surface mount technology for process analytic sampling ...surface mount technology update 2003...

Surface Mount Technology for Surface Mount Technology for Process Analytic Sampling Systems Process Analytic Sampling Systems

Update 2003Update 2003Steve Doe, Parker Hannifin CorporationSteve Doe, Parker Hannifin Corporation

Instrumentation

Surface Mount Technology Surface Mount Technology Update 2003Update 2003

Agenda:Agenda:Lessons Learned Over Last 12 MonthsLessons Learned Over Last 12 MonthsFunctional ClustersFunctional ClustersStream Switch OptionsStream Switch OptionsRelative System Cost Comparison: Relative System Cost Comparison: Conventional vs. Surface MountConventional vs. Surface MountBeating the ParadoxBeating the Paradox


Lessons LearnedLessons Learned1111//88” “defacto” “defacto--standard” standard”

interface interface used by used by

semiconductor semiconductor

industry is not for usindustry is not for us


Lessons LearnedLessons LearnedCosts are higher than Costs are higher than conventionally conventionally

plumbed systemsplumbed systemsCost challenge is Cost challenge is “Chicken or Egg” “Chicken or Egg” production paradoxproduction paradox

vs.vs.But also inherentBut also inherent cost cost adders such as additional adders such as additional parts for pressure parts for pressure indicationindication


Lessons LearnedLessons Learned““Functional clusters” Functional clusters” simplify flow paths simplify flow paths for easier understanding for easier understanding in fieldin field


Functional ClustersFunctional ClustersStandardized FunctionsStandardized Functions

TO GC SIV

FROM GC

TO DRAINHEADER

PURGE GASINLET

SAMPLE INLET

FROMGRAB SAMPLE

N2 PURGETO FLARE

TO GRAB-SAMPLE

SQC STD. ACTUATINGAIR

FILTER.5 micron

FILTER

STREAM 1BY-PASSFLOW

300PRESSURE

GAUGE

300PRESSURE

GAUGE

OUT

CAL.STD.

SAMPLERETURN HEADE

STEAM

300PRESSURE

GAUGE

PCA205SAMPLE SYSTEM LAYOUT

WALLACE & TIERNAN5125M

FAST LOOP FLOW


ANALYZER LOOP FLOW

-- Fast LoopFast Loop

-- Stream SwitchingStream Switching

-- Analyzer InterfaceAnalyzer Interface

GO


TO GC SIV

FROM GC

TO DRAINHEADER

PURGE GASINLET

SAMPLE INLET

FROMGRAB SAMPLE

N2 PURGETO FLARE

TO GRAB-SAMPLE

SQC STD. ACTUATINGAIR

FILTER.5 micron

FILTER

STREAM 1BY-PASSFLOW

300PRESSURE

GAUGE

300PRESSURE

GAUGE

OUT

CAL.STD.

SAMPLERETURN HEADE

STEAM

300PRESSURE

GAUGEWALLACE & TIERNAN

5125M

FAST LOOP FLOW


ANALYZER LOOP FLOW

TO GC SIV

FROM GC

TO DRAINHEADER

PURGE GAS INLET

SAMPLE INLET

FROMGRAB SAMPLE

N2 PURGETO FLARE

TO GRAB-SAMPLE

SQC STD.

FILTER

STREAM 1BY-PASSFLOW

300PRESSURE

GAUGE

300PRESSURE

GAUGE

CAL.STD.

SAMPLERETURN HEADE

SAMPLE INLET

FROMGRAB SAMPLE

N2 PURGETO FLARE

TO GRAB-SAMPLE

FILTER

STREAM 1BY-PASSFLOW

300PRESSURE

GAUGE

300PRESSURE

GAUGE

300PRESSURE

GAUGE

STEAM

FILTER.5 micron


FAST LOOP FLOW


FAST LOOP FLOW


FAST LOOP FLOW

Functional ClustersFunctional ClustersProvide design flexibilityProvide design flexibility


Functional ClustersFunctional ClustersConfigurable based on your Configurable based on your needsneedsAvailable as a part number ordered Available as a part number ordered from your “catalog” of functionsfrom your “catalog” of functionsProvide functional standardization Provide functional standardization for ease of maintenance

SAMPLE BY-PASS FILTER SYSTEM(1-1/2" SUBSTRATE)

SAMPLEINLET

BY-PASSFLOW

TO STREAMSWITCH

MOUNTINGPLATE

5.75 in

STREAM 1BY-PASSFLOW

SUPPLYPRESSURE

RETURNPRESSURE

Fig. 1

FILTER WITHGAUGE MOUNTED

ON BOWL

5.19

in

for ease of maintenance


Functional ClustersFunctional ClustersStream SwitchingStream Switching

Stream Switch OptionsStream Switch OptionsStream Switching Valve’s Stream Switching Valve’s Function:Function:


Stream Switch OptionsStream Switch OptionsStream Switching Valve’s Stream Switching Valve’s Mortal Sin:Mortal Sin:


????

????

????

????

????

Cross Contamination!!!Cross Contamination!!!


