner SpectraSensors David Novak Kaiser Analytics Joe Slater Ron Fairchild 31
Thank You 32
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