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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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
Lessons LearnedLessons Learned““Functional clusters” Functional clusters” simplify flow paths simplify flow paths for easier understanding for easier understanding in fieldin field
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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
WALLACE & TIERNAN5125M
ANALYZER LOOP FLOW
-- Fast LoopFast Loop
-- Stream SwitchingStream Switching
-- Analyzer InterfaceAnalyzer Interface
GO
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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
WALLACE & TIERNAN5125M
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
WALLACE & TIERNAN5125M
FAST LOOP FLOW
WALLACE & TIERNAN5125M
FAST LOOP FLOW
WALLACE & TIERNAN5125M
FAST LOOP FLOW
Functional ClustersFunctional ClustersProvide design flexibilityProvide design flexibility
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
Functional ClustersFunctional ClustersStream SwitchingStream Switching
Stream Switch OptionsStream Switch OptionsStream Switching Valve’s Stream Switching Valve’s Function:Function:
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
Stream Switch OptionsStream Switch OptionsStream Switching Valve’s Stream Switching Valve’s Mortal Sin:Mortal Sin:
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
????
????
????
????
????
Cross Contamination!!!Cross Contamination!!!
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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...
Surface Mount Technology Surface Mount Technology Update 2003Update 2003Stream SwitchesStream Switches
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003Stream SwitchesStream Switches
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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)
Surface Mount Technology Surface Mount Technology Update 2003Update 2003
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 2003
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
Surface Mount Technology Surface Mount Technology Update 2003Update 2003Beating the Paradox:Beating the Paradox:Reducing Cost / Increasing ValueReducing Cost / Increasing Value
ZeroZero--clearance fittings to clearance fittings to simplify interconnects and simplify interconnects and function removal function removal
Surface Mount Technology Surface Mount Technology Update 2003Update 2003Beating the Paradox:Beating the Paradox:Reducing Cost / Increasing ValueReducing Cost / Increasing Value
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 Surface Mount Technology Update 2003Update 2003