One of the most essential components of a fluid based industrial system is valves, they are very helpful in controlling and regulation of pressure, the valves also performs a variety of functions. According to the usage of manifold valves, it comes with various kinds of configurations. This valves works perfectly in various kinds of industry and serves different purposes.In some specific conditions, two or more kinds of requirements need to be fulfilled. This is the main point which necessitates the use of two or more valves at a single location in the system. But the challenge is that this may be inefficient because it would take double space. This problem can be solved by configuring a manifold valve.
A manifold valve is an hydraulic which combines a single or more isolate valves which is usually a ball valves, and also has one or more vent valves, which is usually needle or ball valves into a single component for interface with other kinds of components of the hydraulic systems. The main purpose of this manifold is to isolate the flow of fluid in the system so that the fluid which is coming from the upper part of the manifold would not reach other components which are downstream. They would then bleed off or vent the remaining fluid from the system on the downstream part of the manifold. For instance, a manifold valve can be used to stop the flow of fluids to some of the components and then vent the fluid from the part of the manifold so as to effect some kind of work during the replacement or maintenance of the component.
Where are manifolds used?
Manifolds are mainly used in several fluid power applications based on the need in the component. Manifold valve can be used in pneumatics as well as hydraulics, and can also be used to consolidate plumbing or mount valves. When they are used for mounting valves, they would serve as an interface between the valves and the ports which is to be plumbed into.
With the use of industrial type of hydraulic valves like ISO valves which is mounted on 30MN or 50MN patterns, for instance, the terminals of the valves will have plain ports which have O-rings around it, and plumbing it into an hydraulic system won’t be possible. The manifold can either be a block or a series of adjoining blocks with an interface where the valve can be attached to, ports for the fluid to travel and therefore can be plugged to the rest of the circuit. The passage of the pressure can also be parallel to the pressure port of the valve, or in series thereby creating a link between the tanks to the pressure port of the previous valves.
Manifold mounted systems are used by pneumatic valves which can be specific by the manufacturer or ISO standards. Just like the hydraulic valves, a small single blocks which are joined together and have a directional valves which is mounted to the manifolds. The manifold valves will have a common pressure ports which will feed the DCV’s, as well as the return ports which are combined into the manifold and exhaust the air in most cases.
The major benefit of manifold mounted valve system is in the standard of the valves, modularity; easily exchangeable iterations can be mounted to a manifold so as to customize the circuit as well as its number of actuators. In addition to that, a standard valves series can also be attached to manifolds with the aid of any kind of port like NPT, Metric or ORB, instead of producing every valve with a different port, saving the cost of manufacturing as well as inventory costs.
The manifolds can also be used separately; in addition to that, the manifold can be divided into different chambers with two or more ports which are joined in series so as to reduce the plumbing. For instance, a return line manifold which has six smaller ports which is joined to a big tank will help in saving the need for a series of ports which are connected together, this will however help in the reduction of cost and the occurrence of leakage would be reduced. A manifold valve can also be used once in a while in a pressure lines, improving the appearance as well as cleaning up plumbing work.
Manifold valve also serves as an essential part of the transmitter because most of the DP transmitter would either have a single block or bleed manifold, 5-valve manifold or the 3-valve manifold based on the kind of application. The manifold valve can be used for the isolation of the DP transmitter which is used in maintenance process and calibration or to prevent the over-usage of the DP transmitter.
This is a kind of device will include three manual valves which can be used to isolate and also equalize pressure during the process of transmission. It comprises of two different block valves which are the low pressure and the high pressure as well as equalizing valve. When operating under normal condition, the low and high pressure will be opened while the equalizing valve is closed. Whenever the transmitter is placed or removed from service, you have to operate the valve so that the high pressure would not be applied to only one part of the DP transmission capsule.
1. Ensure you check the entire valves and ensure they are closed properly.
2. Make sure the equalizing valve is open so as to ensure the same quantity of pressure will be applied to the two sides of the transmitter and this would result to a balanced differential pressure
3. Ensure the valve is opened gently and check if there is any leakage from the two sides i.e. the side of the transmitter where we have low and high pressure.
