AIT Applied Instrument Technologies

Introduction to
Hamilton Sundstrand
Applied Instrument Technologies

PIONIR Process NIR Solutions

United Technology Corporation AIT Applied Instrument Technologies

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Whitney Carrier

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Hamilton
Sundstrand Otis
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Security
This is Hamilton Sundstrand
AIT Applied Instrument Technologies

Aircraft Systems
72%

Commercial Military
65% 35%

Industrial Space, Land &

21% Sea
7%
Space, Land & Sea
AIT Applied Instrument Technologies

Land
10%

Sea
7%

Space
83%
Facility and Capabilities
AIT Applied Instrument Technologies

Sensor Systems Provides:

– Complete hardware and software design,
development, test and production
capabilities
– Facilities with optical clean rooms,
precision electronic and mechanical
assembly, environmental test
– Located 30 miles East of Los Angeles, CA.
Timeline of AIT History
AIT Applied Instrument Technologies
Partial list of current AIT Customers
AIT Applied Instrument Technologies
Technology Portfolio
AIT Applied Instrument Technologies
Lab & Process Development
Analyzers AIT Applied Instrument Technologies
On-Line Analyzers
AIT Applied Instrument Technologies
Refining Applications
AIT Applied Instrument Technologies
PIONIR
AIT Applied Instrument Technologies
PIONIR
AIT Applied Instrument Technologies
PIONIR 1024 Process NIR
AIT Applied Instrument Technologies

Real-time,
multi-point
analysis of
refinery and
petrochemical
processes.
PIONIR™ 1024 System Features
AIT Applied Instrument Technologies

• Simultaneous measurements of
gasoline and diesel properties,
component streams, and
petrochemical processes
– Multiple parameters predicted
simultaneously (RON, MON, RVP,
Cetane, distillation points)
• Developed in collaboration with
Amoco, University of Washington, and
CPAC
• Rapid Response - Typical cycle time
of < 1 minute
• Fiber Optic Multiplexing
– Allows up to 8 probes from one
analyzer
PIONIR 1024 System Features
AIT Applied Instrument Technologies

• Rugged Design
– High performance optics with no
critical moving parts
– High MTBF - >4 years (excluding
source)
– Class 1 Div 1, Class 1 Div 2, Cenelec
Zone 1, Zone 2, or General Purpose
areas
– Operates in extreme ambient
temperatures, -40° C to +50° C
– Environmentally Hardened Enclosure
• Heater/Air Conditioning
• Splash Proof
• Purge with Interlock
PIONIR 1024 System Features
AIT Applied Instrument Technologies

• Environmentally Hardened Fiber Cable

• Coupling to sample probe up to 1
kilometer from analyzer
• Solid State executive processor with
multi-tasking operating system for reliable
stand-alone operation
• Diode array based spectrometer
• Modbus or 4/20 mA interface
• Incorporates patented AVI instrument
standardization - Allowing model transfer
between instruments
PIONIR 1024 System Features
AIT Applied Instrument Technologies

• Modular, serviceable design

– Lowest cost of ownership in the industry for
a refinery analyzer
PIONIR™ Applications
AIT Applied Instrument Technologies

• Blending
– Gasoline and Diesel

• Unit Measurements

• Naphtha Streams
– PIONA
PIONIR MVP AIT Applied Instrument Technologies

• Designed for lab support of on-line

PIONIR’s

• Available in rack-mount version

• Same optics as process PIONIR

• Allows model transfer between

MVP and PIONIR

• Automated operation allows use

with minimal training
 AIT Applied Instrument Technologies

DESIGN FEATURES
 AIT Applied Instrument Technologies

PIONIR Spectrometer - The Heart of the System

INVAR Fixture
• Low Coefficient of
Thermal Expansion

• Fixed Holographic
Grating
– Does not Move

• Silicon Diode Array

– 1024 Element Array
 AIT Applied Instrument Technologies

Optical Stability is obtained by design, including temperature control

The optical heart of the PIONIR (the
spectrograph) is maintained at a fixed
temperature of 35oC+/-0.1oC
Designed to eliminate wavelength shifts due to
temperature changes.
Graphs below shows error if system is not Air Conditioner and
temperature stabilized. heater maintains
cabinet to 23oC+/-
2oC

Error Vs Wavelength Shift

2
1.8
1.6 Spectrograph has
Prediction Error

1.4
1.2
dedicated heater
1 to keep it at
0.8 35oC+/-0.1oC
0.6
0.4
0.2
0
0 0.01 0.02 0.03 0.04 0.05
Wavelength Shift (nm)
 AIT Applied Instrument Technologies

