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Air Products Gasguard 250 Installation Manual

Valve manifold panel and valve manifold box systems
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Installation Manual
for the
Gasguard
250
®
Valve Manifold Panel and
Valve Manifold Box Systems
Commodity Number: 809-603649
Revision July 1998
Air Products and Chemicals, Inc.
1919 Vultee Street
Allentown, PA 18103

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Summary of Contents for Air Products Gasguard 250

  • Page 1 Installation Manual for the Gasguard ® Valve Manifold Panel and Valve Manifold Box Systems Commodity Number: 809-603649 Revision July 1998 Air Products and Chemicals, Inc. 1919 Vultee Street Allentown, PA 18103...
  • Page 2 Installation Manual Matrix Sheet for the Gasguard ® Valve Manifold Panel and Box Systems Commodity Number: 809-603649, Revision July 1998 Revision Reason for Manual Section Level Revision Cover and Front Change to Section 4 Introduction First issue Section 1: Safety Warnings Per SEMI S2-1993 and CE Mark Section 2: Dimensions and Mounting...
  • Page 4 Electrical Hazard Do not make any changes to the equipment independently. Injury or death may result from unauthorized modifications. If equipment needs to be modified, an Air Products' Representative MUST be contacted. Revision D: June 1997 Page i - i...
  • Page 5 Air Products Support Systems Emergency Response - 24 Hour Service If an emergency occurs that cannot be alleviated by the trained operator or his/her supervisor, call Air Products and Chemicals, Inc. on one of these telephone numbers. • From anywhere in the continental United States, Canada and Puerto Rico - 800-523-9374 (toll free) •...
  • Page 6 Introduction Technical Support - Normal Operation 08:00 to 17:00, except Friday 08:00 to 16:30 European Community Air Products and Chemicals, Inc. (32)-2-725.95.80 The Equipment Centre Leuvnesesteenweg 48C 1932 St.-Stevens-Woluwe Belgium (32) -2-725.97.80 Revision D: June 1997 Page i - iii...

  • Page 7: Table Of Contents

    4.4 External I/O Communication .................4-6 4.4.1 Gasguard 250 Controller..............4-6 4.5 PC and MMMS Gasguard Networks .............4-9 4.5.1 General Description ................4-9 4.5.2 Gasguard 250 Controller Connections..........4-10 4.5.3 PC Network Breakout Box .............4-10 4.5.4 PC Network Field Wiring ...............4-11 4.5.5 MMMS Network Wiring Configuration .........4-12 4.5.6 MMMS Network Interface Box ............4-13...
  • Page 8 Introduction Introduction This manual covers the tasks required to install the Gasguard 250 Valve Manifold Box. Because of unique installation variables from site to site, it is not intended as a step-by-step installation procedure, but relies on the knowledge of qualified personnel to perform the work properly.
  • Page 9 ® Gasguard 250 VMB System Installation Manual Air Products and Chemicals, Inc. Page i - 2...

  • Page 10: Section 1: Safety Warnings

    Section 1: Safety Warnings Section 1: Safety Warnings Please read the following safety warnings carefully before installing the equipment. 1.1 Introduction This section is meant to communicate to the user any hazards involved with the equipment. The following paragraphs will define the hazard warnings used and describe the icons found in various sections of the manual and on the equipment.
  • Page 11 1.1.2 Hazard Types (Symbols) This symbol is a safety alert symbol. This symbol represents asphyxiant, toxic or corrosive gases. Gases used with the Gasguard 250 can cause personal injury or death. This symbol can represent one or more of the following...

  • Page 12: Inert Gas Hazards

    Section 1: Safety Warnings This symbol represents electrical shock hazard. This symbol warns of potential strain or injury when lifting cylinders. This symbol warns of a pinch hazard. This hazard exists on cabinet doors equipped with automatic closers. This symbol warns of the possibility of the cabinet tipping over if it is not installed properly.
  • Page 13 When entering a confined area or area which may contain high inert gas concentrations, a "Buddy System" must be used. One person should remain Air Products and Chemicals, Inc. Page 1 - 4...

