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  • Specialty Gas Mixing
  • Gas Chromatography
  • Process Instrumentation
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University Schedule

  • March 14 - 16 Basic Gravimetric Mixture Filling
  • March 16 - 18 Basic Gas Chromatography
  • June 13 - 15 Advanced Gravimetric Mixture Filling
  • June 15 - 17 Advanced Gas Chromatography
  • September 12 - 14 Basic Gravimetric Mixture Filling
  • September 14 - 16 Basic Gas Chromatography

Intuitive Automated Specialty Gas Technology

The Sur-Fill iQ-s Automatic Specialty Gas Gravimetric Fill System puts automated technology at your fingertips. This easy to use system has touch screen technology that guides you through the specialty gas filling process, providing greater productivity and accuracy.

All four models (Inert, Oxidizer, Flammable, Reactive) include an isolation cabinet, scale, orbital manifold, and touch screen technology. Installation, start-up and training for each system is quick and easy.

Sur-Fill iQ-s is capable of producing mixtures (from up to 10 source gases) from percent down to ppm concentrations, and up to and including EPA Protocol gases. Our Sur-Fill iQ-s system is integrated with AsteRisk’s Specialty Gas Manager software program.

Features & Benefits

  • Unlimited number of recipes can be stored with up to 10 source gas supply stations
  • Intuitive HMI touch screen with self prompting features
  • Produces ultra-consistent mixtures
  • Is less dependent on operators’ actions for highly reliable mixtures
  • Uses significantly less labor to produce highly accurate mixtures
  • Runs unattended after the cylinders are connected and the mixture recipe is selected
  • Includes audio prompting throughout the process
  • Features remote monitoring capability and support
  • Includes a start up and power loss recovery validation mode
  • All components are orbital welded or VCR connections (Oxygen is socket weld Monel)
  • Valves are diaphragm type pneumatically actuated stainless steel (Oxygen is mechanically sealed Monel/brass)
  • Static or dynamic vacuum
  • Performs pigtail deflection test prior to producing each mixture
  • Remote operation and/or remote viewing keeps track of pressure and service cylinder contents
  • Integrated with AsteRisk’s Specialty Gas Manager software program:
    • – Generates recipes for complex mixtures (%, PPM, PPB)
    • – Automatically transfers to filling system software including pre-fill and post fill (vacuum, purge) procedures
    • – Produces DOT, FDA, OSHA AND CGA compliant cylinder labels
    • – Performs post fill component calculations (actual)
    • – Produces Certificates of Analysis
  • Each unit is shipped fully assembled and comes pre-tested