PIONIR/MVP Sample Cell

•Dual Beam Design for
improved stability - each
spectrum includes both a
sample and a reference scan
•Uses 200 micron
environmentally hardened
fiber optics
•Probe can be up to 1 km
from the analyzer

2
PIONIR/MVP Sample Probe Showing: 3 1

1 = Optical Input Assembly

2 = Sample cell
3 = Retroreflector
4 = Retention Rings (hand 4
tightened/loosened for assembly or
removal
 AIT Applied Instrument Technologies

System Block Diagram

Source Housing * Fixed Optics
Filter Lens insures long term
stability Light
Output
Lamp

Spectrograph = 35o + 0.1 C

Light
Input

Grating AVI Technology

System Standardization
allows seamless
Diode Array Filter Wheel (AVI) data and model
Pre-Amp transfer
Board

Power Supply
Digital I/O
Analog Input On-Board Computer
Environmental Control

Remote DCS
Intrinsically Safe Custom Controls
Management Computer
PS Purge - (Option) for Valves, Sensors etc.
Station (Modbus, 4/20mA)
 AIT Applied Instrument Technologies

PIONIR Fiber Optic Cable

Conventional Fiber Optic cables have been repeatedly shown to introduce
spectral artifacts based on microbending, thermal expansion, vibration, and
ambient light. These artifacts result in larger measurement errors. The AIT
proprietary fiber optic packaging eliminates these environmental problems.

Crush-resistant tube

Thixotropic Gel

200 micron fiber

Kevlar Jacket

Environmental Jacket
 AIT Applied Instrument Technologies

Absolute Virtual Instrument (AVI™ )

Instrument Standardization
• The AVI instrument matching procedure allows you to collect data over time and
exchange data between instruments with no degradation in performance. The main
reason for AVI is that small response differences between instruments, or on one
instrument after time or servicing can result in large errors in property predictions.

• The performance of this approach has been demonstrated with our existing customers.
One evaluation in Europe involved developing calibration models on an evaluation
PIONIR. After 2 months, a second demonstration PIONIR was installed. Validation
samples run on the second instrument provided statistically identical results to the
instrument the calibration development was performed on.
 AIT Applied Instrument Technologies

AVI Instrument Standards

AVI Uses 3 internal optical filters to standardize the PIONIR

• Nd Yag crystal used to identify 2 stable peak positions
• Low Finesse Fabret Perot uncoated etalon dispersion standard used to
examine peak positions across whole wavelength range
• Gold Etalon Profile standard used to measure peak shape across
wavelength range
– Result is the spectrum is standardized in wavelength position and
wave shape across the entire wavelength range. This allows data
exchange with no degradation in performance
– Standardization is checked monthly, and can be performed in 10-
15 minutes.
 AIT Applied Instrument Technologies

AVI Standards

1
Nd:Yag Crystal Wavelength Std

Calibration
Lines

Uncoated Etalon Dispersion Std

2

Gold Etalon Profile Standard

3
Calibration transfer using
AVI™ results in no AIT Applied Instrument Technologies
degradation in performance

Octane Transfer
Models were developed on one
103 instrument, and samples were
98
predicted on both the original
and a second PIONIR
93

88

83
83 88 93 98 103
Ana lyze r 1 P re diction
Sample Analyzer 1 Analyzer 2 Difference
1 88.875 88.817 0.060
2 89.595 89.540 0.055
3 84.210 84.105 0.105
4 88.400 88.340 0.060
5 88.985 88.820 0.065
6 99.325 99.315 0.010
7 91.440 91.430 0.010
8 88.840 88.835 0.005
9 89.590 89.590 0.000
10 84.050 84.080 -0.030
11 88.360 88.380 -0.020
12 88.980 88.955 0.025
13 99.280 99.240 0.040
14 93.815 93.885 -0.070
15 92.065 92.115 -0.050
Average 90.387 90.370 0.017
 AIT Applied Instrument Technologies

Sample Conditioning System

(Why most analyzers fail!)
Sample Conditioning System AIT Applied Instrument Technologies

