Air Manifolds

Precision-Engineered Air Header Manifolds by Samvay Fluid Tekniks Inc.

 

Optimize your plant’s compressed air distribution with Samvay Fluid Tekniks Inc.‘s premium range of Air Header Manifolds. Designed to centralize pneumatic connections and eliminate multiple leak points, our manifolds ensure a steady, clean, and reliable supply of instrument air to your critical control devices, valves, positioners, and transmitters across any industrial facility.


Product Overview

An Air Header Manifold serves as the central distribution hub for instrument air systems. Instead of running individual lines from the main compressor to each device, the manifold consolidates connections onto a single forged or seamless pipe body with multiple outlet ports, each typically equipped with an isolation valve.

This engineering approach offers significant advantages over traditional field-fabricated piping:

ParameterTraditional Field PipingSamvay Pre-Assembled Manifold
Installation Time2-3 days2-3 hours
Leak Points20-30 threaded connections2-4 connections
Labor CostHigh (skilled fitters)Low (simple mounting)
Space RequiredExtensiveCompact
Future ExpansionDifficult, costlySimple (blanked ports)
AppearanceCluttered, unprofessionalNeat, organized
Quality ControlSite-dependentFactory tested

Primary Functions:

  1. Distribution: Central point for instrument air supply to multiple devices
  2. Isolation: Individual valves allow maintenance without system shutdown
  3. Organization: Neat, professional layout in control rooms and panels
  4. Future-Proofing: Blanked ports for easy addition of new instruments
  5. Pressure Regulation: Optional integral regulators for zone control

Our manifolds are custom-built to your exact specifications, ensuring perfect integration with your process layout and P&ID requirements.


Key Features & Benefits

FeatureTechnical BenefitOperational Benefit
Custom ConfigurationsBuilt to your P&ID, not off-the-shelf compromisesPerfect fit every time
Pre-Assembled & Tested100% pressure tested before dispatchReduced site installation time and cost
Individual Outlet IsolationBall or needle valves on each outletMaintain or add instruments without system shutdown
Compact FootprintSpace-efficient design for crowded panelsMore instruments in less space
Full Material TraceabilityEN 10204 3.1 certificationComplete documentation for quality audits
Multiple Pressure RatingsFrom 150 PSI to 6000 PSIOne source for all applications
Wide Temperature Range-54°C to +232°CSuitable for any environment
Mounting FlexibilityWall, panel, or free-standingAdapts to your facility layout
Future Expansion PortsBlanked and capped outletsEasy addition of new instruments
Identification TagsStainless steel tags on each outletClear labeling, reduced errors

Technical Specifications

SpecificationDetails
Material of ConstructionAISI 304/L, 316/L Stainless Steel; Carbon Steel (A105), Duplex, Super Duplex, Monel, Inconel on request
Inlet Connection1/2″ to 4″ NPT / BSP / Flanged (ASME 150# to 2500#) / Socket Weld / Butt Weld
Outlet Connections1/4″, 3/8″, 1/2″, 3/4″, 1″, 1-1/4″, 1-1/2″, 2″ NPT / BSP Female
Maximum Operating PressureStandard: 300 PSI (20 Bar); Medium-pressure: 3000 PSI (207 Bar); High-pressure: up to 6000 PSI (414 Bar)
Operating Temperature-54°C to +232°C (standard); -196°C to +800°C (cryogenic/high-temp on request)
Number of OutletsCustomizable: 2 to 40 outlets (even numbers typical, odd available)
Outlet SpacingStandard: 40mm / 1.5″; Custom: 30mm to 100mm as required
Valve OptionsBall valves (on/off), Needle valves (throttling), Blanking plugs, Check valves
Valve MaterialsSS316 barstock body, PTFE seats, Viton®/FKM seals
Valve Pressure Rating3000 PSI (standard), 6000 PSI (high-pressure)
Mounting OptionsWall-mount brackets, panel-mount flanges, free-standing base plates, DIN rail mount
Body ConstructionBarstock (solid), Pipe & weld (fabricated), Forged (compact)
Surface FinishAs-machined, pickled, passivated, electropolished, painted
CleanlinessOil-free assembly for instrument air; Oxygen cleaning available
IdentificationStainless steel tag with P/N, pressure rating, material, customer tag number
DocumentationIFC drawings, MTC, pressure test reports, NDT reports

