Sample systems for the future

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Sample systems for the future

• IndiaChem 2002
• Delhi

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Sample systems cause maximum problems
inInstrumentation Systems
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Why ?

• Your instruments may analyse in ppm , but ..
• Do they have a clean sample to analyse ?
• This will depend upon the capability to deliver a
  clean sample to the instrument

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Critical factor

• Select use clean components that
• Do not trap residue from one sample
• Contaminate the next

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Clean sample design

• Eliminate entrapment areas
• Incorporate clean sweep radii at bends
• Surfaces are highly finished and electropolished
  if need be

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On-line process analysers need

• Proper extraction
• Collection
• conditioning

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Traditional design

• Select all the components that meet functional
  requirements
• Assemble them in unique fashion
• Such that the conditioning occurs repeatedly and
  reliably
• This permits max flexibility

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It is normally necessary to

• Monitor control
• Pressure
• Temperature
• Flow
• Remove particulate matter to avoid contamination
  or damage

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It may be necessary to monitor control other
variables
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Issues with the traditional approach

• Internal volume area is large
• Many dead areas
• Difficult to optimize

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Hence modular systems

• The roots are in complex air logic systems

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Integrated Gas Components

• Integrated gas component (IGC) systems are based
  upon the concept of joining together a group of
  substrate blocks to create unique flow paths that
  are consistent with the requirements of a
  specific system

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Integrated Gas Components

• A minimal number of IGC components
  upstream/downstream, isolation, manifold control,
  elbow, and spacer support a wide array of
  system designs.
• Substrates are connected to create a unique flow
  path for the process gas.

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Integrated Gas Components

• Manifold bases provide the flow path between two
  or more parallel gas streams.

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Integrated Gas Components

• Individual Functional components (valves,
  regulators, sensors and filters) are surface
  mounted to individual substrates to create the
  desired system.

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Integrated Gas Components

• A complete gas system can consist of multiple gas
  streams

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IGC VsConventional , multistream gas panel
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IGC vs Conventional

• Reduces manufacturing time
• Reduces footprint by 43
• Reduces internal wetted surface by 38
• Eliminates 87 of the welds

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Second Generation IGC II

• Reduces the weight price
• Makes it simpler to build and design

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IGC - II

• The new concept consists of a series of miniature
  welded substrates, each having the necessary flow
  path for a specific functional component, all
  contained in a substrate support channel.

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IGC II

• The functional components of the system are
  assembled by surface mounting in the same manner
  as they are with current IGC technology.
  Substrate support channels can be attached to
  manifold support channels to accommodate multiple
  gas streams.

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IGC II the process

• Substrates manufactured by welding selected
  miniature weld fittings, creating a required flow
  path.
• Manufacturing costs greatly reduced - no need to
  machine the complex substrate configurations
• Weld fittings- tees and elbows - simple
  variations of standard industry components.Hence
  economies of scale
• Automatic orbital welding for full-penetration
  butt-welds, which join the weld fittings
  together.

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IGC II the process

• Welded substrate components assembled into an
  aluminum substrate support channel.
• Each rests on a bearing plate within the channel.
• Using aluminum for the substrate and manifold
  channel supports reduces the weight cost
  substantially.
• (VIM-VAR) stainless steel used only for wetted
  parts
• The support channels can be manufactured in
  different lengths to accommodate the appropriate
  number of functional components.

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IGC II - Easier to design and build

• The flow paths in the substrates are clearly
  defined and easy to select.
• Its easy to envision the arrangement of those
  substrates in the substrate support channel and
  keep them consistent with the functional
  requirements of the system being designed.
• The flow path is also easier to understand.
• Its easier for technicians to assemble

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IGC II vs IGC - benefits

• 20 reduction in the weight of the assembly
• Est. 40 to 50 reduction in the cost of the
  substrate components.
• Eliminate the need for special bolts to build an
  assembly
• The number of face seals, each a potential leak
  point if not properly made, is also reduced.

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IGC II - testing

•  Max/Min Seal Compression Test
• Spring Back Seal Test
• Off-center Sealing
•   Adjacent Drop-down Sealing
•   Thread Pull Testing
•   Weld Shrinkage Test
•   Thermal Expansion Test
•   Corrosion Test

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Conclusion

• The use of the new igc-II concept should allow
  designers to design sample systems that
• are more compact and lighter weight
•   easier to purge and keep clean
•   have less internal volume and wetted surface
  area
•   are more cost effective.

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Thank you