Sample conditioning systems are

used to “clean-up” the sample before
it reaches the PIONIR probe by
removing particulates and water, and
may also include temperature control
• Filtration
– Water (Coalescer)
– Particulates (Swirlklean)
• Sample Collection Panel (bombs)- for
collecting calibration samples
• Sample Temperature Control
(sample/probe)
• Solvent Tank for Automatic Probe
Cleaning
• Toluene Standard for System
Checking (Following ASTM
recommended system validation
procedure)
Typical PIONIR System Diagram AIT Applied Instrument Technologies
 PIONIR Analyzer Loop AIT Applied Instrument Technologies

Sample cooled to
10oC to decrease
the solubility of
fouling agents such
as water. Sample
filtered to remove
the water that has
dropped out.
Sample returned to
25oC for optimal
measurement.
Primary Fast Loop AIT Applied Instrument Technologies

• Includes bulk filter for

removal of particulates
• Includes primary
coalescing filter for
removal of water
• May include redundant
filters for uninterrupted
service
 PIONIR Analyzer Loop AIT Applied Instrument Technologies

• Reduces Temperature of filtered

sample stream
• Removal of water using
membrane bypass filter
• Includes a final Guard filter
• Sample “reheat” and control using
an explosion proof heater
Additional Sample System
Components AIT Applied Instrument Technologies

Automated
Sample
Capture
System

Allows Model
Enhancement Over
Time With Little
Operator Interruption
Wash
Validation loop
Allows automated
validation to be
performed to ASTM
requirements
 AIT Applied Instrument Technologies

PIONIR 1024 Software

PIONIR Software AIT Applied Instrument Technologies

• Remote Management Station (RMS) – Runs the

following Software:
– RMS Instrument set up and Maintenance
– Human Machine Interface (HMI) for routine system
monitoring
– Chemometric Model Development and Database
Management
– Diagnostics, Model Maintenance, AVI, & Analyzer
Configuration
PIONIR 1024 Software AIT Applied Instrument Technologies

• Remote Management Station (RMS)

– Windows XP Professional
– Spectrum Quant+ - Chemometric Model Development
and Database Management
– Diagnostics, Model Maintenance, AVI, & Analyzer
Configuration
– Script Language Tools - Permits Customization

– PC-Anywhere for Remote Modem Support

PIONIR 1024 Software
AIT Applied Instrument Technologies

RMS User Screens

Allows Model
Enhancement Over
Time With Little
Operator Interruption
PIONIR 1024 Software AIT Applied Instrument Technologies

• Human Machine Interface (HMI)

– Provides a graphical “window” into the Modbus
Controller traffic
– Provides the ability to view and control in real-time
– Provides Diagnostic Information
– Modbus data is displayed
PIONIR 1024 Software
AIT Applied Instrument Technologies

HMI Main User Screen

Main system Monitor

Allows user to see
results
and DCS data
PIONIR 1024 Software
AIT Applied Instrument Technologies

• DCS Communication
– Prediction Values
– Diagnostics and Alarms
– DCS Control
• Blend Status / Recipe
PIONIR 1024 Software
AIT Applied Instrument Technologies

• Remote Communication
– Uses PC AnywhereTM from Symantec
– Telephone dial in over a modem line
– Network connection within a refinery
• Allows data and spectra to be moved back and forth from the
lab to the process
• Allows new models to be transferred from the lab system
 PIONIR 1024 Software
AIT Applied Instrument Technologies

Remote Communication

• Remote Site: Remote

– HS Headquarters,
Site
– Field Service, Maintenance or
– Plant Supervisory Personnel
• Remote Control
• File Transfer

• Modem Support Allows Complete

Troubleshooting From Our Offices

Home
Office
 AIT Applied Instrument Technologies

Chemometrics
PIONIR 1024 Software
AIT Applied Instrument Technologies

• Chemometrics
– Models are developed using chemometrics
• Combines “chemo” + “metrics”
– Chemo = chemical disciple
– Metrics = mathematics and statistics
PIONIR 1024 Software
AIT Applied Instrument Technologies

• Chemometrics
– Has been defined as:
• “that field of chemistry which combines chemistry,
computer science, mathematics, and statistics”
• A field of multivariate analysis
• Can be quantitative and/or qualitative

– PIONIR Uses Spectrum Quant+ from Perkin Elmer

PIONIR 1024 Software - Modeling
AIT Applied Instrument Technologies

Spectrum Quant+

All saved spectra are

date and time stamped,
and can include user
information such as
sample id or source
PIONIR 1024 Software - Modeling AIT Applied Instrument Technologies