Complete Product Range

By Valve Type:

Manifold TypeValve DescriptionBest ForPressure Rating
Ball Valve ManifoldQuarter-turn on/off isolation, full portQuick shut-off, high cycle life, minimal pressure drop3000-6000 PSI
Needle Valve ManifoldMulti-turn throttling control, fine adjustmentPrecise flow adjustment, metering applications3000-6000 PSI
No-Valve ManifoldBlanked ports only, customer adds valvesFuture expansion, customer preferenceN/A
Mixed Valve ManifoldCombination of ball and needle valvesMulti-function requirements, different services3000 PSI
Check Valve ManifoldIntegral check valves on outletsPreventing backflow, critical applications3000 PSI
Regulator ManifoldPressure regulators on selected outletsZone pressure control, different pressure requirements300 PSI

By End Connection Type:

Connection TypeStandardSize RangePressure RatingApplication
Threaded (NPT)ASME B1.20.11/8″ to 2″Up to 3000 PSIGeneral purpose, easy installation
Threaded (BSP)ISO 2281/8″ to 2″Up to 3000 PSIEuropean/Asian markets
Socket WeldASME B16.111/8″ to 2″Up to 6000 PSIHigh-pressure, permanent installations
Butt WeldASME B16.91/2″ to 4″Up to 6000 PSI+Severe service, high temperature
Flanged (ASME)ASME B16.51/2″ to 4″150# to 2500#Large manifolds, frequent dismantling
Flanged (DIN)EN 1092DN15 to DN100PN16 to PN400European projects
Flanged (JIS)JIS B222015A to 100A10K to 40KJapanese/Asian projects
Tube Fitting EndsVarious1/4″ to 1″Up to 3000 PSIDirect tube connection

By Body Construction:

ConstructionDescriptionSize RangeAdvantagesTypical Application
BarstockMachined from solid bar1/2″ to 2″Highest strength, no welds, compactHigh-pressure, critical service
Pipe & WeldFabricated from pipe with welded outlets2″ to 4″Cost-effective, large sizesGeneral purpose, instrument air
ForgedForged body with threaded outlets1/2″ to 1″Compact, high-pressure capabilityLimited space, high pressure
ModularInterconnected blocksVariousExpandable, flexibleControl panels, frequent changes

By Mounting Configuration:

Mounting TypeDescriptionBest For
Wall MountBrackets for vertical surface mountingPlant areas, compressor rooms
Panel MountFlanges for cutout mountingControl panels, analyzer houses
Free-StandingBase plate or legs for floor mountingLarge manifolds, dedicated areas
DIN RailClip-on mounting for standard railsElectrical/control cabinets
Pipe StandClamp mounting on vertical/horizontal pipesSpace-limited areas

By Number of Outlets:

Outlet CountTypical Inlet SizeCommon Applications
2-4 outlets1/2″ or 3/4″Small panels, local control stations
6-8 outlets3/4″ or 1″Analyzer houses, equipment skids
10-12 outlets1″ or 1-1/4″DCS panels, control rooms
14-20 outlets1-1/2″ or 2″Large control rooms, plant areas
20-40 outlets2″ or largerMain plant distribution, multiple zones

By Special Features:

FeatureDescriptionApplication
Drain ValvesBottom drain for moisture removalWet air systems, outdoor installations
Pressure GaugesIntegral gauge on inlet or outletsMonitoring local pressure
RegulatorsPressure reducing on selected outletsDifferent pressure requirements
FiltersIntegral filter elementsCritical instrument protection
Check ValvesPrevents backflowSensitive instruments
Quick DisconnectsTool-free outlet connectionsFrequent changes
Color CodingAnodized or painted outletsService identification
Heating/TracingElectric or steam tracingFreeze protection

Material Specifications

Stainless Steel Grades:

GradeChemical CompositionMechanical PropertiesApplications
SS304/L18% Cr, 8% Ni, Low CTensile: 515 MPa, Yield: 205 MPaGeneral purpose, food, water
SS316/L16% Cr, 10% Ni, 2% MoTensile: 515 MPa, Yield: 205 MPaChemical, marine, pharmaceutical
SS32117% Cr, 9% Ni, Ti stabilizedTensile: 515 MPa, Yield: 205 MPaHigh temperature, welding
SS34717% Cr, 9% Ni, Cb stabilizedTensile: 515 MPa, Yield: 205 MPaHigh temperature, nuclear
Duplex 220522% Cr, 5% Ni, 3% MoTensile: 620 MPa, Yield: 450 MPaOffshore, high chloride, sour service
Super Duplex 250725% Cr, 7% Ni, 4% MoTensile: 795 MPa, Yield: 550 MPaExtreme corrosion, subsea

Carbon Steel Grades:

GradeChemical CompositionMechanical PropertiesApplications
A105C-Mn steelTensile: 485 MPa, Yield: 250 MPaGeneral purpose, non-corrosive
A106 Gr BC-Mn steel seamlessTensile: 415 MPa, Yield: 240 MPaPiping, high temperature
A350 LF2Low temp carbon steelTensile: 485 MPa, Yield: 250 MPaLow temperature, -50°F

Nickel Alloys:

GradeDescriptionApplications
Monel 400Ni-Cu alloyHydrofluoric acid, seawater, marine
Inconel 600Ni-Cr alloyHigh temperature, oxidizing conditions
Inconel 625Ni-Cr-Mo alloyExtreme corrosion, high temperature
Hastelloy C276Ni-Cr-Mo alloyExtreme chemical resistance
Titanium Gr2Commercially pureAerospace, medical, extreme corrosion

Quality & Compliance

Design & Engineering:

Quality ParameterStandard / Test
Design CodeASME B31.3 (Process Piping)
Pressure DesignASME B16.34 (Valve Design)
Wall ThicknessASME B36.10 / B36.19
Flange DesignASME B16.5 / B16.47
Thread StandardsASME B1.20.1 (NPT), ISO 228 (BSP)
Socket Weld DimensionsASME B16.11
Butt Weld DimensionsASME B16.9

Material Quality:

ParameterStandard / Test
Raw Material SourcingPrime mills with ISO 9001 certification
Material CertificationEN 10204 3.1 Mill Test Certificate
Chemical CompositionSpectro analysis verification
Mechanical PropertiesTensile, yield, elongation testing
Hardness TestingBrinell or Rockwell
PMI TestingPositive Material Identification on all alloys

Welding Quality:

ParameterStandard / Test
Visual Inspection100% of all welds
Dye Penetrant Test (DPT)Optional on critical welds
Radiography (RT)Optional on pressure retaining welds
Ultrasonic Test (UT)Optional on thick sections
Hydrostatic Test1.5x design pressure for 30 minutes minimum
Pneumatic Test1.1x design pressure (when specified)

Cleanliness & Surface:

ParameterStandard / Test
Standard CleanlinessOil-free, debris-free for instrument air
Industrial CleaningDegreased, washed, dried
Oxygen CleaningCGA G-4.1 (for oxygen service)
Surface FinishAs-welded, pickled, or electropolished
PassivationASTM A967 for stainless steel
PicklingRemoval of heat tint and scale

Testing & Inspection:

Test TypeMethodAcceptance Criteria
Hydrostatic TestWater at 1.5x design pressureNo leakage, no permanent deformation
Pneumatic TestAir or nitrogen at 1.1x design pressureNo leakage (soap bubble test)
Dye Penetrant TestVisible or fluorescent dyeNo indications per ASME V
RadiographyX-ray or Gamma rayASME VIII UW-51 or UW-52
Ultrasonic TestThickness gaugingPer specification
Hardness TestBrinell or RockwellWithin material spec
Dimensional InspectionCalibrated instrumentsPer drawing tolerances

Certifications & Compliance:

CertificationApplicability
ISO 9001:2015Quality management system
EN 10204 3.1Material traceability
ASME B31.3Process piping design
NACE MR0175 / ISO 15156Sour service (oil & gas)
NACE MR0103Sour service (refining)
EAC / TR CUEurasian customs union

Installation Guidelines

Mounting Recommendations:

Wall Mounting:

  • Use appropriate anchors for wall material
  • Ensure manifold is level (use bubble level)
  • Leave minimum 6″ clearance above/below for valve operation
  • Provide adequate lighting for valve identification