Choose from four different models; Inert, Flammable, Reactive or Oxidizer

Inert Model
  • Designed for inert gas service
  • Oxidizers are limited to 500 PSI
  • 580 and 590 CGA connections are used for USA units
Flammable Model
  • Designed for flammable and inert gas service
  • 580 and 350 CGA connections are used for USA units
  • The included Sartorius 150 kg x 0.1g gravimetric scale and 0-4000 PSIG pressure transmitter are rated (explosion proof) for this model
  • Features a purge assembly designed specifically for putting an inert gas purge into the electrical enclosure mounted on the cabinet to prevent the possibility of a fire hazard
  • Please note, with this model, the console must be located outside the rated room
Oxidizer Model
  • Designed for oxidizer and inert gas service
  • 580 and 590 CGA connections are used for USA units
  • All processed filling components such as valves, check valves, etc. are made out of either brass or monel
  • All process piping is made out of monel
  • Brass and/or monel is used due to its great compatibility with high pressure oxygen
Reactive/Corrosive Model
  • Designed for reactive/corrosive and inert gas service
  • 580, 350 and 660 CGA connections are used for USA units
  • The included Sartorius 150 kg x 0.1g Gravimetric Scale and 0-4000 PSIG pressure transmitter are rated (explosion proof) for this model
  • Features a purge assembly designed specifically for putting an inert gas purge into the electrical enclosure mounted on the cabinet to prevent the possibility of a fire hazard
  • The hood on this model has an extension on the sides of the cabinet, PVC curtain strips along the entire edge of the hood and a 10” vent port for an exhaust duct with fan to be connected to (duct and fan not included). All these design features ensure that any possible gas leaks are safely contained, directed and released through the duct above the hood.
  • Please note, with this model, the console must be located outside the rated room
  • iQs-2
  • iQs-3
  • iQs-1
  • iQs-4
  • iQs-5
Components common in every model
  • Up to (10) supply gases with double block & bleed
  • Max. service pressure 3045 PSIG MAWP
  • Pneumatic actuated diaphragm packless valves used for gas supplies, vent, vacuum and (3) fill valves utilizing critical orifices for varying flow requirements
  • Check Valve – 10 PSI cracking pressure with VCR end connections
  • 0-4000 PSIG pressure transmitter, 0.1% FSA
  • Pirani vacuum gauge with O-ring flange connection for micron readings
  • ¼” or 1/8” rigid stainless steel leads
  • Individual pneumatically operated cylinder isolation valves on leads
  • 6 or 10 cylinder 316 stainless steel orbital manifold
  • All units with CGA 580 fittings supplied for connecting to target cylinders
  • Powder coated, load centering base with stainless steel sartorius 150 kg x 0.1g high accuracy scale
  • Source gas cylinder storage rack built into base
  • Pneumatics filter/regulator and solenoid valves
  • Interconnection piping made of ” x 0.035” wall 316 stainless steel tubing (with the exception of the oxidizer model which used monel tubing instead)
    • – Where possible connections are orbitally welded with VCR end connections
  • Operator console with HMI touch screen, keyboard and mouse, printer and audible speaker
Safety features common in every model
  • All process piping has been hydrostatically tested to 5250 PSIG
  • The Swagelok pneumatic valves, and check valves have been cleaned by Swagelok per: ASTM G93, practice for cleaning methods and cleanliness levels for material and equipment used in oxygen-enriched environments
  • All piping components manufactured by Precision Specialty Gas Products (PSGP) have been cleaned for oxygen service per: PSGP oxygen cleaning procedure # PSMB-O2 CLEAN
  • Every morning, when logged into, the system performs an integrity check prior to starting the unit
  • Relief valves are installed for over pressure protection fill process. This is to check the entire system, making sure there are no leaks in the common piping.

Specialty Gas Manager

The latest version of AsteRisk’s Specialty Gas Manager Software is downloaded into every Sur-Fill iQ-s model. The Specialty Gas Manager assists your operations and sales personnel with

Mixture Recipes

It applies safe mixture making procedures, which have been developed from years of specialty gas mixture experience (vapor pressure limitation, BTU/ LEL limitation, compatibility, etc.). It recommends the CGA outlet, hydrotest frequency and eligibility for 10% overfill. It is also customizable to prohibit certain gases or conditions (fuel/oxidizer, etc.). PPM mixtures are automatically calculated using base (dilution) mixtures.

Post Fill Mixture Calculator

This utility assists you in calculating the concentration of the mixture from the actual grams added on the scale. The data is entered once and available to other modules (labels, recipe, etc.).

Mixture Label Generation
You select the gases in the mixture and the labels module prints a medical or industrial label with the following:
  • DOT shipping diamonds
  • CAS ID numbers
  • DOT proper shipping name
  • UN number
  • OSHA, DOT and FDA warnings
  • Your address, logos, etc.
Sales Quotation Tool

This module recommends a mixture price based on the gases in the mixture, technician labor, cylinder maintenance costs, materials costs, delivery costs, desired margin, etc. It facilitates a consistent pricing strategy, which protects your margin.

System Settings

The Specialty Gas Manager is highly configurable to your specific needs. Your preferences are entered into the system settings. Your company logo, fill procedures, units of measure, cylinder preferences, labor/gas cost assumptions, print preferences, etc. are easily entered and can be modified. In addition, system information including validation certificate, upgrade history, etc., is displayed.