4. Close the equalizing valve so as to locks the pressure on the two sides of the transmitter.
5. Open the block valve with low pressure in order to apply pressure which is processed to the low pressure side of the transmitter; this will also help in establishing the differential pressure.
The transmitter is now in use and after removing it from service, it may be essential to blend air which is trapped from the DP transmitter capsule housing.
When Removing The 3-Valve Manifold from Service:
You can remove the transmitter from service with the aid of the step which are outlined below:
You won’t be using the transmitter once it has been removed from service, however the transmitter capsule which serves as house will still contains the process pressure and such will result to bleeding.
When it is operating normally, those that will be open are the low pressure and high pressure valves while the bleed valve and equalizing valve will be in closed position. It is however essential to close the equalizing valve(s) while you open the block valves. But if the fluid which is processed is radioactive or dangerously hot, the combination of block valves and open equalizing will allow the dangerous fluid to reach the manifold and transmitter which might lead to a personal hazard or damage.
1. Check the entire high pressure, low pressure, the bleed valve and the equalizing valves are in closed position.
2. Open the equalizing valves, this will ensure that the same pressure will be applied to the two sides of the transmitter thereby leading to zero differential pressure.
3. Open the block valve with high pressure gently so that you can check for any leakage from the high and low pressure side of the transmitter.
4. The equalizing valve should be closed so that the pressure on both side of the transmitter will be locked.
5. Open the block valve with low pressure so as to apply process pressure to the side of the transmitter with low pressure and also establish the working differential pressure. The transmitter is now in service.
Any DP transmitter which has a 5-Valve manifold can be removed easily by adhering to the step below:
After doing this, the transmitter will be out of service, but in most cases the housing of the transmitter capsule will contains process pressure which will require bleeding.
Note that the 3-valve and 5-valve transmitter manifold are mostly manufactured as a monolithic or single units.
The transmitter valve manifold likewise come in a single block and bleed configuration. In this case, the transmitter would be used for gauging pressure applications. In this scenario, the low pressure port of the transmitter is vented into the atmosphere with only the high pressure port connected to the process medium with the aid of an impulse lines.
It is very easy to remove DP transmitter, all you need to do is close the block valve and then open the bleed valve so as to vent the process pressure into the atmosphere. The DP transmitter is already out of service.
It can also be placed easily into the operation, however you need to ensure that both block and bleed valves are initially closed. Then the block valve as well as the transmitter can be placed back to service.
A manifold valve can be used in various kinds of applications which may include mobile machineries to heavy industrial equipment which are used in oil and gas industries. Whenever it is included in a fluid control regulation system, the presence of valve manifold has shown an increase in efficiency as well as reduction in the energy costs. Other benefits which can be derived include the following:
A shorter path flows which helps in the reduction of pressure drop and heat fluctuations, thereby improving the overall energy efficiency of the system.
A reduced installation costs as well as fluid connections due to the nature of the design which is simpler and more compact.
Minimal chances of oil leak due to fewer numbers of connections which aids in the reductions of the need for lose joints, wear as well as fatigue.
An improvement in the layout due to the less hoses and connections
A small and compact design cartridge sizes which is perfect for a confined spaces
In most of the manifold design, the solenoid valve plays an essential role in the function of the changeover. So as for the manifold to retain a bank of compressed or liquefied gas in reserve, the solenoid valve has to be in close position and must be intact as well. When it’s time for the reserve bank to become the bank or service in use, the solenoid valve must be in open position.
The valve must be designed in such a way that:
It is compatible with different kinds of services
Have enough orifices so as to provide a perfect flow which will automatically open if there is an outage of power, it will continue to operate
In case of a failure of some other components to regulate or maintain a normal operating pressure, it will open and provide a life sustaining medical gases.
Whenever we design our manifold valves, we ensure that the solenoid valve is included as a critical component. We also ensure that the design has a general acceptance and wide usage and we can also provide a custom design which will meet the standard of the user. These valves have several benefits over other ones in terms of higher flow rate, durability, as well as the differential pressure rating.