Panel Mounting:

  • Cutout dimensions per drawing
  • Support heavy manifolds from back
  • Label outlets clearly on panel face
  • Consider access for valve operation

Free-Standing:

  • Secure base to floor with anchors
  • Ensure vertical alignment
  • Provide vibration isolation if needed
  • Allow access from all sides

Valve Operation:

Valve TypeOperationMaintenance
Ball Valve1/4 turn open/close, do not leave partially openCycle monthly to prevent sticking
Needle ValveMulti-turn for precise control, do not overtightenLubricate stem annually

Common Mistakes to Avoid:

MistakeConsequencePrevention
Oversized manifold for flowPressure drop, insufficient airCalculate total flow requirement
Undersized inletStarvation of end outletsInlet at least 2x sum of outlets
No isolation valvesCan’t maintain without shutdownSpecify valves on all outlets
Poor labelingOperator errorsStainless steel tags on all outlets
Inadequate supportVibration, stress on connectionsSupport at both ends
Wrong materialCorrosion failureVerify chemical compatibility

Sizing Guidelines

Selection Guide by Application:

ApplicationRecommended ConfigurationMaterialPressure Class
Control Room Panels8-12 outlets, ball valves, panel mountSS304300 PSI
Analyzer Houses6-10 outlets, needle valves, wall mountSS316L3000 PSI
Offshore Platforms10-20 outlets, ball valves, SS tagsSuper Duplex3000 PSI, NACE
Compressor Stations4-8 outlets, no valves, pipe mountCS or SS300 PSI
High-Pressure Test Stands2-6 outlets, needle valves, barstockSS3166000 PSI
Food Processing6-12 outlets, ball valves, electropolishedSS316L300 PSI, FDA
Pharmaceutical8-16 outlets, sanitary valvesSS316L, electropolished150 PSI, USP
Mining10-20 outlets, ball valves, ruggedSS304300 PSI

Global Export Destinations

Samvay Air Header Manifolds are trusted by engineers worldwide. We export regularly to:

North America:

CountryKey IndustriesPorts of Entry
USAOil & Gas, Power, Chemical, PharmaHouston, New York, Los Angeles
CanadaOil Sands, Power, MiningVancouver, Montreal, Toronto
MexicoOil & Gas, AutomotiveVeracruz, Manzanillo

Europe:

CountryKey IndustriesPorts of Entry
United KingdomOil & Gas, PharmaceuticalFelixstowe, Southampton
GermanyChemical, AutomotiveHamburg, Bremerhaven
FranceOil & Gas, NuclearLe Havre, Marseille
ItalyOil & Gas, ManufacturingGenoa, Naples
NetherlandsChemical, RefiningRotterdam
NorwayOil & Gas, MarineOslo, Bergen
RussiaOil & Gas, PowerSt. Petersburg

Middle East:

CountryKey IndustriesPorts of Entry
UAEOil & Gas, PetrochemicalJebel Ali
Saudi ArabiaOil & Gas, PetrochemicalDammam, Jeddah
QatarOil & Gas, LNGDoha, Mesaieed
KuwaitOil & GasShuwaikh
OmanOil & GasSohar

Asia Pacific:

CountryKey IndustriesPorts of Entry
SingaporeOil & Gas, MarineSingapore Port
MalaysiaOil & Gas, ElectronicsPort Klang
IndonesiaOil & Gas, MiningJakarta
ThailandAutomotive, ChemicalLaem Chabang
South KoreaShipbuilding, ChemicalBusan
JapanOil & Gas, ManufacturingTokyo, Yokohama
AustraliaMining, LNGPerth, Sydney

Africa:

CountryKey IndustriesPorts of Entry
South AfricaMining, PowerDurban
NigeriaOil & GasLagos
EgyptOil & Gas, PetrochemicalAlexandria
AlgeriaOil & GasAlgiers

Industry Applications

Oil & Gas – Upstream:

ApplicationManifold TypeMaterialSpecial Requirements
Wellhead Control Panels6-12 outlets, needle valvesSS316NACE MR0175, 6000 PSI
Offshore Platforms10-20 outlets, ball valvesSuper DuplexSaltwater resistance, compact
FPSO Vessels8-16 outlets, mixed valvesDuplexMarine approvals
Gas Plants12-24 outlets, ball valvesSS316Low temp, -50°C