  • Page 14: Pressurized Fluids / Gases

    Section 1: Safety Warnings outside the suspect area, but within view of the other person. This method ensures that the other person can respond in the event of an emergency. 1.3 Pressurized Fluids / Gases Pressurized gas and water sprinkler lines can injure personnel and damage equipment.

  • Page 15: Falling Equipment Hazard

    Due to the top heavy nature of the system, if not installed properly, it could tip over, injuring, crushing or possibly killing personnel in the area. 1.6 Pinch Hazard A pinch hazard exists on cabinet doors equipped with automatic closers. Air Products and Chemicals, Inc. Page 1 - 6...

  • Page 16: Section 2: Dimensions And Mounting

    Section 2: Dimensions and Mounting 2.1 Outline Dimensions The Gasguard 250 Valve Manifold Boxes are typically mounted to a free-standing floor mounted rack. An alternate wall mounting method utilizes vertical unistrut attached to the rear of the enclosure. Figure 2.1 shows the outline dimensions for an eight branch valve manifold box with unistrut for wall mounting.
  • Page 17 ® Gasguard 250 VMB System Installation Manual Weight = 275 Pounds (124.43 Kilograms) Figure 2.1: Outline Dimensions for 8 Branch Valve Manifold Box with Vertical Unistrut Air Products and Chemicals, Inc. Page 2 - 2...
  • Page 18 Section 2: Dimensions and Mounting Weight = 405 Pounds (183.26 Kilograms) Figure 2.2: Outline Dimensions for 4 Branch Valve Manifold Box Mounted on a Free Standing Rack Revision B: May 1997 Page 2 - 3...

  • Page 19: Mounting Hole Locations

    250 VMB System Installation Manual 2.2 Mounting Hole Locations The Gasguard 250 Valve Manifold Box rack assembly is mounted to the floor using the four (4) 3/8" holes located in each corner of the rack. See Figure 2.3 for typical mounting hole locations for the 4 and 8 branch VMB racks. The mounting location should be clean and level.

  • Page 20: Section 3: Tubing Connections

    Section 3: Tubing Connections Section 3: Tubing Connections All tubing should be designed and installed following the local piping codes and the following: • ASME B31.3 "Chemical Plant and Petroleum Refinery Piping" • SEMC-005 "UHP Tubing and Fitting Specification" (found in the Appendix) Tubing must be sized to flow the maximum amount of gas required by the process system.
  • Page 21 Figure 3.1: Typical 4 Branch VMB Installation Connection Points NOTE: The above figure shows typical installation connection points. Reference the system drawings for the exact tubing connection locations for your system. Air Products and Chemicals, Inc. Page 3 - 2...

  • Page 22: Process Line Connection

    Section 3: Tubing Connections 3.2 Process Line Connection The process line connection is designed to use a 1/2" stainless steel outer jacket which can be attached to a coaxial tee supplied at the valve manifold box. This outer jacket is either pressurized with nitrogen at a pressure above that of the process line and monitored with a pressure switch, or purged with nitrogen into an exhaust system which contains gas detection devices.

  • Page 23: Vent Line

    Air Products and Chemicals, Inc. Page 3 - 4...
  • Page 24 Section 3: Tubing Connections When multiple gases are to be vented, ensure compatibility before plumbing vents together. Contact your Air Products Representative for this information. A nitrogen trickle purge is constantly bled into the vent line through the vacuum venturi assembly to maintain an inert atmosphere and prevent back diffusion through the vent system.

  • Page 25: Venturi Line

    Gasguard 250 VMB System Installation Manual 3.4 Venturi Line Air Products strongly recommends a separate venturi supply source rather than a houseline source. Most process cylinder pressures are significantly higher than houseline operating pressures. In the event of multiple failures of certain process panel components, there is a remote possibility of back contamination of the houseline source connected to the vacuum venturi.

  • Page 26: Pneumatic Supply

    Section 3: Tubing Connections 3.6 Pneumatic Supply A nitrogen (or compressed clean dry air) source is required for pneumatic valve operation. This nitrogen supply needs to be regulated to 75-95 psig (100 psig maximum allowable working pressure). The flow rate required for pneumatic valve operation is negligible.