INLET OUTLET

VENT VENT

"OFF"Leaking Seat

sample

TO BUBBLER

Stream SwitchesStream SwitchesOption 1: Double Block & Bleed (DBB)Option 1: Double Block & Bleed (DBB)

-- Fault tolerantFault tolerant-- Diagnostic capableDiagnostic capable

Surface Mount Technology Surface Mount Technology Update 2003Update 2003Stream SwitchesStream Switches

DBB Valves: Two ChoicesDBB Valves: Two Choices

RR--Max:Max:•• Is not geometrically Is not geometrically

compliantcompliant•• Is intent compliantIs intent compliant

Diaphragm Valves:Diaphragm Valves:•• Total complianceTotal compliance•• Cost 65% more than RCost 65% more than R--MaxMax

ANSI/ISA76.00.02ANSI/ISA76.00.02--20022002compliant?compliant?

But consider also...But consider also...


Double Block & Bleed ValvesDouble Block & Bleed Valves

RR--Max:Max:•• Conically machined elastomer Conically machined elastomer •• Engages radiused seatEngages radiused seat•• More contact areaMore contact area•• Contaminant induced leakage risk lowerContaminant induced leakage risk lower

Diaphragm Valves:Diaphragm Valves:•• Donut machined seatDonut machined seat•• Diaphragm seals on knife edgeDiaphragm seals on knife edge•• Less contact areaLess contact area•• Contaminant induced leakage risk higherContaminant induced leakage risk higher

Seat Geometry ComparisonSeat Geometry Comparison


Option 2: Diaphragm Valve ManifoldOption 2: Diaphragm Valve Manifold-- Single diaphragmSingle diaphragm

valve for streamvalve for streamswitchswitch

-- High integrity valve, High integrity valve, but no safety netbut no safety net

-- Per stream cost Per stream cost 50% more than R50% more than R--MaxMax

Surface Mount Technology Surface Mount Technology Update 2003Update 2003Stream Switch OptionsStream Switch Options

Conclusions:Conclusions:

Diaphragm valves inherently more Diaphragm valves inherently more expensive & ultra high purity roots drive expensive & ultra high purity roots drive cost up further cost up further Stream cleanliness proportional to risk of Stream cleanliness proportional to risk of cross contamination on single cross contamination on single diaphragm valve manifold designdiaphragm valve manifold designChoose wiselyChoose wisely


Relative Cost ComparisonsRelative Cost Comparisons

P

SAMPLE GAS COOLER

PRESSUREGAUGE

PRESSUREGAUGE

PRESSUREGAUGE

AV

AV

CALIBRATION GASES

GT-62 CEMS INLET SYSTEMDOW CHEMICAL CO.

TEXAS DIVISIONRev.3 (9-3-02)

OUT

NC NC NC

NCNCNC

NO NO NO

PI-2 PI-3F-1

LIQUIDBARRIER

FM-1

FM-3

FM-4

FM-5

FM-2

VENT

FS-1

FS-2

FS-3

A

A

A

PS-1 PI-4

BLOWBACK NITROGEN

ZERO NITROGEN

INSTRUMENT AIR CAL.

goCEMS project at CEMS project at Dow/FreeportDow/Freeport

Several conventionalSeveral conventionalsystems in servicesystems in service

Prototype NeSSI unit to Prototype NeSSI unit to evaluate for balance of evaluate for balance of project (18+ units)project (18+ units)


Relative Cost ComparisonsRelative Cost Comparisons

As supplied NeSSIAs supplied NeSSI--1 1 prototype user cost was prototype user cost was 50% higher than conventional50% higher than conventional

Surface Mount Technology Surface Mount Technology Update 2003Update 2003Cost Comparison QuestionsCost Comparison Questions

Will NeSSIWill NeSSI--1 functional 1 functional savings outweighsavings outweighprocurement cost procurement cost increase?

Conv Gen1Conv Gen1 Gen2 Gen3Gen2 Gen3Type of SystemType of System

Syst

em C

ost

Syst

em C

ost

Benefit Curve

Benefit Curve

50%50%increase?

Can NeSSICan NeSSI--1 advantages 1 advantages over conventional systems over conventional systems carry further development carry further development for NeSSIfor NeSSI--2 & 3?2 & 3?

AnswersAnswers: Probably NotProbably Not

Beating the ParadoxBeating the ParadoxNeSSINeSSI--1: Chicken or the 1: Chicken or the

Egg?Egg?

Benefit Curve

Benefit Curve

50%50%What percent of analyzer What percent of analyzer

sample sample systems are systems are candidates for NeSSIcandidates for NeSSI--1 1

technology?technology?When will NeSSIWhen will NeSSI--1 volumes 1 volumes approach conventional approach conventional


Surface Mount Technology Surface Mount Technology Update 2003Update 2003Beating the Paradox:Beating the Paradox:Reducing Cost / Increasing ValueReducing Cost / Increasing Value

Reconfigured manual Reconfigured manual ball valve to eliminate ball valve to eliminate higher cost diaphragm higher cost diaphragm valves valves 50% savings in manual 50% savings in manual applicationsapplications


ZeroZero--clearance fittings to clearance fittings to simplify interconnects and simplify interconnects and function removal function removal


Eliminate ultraEliminate ultra--highhigh--purity purity features from substrate features from substrate block to reduce costblock to reduce cost

Surface Mount Technology Surface Mount Technology Update 2003Update 2003The Better We Reduce Cost & Increase Value...The Better We Reduce Cost & Increase Value...

The Better We Beat the Paradox!The Better We Beat the Paradox!

surface mount technology for process analytic sampling ...surface mount technology update 2003...

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