Instrumentation Surface Mount Technology for Process Analytic Sampling Systems Update 2003 Steve Doe, Parker Hannifin Corporation Agenda: n Lessons Learned Over Last 12 Months n Functional Clusters n Stream Switch Options n Relative System Cost Comparison: Conventional vs. Surface Mount n Beating the Paradox Surface Mount Technology Update 2003 Lessons Learned n 1 1 / 8 defacto-standard interface used by semiconductor industry is not for us Surface Mount Technology Update 2003 Lessons Learned n Costs are higher than conventionally plumbed systems Surface Mount Technology Update 2003 n Cost challenge is Chicken or Egg production paradox vs. But also inherentcost adders such as additional parts for pressure indication But also inherent cost adders such as additional parts for pressure indication Lessons Learned n Functional clusters simplify flow paths for easier understanding in field Surface Mount Technology Update 2003 Functional Clusters n Standardized Functions Surface Mount Technology Update Fast Loop - Stream Switching -Analyzer Interface - Analyzer Interface GO Functional Clusters n Provide design flexibility Surface Mount Technology Update 2003 Functional Clusters n Configurable based on your needs n Available as a part number ordered from your catalog of functions n Provide functional standardization for ease of maintenance Surface Mount Technology Update 2003 Functional Clusters n Stream Switching Surface Mount Technology Update 2003 Stream Switch Options n Stream Switching Valves Function: Surface Mount Technology Update 2003 Stream Switch Options n Stream Switching Valves Mortal Sin: Surface Mount Technology Update 2003 ?? ?? ?? ?? ?? Cross Contamination!!! Leaking Seat sample TO BUBBLER Surface Mount Technology Update 2003 Stream Switches n Option 1: Double Block & Bleed (DBB) - Fault tolerant - Diagnostic capable Surface Mount Technology Update 2003 Stream Switches n DBB Valves: Two Choices R-Max: Is not geometrically compliant Is not geometrically compliant Is intent compliant Is intent compliant Diaphragm Valves: Total compliance Total compliance Cost 65% more than R-Max Cost 65% more than R-Max ANSI/ISA compliant? But consider also... Surface Mount Technology Update 2003 Stream Switches n Double Block & Bleed Valves R-Max: Conically machined elastomer Conically machined elastomer Engages radiused seat Engages radiused seat More contact area More contact area Contaminant induced leakage risk lower Contaminant induced leakage risk lower Diaphragm Valves: Donut machined seat Donut machined seat Diaphragm seals on knife edge Diaphragm seals on knife edge Less contact area Less contact area Contaminant induced leakage risk higher Contaminant induced leakage risk higher Seat Geometry Comparison Surface Mount Technology Update 2003 Stream Switches n Option 2: Diaphragm Valve Manifold - Single diaphragm valve for stream valve for streamswitch - High integrity valve, but no safety net - Per stream cost 50% more than R-Max Surface Mount Technology Update 2003 Stream Switch Options n Conclusions: n Diaphragm valves inherently more expensive & ultra high purity roots drive cost up further n Stream cleanliness proportional to risk of cross contamination on single diaphragm valve manifold design n Choose wisely Relative Cost Comparisons Surface Mount Technology Update 2003 go n CEMS project at Dow/Freeport n Several conventional systems in service n Prototype NeSSI unit to evaluate for balance of project (18+ units) Relative Cost Comparisons Surface Mount Technology Update 2003 n As supplied NeSSI-1 prototype user cost was 50% higher than conventional Surface Mount Technology Update 2003 n Will NeSSI-1 functional savings outweigh procurement cost increase? Conv Gen1 Gen2 Gen3 Type of System System Cost Cost Comparison Questions Benefit Curve n AnswersProbably Not n Answers : Probably Not 50% n Can NeSSI-1 advantages over conventional systems carry further development for NeSSI-2 & 3? Beating the Paradox Surface Mount Technology Update 2003 n NeSSI-1: Chicken or the Egg? Benefit Curve 50% n What percent of analyzer sample systems are candidates for NeSSI-1 technology? n When will NeSSI-1 volumes approach conventional component volumes? Beating the Paradox: Reducing Cost / Increasing Value Surface Mount Technology Update 2003 n Reconfigured manual ball valve to eliminate higher cost diaphragm valves n 50% savings in manual applications Beating the Paradox: Reducing Cost / Increasing Value Surface Mount Technology Update 2003 n Zero-clearance fittings to simplify interconnects and function removal Beating the Paradox: Reducing Cost / Increasing Value Surface Mount Technology Update 2003 n Eliminate ultra-high-purity features from substrate block to reduce cost The Better We Reduce Cost & Increase Value... Surface Mount Technology Update 2003 The Better We Beat the Paradox! Surface Mount Technology Update 2003