Manual Gravimetric Fill Systems

Pre-engineered. Pre-assembled. Precise.

Our Manual Gravimetric Fill Systems for specialty gas have the technical options to be customized to meet you specialty gas filling needs. This manual system is designed to produce mixtures (from up to 17 source gases) from percent down to ppm concentrations. Each unit is pre-engineered and tested before it is delivered and installation is quick and easy.

Benefits of a Manual Gravimetric Fill System

  • Designed to produce mixtures with components from percent down to ppm concentrations from multiple source gases
  • Installation is quick and easy
  • Self-contained cabinet aids in reducing environmental influences to scale
  • Orbital fill head provides equal flow to each cylinder connected to the manifold
  • A digital vacuum compound gauge, digital high pressure gauge and digital micron meter are all included
  • Entire unit is pre-engineered, oxygen cleaned and pressure tested before it is delivered

Types

  • Oxidizer/inert gases
  • Inert (with limited Oxygen 500 psi or less)
  • Flammable/inert gases
    • – Flammable gases as defined by CFR-49. Gases that pose a hazard of ignition when combined with an oxidizer
  • Reactive/corrosive and inert gases
    • – For gases that may react due to other components due to their acidity or alkalinity

Blend Panels Process Types

  • For gases filled by high pressure pumps
    • – Requires master shut off valves
    • – 3/8 or 1/4” piping headers
    • Swing arm with CPV type connections
  • For gases filled from gas storage (banks or single cylinders)
    • – Uses diaphragm packless valves
    • – 1/4” piping headers
    • – VCR connections for most mechanical joints

WARNING: The PSGP Manual Gravimetric Fill Systems are not intended or designed for blending flammable and oxidizer gases together. These gases MUST be kept separate from any one Manual Gravimetric Fill System otherwise there is a potential for a flash or explosion. The concern is having residual hydrocarbons on valve seats and then having high-pressure oxygen passing through those valves.

Components in every system

  • Powder-coated, custom cabinet
  • Blend panel with swing arm for up to 9 supply gases
  • 6 or 12 cylinder orbital manifold with pigtails
  • Sartorius high accuracy scale
  • Max. service pressure 3500 PSIG MAWP
  • Digital pressure gauge for high pressure and a compound vacuum gauge
  • Pirani vacuum gauge for micron readings
  • Typical interconnection piping is orbitally welded with VCR end connections

Additional Options

  • Source gas cylinder storage rack
  • Micro-cylinder for producing ppm components
  • Swing arm for premix cylinders for making diluted mixtures

Safety features common in every model

  • All process piping has been hydrostatically tested to 5250 PSIG
  • All piping and components manufactured by Precision Specialty Gas Products (PSGP) have been cleaned for oxygen service per: PSGP oxygen cleaning procedure number PSMB-O2 CLEAN
  • Relief valves are installed for Over Pressure Protection fill process
  • Manual-1
  • Manual-2
  • Manual-3

Linear Fill/Prep Stations

Easy to use and quick to install.

The Vent and Evacuation System is used to prepare the cylinders for processing prior to going to the blend cell. Includes a control panel, linear manifold and vacuum pump system. It is delivered assembled and ready to go. Simply uncrate the unit, position it in place, anchor it to the floor and connected it to the existing plumbing.

Types Available:
  • Oxidizer/Inert Gases low concentrations of O2 below 21%
  • Inert Gases
  • Flammable/ Inert Gases
Features & Benefits

Our system is high integrity, with all welded construction and VCR or VCO connection points. This allows a lower ultimate vacuum to be reached which would result in high purity straight gas or more stable reactive gas mixture

  • Efficiently preps cylinders for blending
  • Leads are metal flex hoses with VCR fitting welded fittings
  • Durable, powder coated frame
  • Valves are provided for vent, purge and vacuum and static vacuum
  • Each unit is shipped assembled, oxygen cleaned and pressure tested
  • Linear-2