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Checklist for Excellence in NeSSI Surface Mount Components
CPAC Fall 2006 Sponsors Meeting NeSSI Workshop Thursday, November 9, 2007 Dave Simko John Wawrowski © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Components of excellence
Design Manufacture Assembly Performance Reliability End-user satisfaction © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Design Establish reliability goals Maintain adequate specifications
Minimize or eliminate dead legs Consider service conditions Cleanliness Utilize proven concepts Ease of Maintenance Build Redundancy Establish reliability goals appropriate for intended use The NeSSI Specifications Intrinsic safety Cleanliness Environmental requirements Impact of Clean Air Act and Clean Water Act Fugitive emissions Maintain adequate specifications following established standards ISA, ANSI/ASME, ASTM, IEEE, BSA, DIN, JIS, EN, in general ANSI/ISA , specifically Certified by UL, ATEX, etc. Minimize or eliminate dead legs Consider service conditions and apply adequate safety factors Cleanliness requirements Avoid entrapment areas Consider the impact of adsorption, absorption, chemisorption, and outgassing Consider surface finiash, surface treatments, and coatings Utilize proven concepts Avoid novel concepts that must be learned before the component can applied Go simple and elegant; not complex Ease of maintenance Establish diagnostic routines Identify potential failure points and determine remedies Make spare parts easily available Design for easy replacement of failed parts Simplify replacement, ideally on-line, plug-and-play Build redundancy into the design Back up seals (secondary sealing systems) with vents between Back seat sealing in needle valves Overpressure protection Bypass filters xx © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Manufacture Materials Machining Quality control Materials Metals
Polymers Elastomers Machining Tooling Surface finish Tolerances xx Quality control Inspection and SPC Proof testing © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Assembly Easy component and/or subassembly replacement
Intuitive disassembly and replacement No special tools © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Performance Leak-free Meet service conditions Cycle life
Contamination tolerant Vibration resistant Leak-free Inboard and outboard Internal (cross contamination) Simple on-line leak testing Meet service conditions with liberal performance margins Consider environmental extremes Functional within normal and abnormal operating conditions Cycle life Maximize based upon application requirements Isolate – once per maintenance cycle Calibrate – once per shift Operate – twelve times per hour Contamination tolerant Resist hard contaminants in the fluid stream Resist entrained gas bubbles Avoid formation of internal contamination Vibration resistant Robust xx © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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Reliability Structural Operational Safety Small components
Large components Operational Mechanical Electrical Functional Safety Structural Small components Built by machining small holes in a block of material Larger than necessary safety factors with respect to burst Catastrophic failures are rare Large components Built by placing material around holes (castings, near net shape forgings) Carefully designed safety factors Catastrophic failure is a serious concern Operational Small component failures are performance failures Mechanical Static seal leakage (inboard, outboard) Dynamic seal leakage, sliding and rotating (inboard, outboard) Seat leakage (internal, cross contamination) Thread failures Plugging Electrical Electrical sensors are inherently stable Infant failures – very short term Wear out failures – long term Functional Does not perform its intended function Operates outside of the required range Cannot be calibrated properly Safety OSHA – Process Safety Management EPA – VOC’s and Fugitive Emissions © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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End-User Satisfaction
Increased Uptime Efficiency Mean time to failure Safety Accuracy Decreased Failure rate Maintenance Overall operating cost Cycle time © 2006 Swagelok Company. Swagelok confidential. For internal use only.
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© 2006 Swagelok Company. Swagelok confidential. For internal use only.
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