Conceptual Model:
•Think of each sample as an point.
•The model is a bar that is placed so that each point is as
close as possible to the bar.
•The overall distance, or error, is minimized -- meaning there
may be a few points who have to really stretch to reach the
bar (may have a high error).
PIONIR 1024 Software - Modeling AIT Applied Instrument Technologies

Summary of Modeling Steps

• Collect data
– NIR spectra
– Lab (or on-line) values for properties of interest
• Create calibration set
• Create and evaluate models
• Validate models
• Repeat as required until satisfactory models are obtained
PIONIR 1024 Software - Modeling
AIT Applied Instrument Technologies

Model Building with Quant+™

• Spectra and lab data are maintained in a database.
• Algorithms available through Quant+ are
– Principle Components Regression (PCR)
– Partial Least Squares 1 (PLS1)
– Partial Least Squares 2 (PLS2)
• Validation methods available though Quant+ are:
– Full Cross, Independent and External

Quant+™ is a registered trademark of the Perkin Elmer Corporation

PIONIR 1024 Software - Modeling
AIT Applied Instrument Technologies

Model Building with Quant+™

• Outlier detection tools available include:
– Mahalanobis Distance, Spectral Residual, Spectral Qualifiers
• Expert Assist is an option that can be chosen when calibration is
started
• Expert Assist will determine and remove outliers according to its rules
• Advantages
– Allows the non-expert to build models

Quant+™ is a registered trademark of the Perkin Elmer Corporation

PIONIR 1024 Software - Modeling AIT Applied Instrument Technologies

Why Update Models?

• A model is only as good as its real-world performance
• A good calibration can become a bad calibration with a change in
measurements or process
– Change in crude or other stream
– Change in operating conditions
– Change in blend recipes
• Summer vs. Winter blend
• Switch to reformulated gasoline
– Change in primary reference
PIONIR 1024 Software - Modeling AIT Applied Instrument Technologies

Options for Updating Models

• Models should be updated as needed either by AIT or refinery

personnel. The AIT main modeling software is well documented, and

user friendly.

• AIT provides complete training programs so that customers can build

and maintain their own models.

PIONIR Performance
AIT Applied Instrument Technologies

The repeatability (or precision) of the PIONIR is

extremely high. A typical example is shown here.

RON REPEATIBILITY
P
R 94.525
E
D
94.52
I
C
T 94.515
E 0 10 20 30 40
D
REPEAT SAMPLE #
PTR in India
AIT Applied Instrument Technologies

• First installation at HPCL Mumbai Refinery thru HONEYWELL in 1999

– Measurement of RON in MS stream
– Currently under AMC with LABINDIA
– Up for upgrade as part of GFEC project

• Installation at IOCL Haldia as part of Offsites Automation project thru HONEYWELL in 2000
– One PIONIR for measurement of Diesel properties
– One PIONIR duplexed for measurement of MS and SRN stream
– Currently under AMC with LABINDIA

• Repeat order for PIONIR from IOCL Haldia for MSQ project executed thru YOKOGAWA in 2004
– PIONIR NIR duplexed analyzer with Sample Conditioning System, Wash/Validation System, Sample
Capture Panels for two MS streams

• Installation at CPCL Chennai thru HONEYWELL in 2006

– PIONIR NIR duplexed analyzer with Sample Conditioning System, Wash/Validation System, Sample
Capture Panels for two MS streams

• Repeat order from HPCL Mumbai thru HONEYWELL in 2007 for GFEC project
– PIONIR NIR duplexed analyzer with Sample Conditioning System, Wash/Validation System, Sample
Capture Panels for two MS streams
– Upgrading the existing PIONIR (installed in 1999-2000) and upgrading the electronics and the software to
current blend configurations.
– Connecting the new and the upgraded PIONIR to the two sample handling systems to run simultaneously for
property predictions.
 AIT Applied Instrument Technologies

PIONIR 1024 Validation

Automated ASTM Analyzer Validation

• Allows you to validate the analyzer system – Designed to separate
modeling problems from analyzer system problems.
• Introduces reference material, typically toluene, into the cell on a
periodic basis.
• Uses control charts to indicate changes in system performance, and
need for service. If no change in system, indicates model weakness
 AIT Applied Instrument Technologies

PIONIR 1024 Validation

Automated ASTM Analyzer Validation
• Follows ASTM Practice Guidelines
– Automatic Calculation and display of:
• Wavelength Stability
• Photometric Noise
• Baseline Stability
• Spectral Resolution
• Photometric Linearity
• Toluene PCR Models
• Gasoline Prediction Models
– Predicted Value
– Mahalanobis Distance
– Spectral Residual
 AIT Applied Instrument Technologies

The IOCL Haldia Installations.