  • Page 27: Enclosure Exhaust System Requirements

    If these steps are not followed, the controller must be purged by the times stated on the label attached to the controller. Figure 3.5: Rear View of Gasguard 250 Controller 3.7 Enclosure Exhaust System Requirements The VMB enclosure must be connected to an exhaust system that is capable of meeting the following criteria: 1.
  • Page 28 Section 3: Tubing Connections 3. In silane service, an air velocity of 200 feet per minute must be achieved across all unwelded fittings per UFC Article 80, Section 8004.1.18, 1994 edition. The table below lists the exhaust requirement for GG250 VMB Enclosures to meet the above requirements.

  • Page 29: Weld Shield Gas, Purge Gas Connection

    100 psig should be used on the high pressure inert gas supply. A safety relief device set at 150 psig should be installed downstream of the pressure regulator. Air Products and Chemicals, Inc. Page 3 - 10...

  • Page 30: Helium Leak Test Port

    Section 3: Tubing Connections 3.9 Helium Leak Test Port (Optional) An optional helium leak test port may be provided on the vent header for connection to a helium mass spectrometer. Two manual valves are included in the assembly; MV-31 isolates the helium leak test port, and MV-32 isolates the downstream vacuum venturi/vent system to achieve vacuums required for inboard leak testing upstream.

  • Page 31: Section 4: Electrical Connections

    Section 4: Electrical Connections Section 4: Electrical Connections All electrical connections must comply with Article 300 - Wiring Methods and Article 500 - Hazardous (Classified) Locations of the National Electric Code (NEC) 1993. Reference to the use of this equipment in Hazardous Locations only applies to installations located within the United States of America.

  • Page 32: Grounding Method

    Figure 4.1 shows a suggested grounding method for a typical system. This drawing may not be applicable to your specific system. Figure 4.1: Suggested Grounding Method Air Products and Chemicals, Inc. Page 4 - 2...

  • Page 33: Power Supply Connection

    VAC power supply to the GASGUARD™ 250 Controller. The conduit hole is located on the top of the controller enclosure. See Figure 4.2 below. Figure 4.2: View of Top of Gasguard 250 Controller Revision E: July 1998 Page 4 - 3...
  • Page 34 See Figure 4.3 for the location of the screw terminals. For additional detail on the power connection, see Figure 4.4. Figure 4.3: Inside View of GG250 Controller Figure 4.4: AC Power Connection Details Air Products and Chemicals, Inc. Page 4 - 4...

  • Page 35: Field Connections

    Section 4: Electrical Connections The power requirements are as follows: 120/240 VAC, 50/60 Hz, 1 phase Typical Load: 300 milliamperes @ 120 volts AC 150 milliamperes @ 240 volts AC Overcurrent protection: Recommended Sizing: 25% (minimum) over required load (add all cabinet loads and divide by 0.75) Internally fused: 1.5 amps...

  • Page 36: External I/O Communication

    Figure 4.5: Conduit and Conduit Seals 4.4 External I/O Communication 4.4.1 Gasguard 250 Controller Connections between the GG250 controller and external I/O devices are made at the main I/O board (digital inputs) and the relay output board (digital outputs). See Figure 4.3.
  • Page 37 Section 4: Electrical Connections Recommended External I/O Communications Digital Outputs Response Gas unavailable Notify process tool that gas is Branches A-D unavailable (also E-H on dual controllers) Digital Inputs Response Vent system unavailable Prevent purge modes from starting. Branch Shutdown (Process tool down) Prevent branch from flowing process Branches A-D (also E-H on dual controllers)
  • Page 38 + 24 V Ground Digital Input # Terminal #7 Terminal #7 + 24 V Ground Digital Input # Terminal #11 Terminal #11 + 24 V Ground Digital Input # Aux. Terminal Aux. Terminal Air Products and Chemicals, Inc. Page 4 - 8...

  • Page 39: Pc And Mmms Gasguard Networks

    Section 4: Electrical Connections 4.5 PC and MMMS Gasguard Networks 4.5.1 General Description The Gasguard Networks provide continuous on-line 24 hour per day monitoring of the status of all connected Gasguard Cabinets and VMBs. Figure 4.6 shows the required daisy-chain network wiring configuration between the GG controllers and the network host computer.

  • Page 40: Gasguard 250 Controller Connections

    If the optional network communications card is installed, electrical connections to the Air Products Gasguard network will be made at the master control processor board (T6) on the inside of the controller door. See Figures 4.7 and 4.9 for details.

  • Page 41: Pc Network Field Wiring

    Section 4: Electrical Connections Figure 4.8 PC Network Break-Out Box 4.5.4 PC Network Field Wiring Figure 4.9 shows the PC network field wiring between GG250 cabinets/VMBs and the host PC. Figure 4.10 shows the field wiring between Span LR300 displays and the host PC.

  • Page 42: Mmms Network Wiring Configuration

    AT ONE END ONLY Figure 4.10: Network Field Wiring Between Span LR300 and Host PC 4.5.5 MMMS Network Wiring Configuration Figure 4.11 shows the MMMS Gasguard Network Wiring Configuration. Figure 4.11: MMMS Network Interface Air Products and Chemicals, Inc. Page 4 - 12...

  • Page 43: Mmms Network Interface Box

    Section 4: Electrical Connections 4.5.6 MMMS Network Interface Box The MMMS Network Interface Box consists of a rack enclosure which contains a RS232 communications processor and a bank of RS-485 converter boards. The cabling which connects to the cabinet and VMB controllers is terminated to the rear of the RS-485 converter rack via screw terminals.
  • Page 44 Gasguard 250 VMB System Installation Manual Figure 4.12: Network Field Wiring Between Cabinets/VMBs and MMMS GG250 Interface Box Figure 4.13: Network Field Wiring Between SPAN LR300 and MMMS GG250 Interface Box Air Products and Chemicals, Inc. Page 4 - 14...

  • Page 45: Section 5: Helium Leak Testing

    These valves can be manually opened and closed through "Manual Mode" operation on the front keypad of the controller. Air Products strongly recommends that anyone who has not already done so, receive operations training by an Air Products representative prior to operating the GG250 Valve Manifold Box in "Manual Mode".
  • Page 46 VMB at this time. If one is or was connected, do not continue, as personal injury or death can result. Contact an Air Products and Chemicals representative for system verification. NOTE: Due to the potential hazards listed above, Manual Mode operation requires a second or higher level security code.
  • Page 47 Air Products representative for system verification prior to leak testing 1. Enter second or higher level security code (if not known, contact your appropriate Air Products representative for second level password) as follows: Press The LCD screen will prompt: "PASSWORD"...
  • Page 48 Type the number of the valve you wish to close. Press The valve will close. Extreme care must be taken when operating valves manually. Only those valves required for adequate leak testing should be opened. Air Products and Chemicals, Inc. Page 5 - 4...
  • Page 49 Section 5: Helium Leak Testing 7. When leak testing is complete, press to return to the Cabinet Configuration menu. NOTE: Any valves left in open position will be closed automatically. 8. Press to return to the main menu. 9. From the Main Menu screen, press to return to normal display.
  • Page 50 ® Gasguard 250 VMB System Installation Manual Air Products and Chemicals, Inc. Page 5 - 6...