• 2 Nos. PIONIR 1024 installed as part of the Offsites Automation Project in

the year 2000 thru Honeywell.
• 1 No. on HSD stream, measuring Flash Point and % Recovery at 370 DegC
• 1 No. duplexed to measure RVP (Reid Vapor Pressure) on SRN (Straight
Run Naptha) stream and RON, MON, RVP, T-10 and Specific Gravity on MS
Stream.
• 1 No. PIONIR MVP Laboratory analyzer supplied with the sytem package.
The MVP is a useful tool in developing models for the online analyzer.
• Uses MODBUS communication for data transfer between analyzer and
DCS.
• Fiber Optic communications link between analyzer and DCS.
• Sample handling systems manufactured by Hobre Instruments, designed
by HS-AIT.
• System commissioned successfully in 2001.
 AIT Applied Instrument Technologies

Maintenance Work Carried out on the PIONIR systems

• Sample Handling System routine maintenance. Changing elements for
Swirlklean filters, membrane filters and coalscer elements.
• Carried out model updates for MS and HSD streams.
• HSD stream model update was necessitated by the fact that the DHDT
plant was commissioned after NIR analyzer was commissioned.
• Currently HSD system working online. MS / SRN system not being
used as new PIONIR procured for the MSQ upgradation project.
• System being maintained by our local rep LABINDIA.
• We have recently suggested upgrading the existing communications
system with addition on new HMI for the analyzer.
 AIT Applied Instrument Technologies

New PIONIR for MSQ Upgradation Project

• Supplied thru YOKOGAWA India Limited

• One PIONIR with sample conditioning system for MS stream and PIONIR MVP
laboratory analyzer supplied as part of contract
• New generation redundant modbus communication link between analyzer and
DCS
• New HMI for analyzer interface
• Properties measured:
• RON
• MON
• RVP
• Denisty
• E-70
• E-100
• Benzene
• Aromatics
• Olefins
• Installation and commissioning carried out with local contractor and Indian
representative LABINDIA
• Sample and Data collection for model development done locally
• Commissioning completed on schedule
• PIONIR MVP laboratory analyzer supplied as part of contract
• Models working within specified range of accuracy till date
• Post warranty AMC awarded to local rep LABINDIA
PIONIR Customer Experiences AIT Applied Instrument Technologies

• A Gulf Coast refiner has estimated that the on-line use of the PIONIR
reduced the number of reblends by 75%!
• Another Gulf Coast refiner sold their 6 on-line knock engines relying
solely on the PIONIR.
• A European refinery has stated that:
– their unleaded gasoline model has a standard error of prediction of
0.22 RON and 0.19 MON.
– long-term stability of 0.03 ON and the ability to transfer models
between instruments within 0.04 ON.
• Refineries using the PIONIR in the United States, Caribbean, and
Norway all blend directly to ships/pipelines, reducing tankage/storage
costs
Partial List of Satisfied Customers
AIT Applied Instrument Technologies

Maintained Systems Have Provided > 99% Up-Time

• BP Arco, BP Amoco Refining
• ConocoPhillips
• Citgo Refining
• Lyondell refining Refineria Isla
• Chevron Canada Refining
• Tosco Refining
• Statoil Norway
• Petroleos de Mexico
• Cenex Refining
• Omsk Refinery Russia
• Hindustan Petroleum Corporation, Ltd. (India)
• Indian Oil Corporation Ltd. (India)
• Chennai Petroleum Corporation Limited (India)
Summary AIT Applied Instrument Technologies

• AIT can provide complete NIR analysis systems including:

– Analyzer
• General Purpose or Hazardous Environment Sample System
• Sample treatment, temperature conditioning, automatic sample
capture and probe cleaning, system validation
– Models and model support from our Applications Specialists
– Service support by our Field Service Engineers
– Installation and training support
– Project Engineering Support from our Project Engineers
• Ability to retrain and actually remodel, change and modify systems is
essential for long term use.
• Calibration transfer is a non-issue since all PIONIR systems are
identical due to AVI™.
AIT Applied Instrument Technologies

Contact Information
Ajay Laghate
In-Country Manager – INDIA
Phone: 91 20 6470 6085
Mobile: 91 98220 81471
Email: [Link]@[Link]
[Link]