  • Page 51: Section 6: Valve Manifold Box Functional Checklist

    The functional check is an additional service provided for a cost. The cost of this service may have been pre-arranged during the sale and scope review of the project. Contact your Air Products Representative to discuss this. ®...
  • Page 52 11. Pneumatic supply connected to controller and 75-95 psig of nitrogen available (see Section 3.6). 12. Valve manifold box internal piping helium leak tested (see Section 5). 13. Purge cylinder available, if required. 14. Hazardous gas monitor installed and operating. Air Products and Chemicals, Inc. Page 6 - 2...
  • Page 53 Section 6: VMB Functional Checklist Inspection Sign-Offs Electrical Mechanical Quality Safety APCI (Field Start-Up Checklist Complete) Revision A: July 1995 Page 6 - 3...
  • Page 54 ® Gasguard 250 VMB System Installation Manual AIR PRODUCTS VALVE MANIFOLD BOX FIELD START-UP CHECKLIST page 1 of 6 CUSTOMER __________________VMB # _____________ SERIAL #___________ DEVICE DESCRIPTION __________________________________MODEL# _____________ GAS TYPE ___________________START DATE ___________ FINISH DATE ________ TOOL NAME ____________________ TECH REP _________________________________...
  • Page 55 Section 6: VMB Functional Checklist AIR PRODUCTS VALVE MANIFOLD BOX FIELD START-UP CHECKLIST page 2 of 6 ELECTRICAL Check off line item when completed Sign and date when section is completed Branch A-D Left Branch E-H Right Earth ground installed...
  • Page 56 ® Gasguard 250 VMB System Installation Manual AIR PRODUCTS VALVE MANIFOLD BOX FIELD START-UP CHECKLIST page 3 of 6 CALIBRATION Verify analog scaling (psig) with program documentation Transducers must be powered up a minimum of 15 minutes. Zero and span should be checked a minimum of...
  • Page 57 Section 6: VMB Functional Checklist FUNCTIONAL TEST - RELAY OUTPUTS Check off line item when completed Sign and date when section is completed Branch A-D Branch E-H Relay outputs (digital outputs) tested Relay # 1 Relay # 2 Relay # 3 Relay # 4 Relay # 5 Relay # 6...
  • Page 58 ® Gasguard 250 VMB System Installation Manual AIR PRODUCTS VALVE MANIFOLD BOX FIELD START-UP CHECKLIST page 5 of 6 FUNCTIONAL TEST- PROGRAM MODES Check off line item when completed Sign and date when section is completed VMB Programs Branch A-D Left...
  • Page 59 Section 6: VMB Functional Checklist AIR PRODUCTS VALVE MANIFOLD BOX FIELD START-UP CHECKLIST page 6 of 6 __________________________________________________ Comments _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ ___________________________________________________ I have received and understood training on the operation of this valve manifold box on the date given below.
  • Page 60 ® Gasguard 250 VMB System Installation Manual Air Products and Chemicals, Inc. Page 6 - 10...

  • Page 61: Appendix

    Appendix Appendix The Appendix contains the SEMC-QAF030 "UHP Tubing and Fitting Specification" and the system specific drawings referenced in this manual. Revision B: May 1997 Page A - 1...
  • Page 62 ASTM A479 - Specification for general requirements for carbon, ferritic alloy, and austenitic alloy steel bar. ASTM A632 - Specification for seamless and welded austenitic stainless steel tubing (small diameter for general service). Air Products and Chemicals, Inc. Page A - 2...
  • Page 63 Appendix ANSI/ASME B46.1 - 1985 - Specification for surface texture-surface roughness, waviness, and lay. Procedure: General Requirements 6.1.1 All tube and bar stock shall be produced from ASTM grade TP316L raw material unless specified in the purchase order. Tubing sized smaller than 3" shall be seamless and larger than 3"...
  • Page 64 Final cleaning of tubing shall be performed under Class 100 clean room conditions. Tube washing shall utilize heated DI water (60 o C, minimum). The tube shall 6.5.3 be flushed with heated DI water until the resistivity of the effluent measures Air Products and Chemicals, Inc. Page A - 4...
  • Page 65 Appendix at least 17.5 Megohm-cm for diameters less than 3 inches and 17.0 megohm-cm for diameters greater than or equal to 3 inches. 6.5.4 The tube shall be blown dry with heated nitrogen gas Fittings Cleaning 6.6.1 Final cleaning of fittings shall be performed under Class 100 environment. Fittings shall be flushed with heated DI water ( 60 o C) minimum.
  • Page 66 A Rockwell hardness test shall be performed on each mill heat of material to assure a Rockwell Rb 90 maximum hardness. This test shall be performed for each size after "pulling". Air Products and Chemicals, Inc. Page A - 6...
  • Page 67 Appendix 6.8.12 APCI reserves the right to source inspect all tubing and fittings and inspect the manufacturers facilities upon request. Reports and Certifications: 6.9.1 The vendor shall supply the following reports and certifications as follows: 6.9.1.1 One set of reports shall be sent to SEMC QA prior to receipt of material at SEMC.
  • Page 68 ® Gasguard 250 VMB System Installation Manual Air Products and Chemicals, Inc. Page A - 8...

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