Oil & Gas – Downstream:

ApplicationManifold TypeMaterialSpecial Requirements
Refineries8-20 outlets, ball/needleSS316Fire-safe valves, high temp
Petrochemical Plants10-24 outlets, mixedSS316/LChemical resistance
LNG Facilities6-16 outlets, extended bonnetSS316Cryogenic service

Power Generation:

ApplicationManifold TypeMaterialSpecial Requirements
Thermal Power Plants8-20 outlets, ball valvesSS304/CSHigh temp, vibration resistant
Nuclear Power4-12 outlets, special valvesSS316/LSeismic qualified, nuclear grade
Gas Turbine Plants6-16 outlets, needle valvesSS316High pressure, 3000 PSI
Hydroelectric4-10 outlets, ball valvesSS304Outdoor, weatherproof

Chemical & Petrochemical:

ApplicationManifold TypeMaterialSpecial Requirements
Control Rooms12-24 outlets, ball valvesSS304Organized, labeled
Analyzer Houses6-12 outlets, needle valvesSS316LZero dead volume
Batch Processing8-16 outlets, mix valvesSS316Quick disconnect options
Pilot Plants4-8 outlets, modularSS316Flexible, reconfigurable

Water & Wastewater:

ApplicationManifold TypeMaterialSpecial Requirements
Treatment Plants8-16 outlets, ball valvesSS304NSF/ANSI 61, UV resistant
Desalination10-20 outlets, ball valvesDuplexHigh chloride resistance
Pumping Stations4-12 outlets, no valvesSS304/CSOutdoor, weatherproof
Filter Controls6-12 outlets, solenoid readySS304Panel mount

Food & Beverage:

ApplicationManifold TypeMaterialSpecial Requirements
Processing Lines8-16 outlets, ball valvesSS316LElectropolished, FDA seals
Packaging Areas12-24 outlets, quick disconnectSS304Washdown capable
CIP Systems4-10 outlets, special valvesSS316LHigh temp, chemical resistant
Breweries/Dairies6-12 outlets, sanitarySS316L3A standards, crevice-free

Pharmaceutical:

ApplicationManifold TypeMaterialSpecial Requirements
Cleanrooms8-16 outlets, panel mountSS316LElectropolished, Ra <0.4μm
WFI Systems4-10 outlets, sanitarySS316LUSP Class VI, drainable
Bioreactors6-12 outlets, needle valvesSS316LSIP/CIP capable
Tableting Areas10-20 outlets, compactSS304Oil-free, particle-free

Customization Options

At Samvay, we understand that every application is unique. Our manifolds can be customized with:

Material Options:

  • Standard: SS304, SS316/L, Carbon Steel
  • Premium: Duplex, Super Duplex, 6% Mo
  • Exotic: Monel, Inconel, Hastelloy, Titanium
  • Lined: PTFE-lined for corrosive services

Valve Options:

  • Manufacturers: Samvay, or customer-specified brands
  • Types: Ball, needle, check, plug, diaphragm
  • Special: Fire-safe, low emission, oxygen service
  • Actuation: Manual, pneumatic, electric

Connection Options:

  • Inlet: Any combination of thread, weld, flange
  • Outlets: Mixed sizes on same manifold
  • Special: Tube fittings, compression, push-in

Finishing Options:

  • Standard: As-machined, pickled
  • Premium: Passivated, electropolished
  • Special: Painted (customer color), coated

Documentation Options:

  • Standard: MTC, pressure test report
  • Premium: NDT reports, welding maps
  • Comprehensive: IFC drawings, calculation notes, O&M manual

Special Features:

  • Heating: Electric heat tracing, steam jacketing
  • Insulation: Pre-insulated with cladding
  • Instrumentation: Pressure gauges, switches, transmitters
  • Tagging: Stainless steel tags, laser etched labels
  • Mounting: Custom brackets, seismic rated

Standard Dimensions & Weights

Barstock Manifolds (SS316):

Inlet SizeOutlet SizeOutletsLength (mm)Width (mm)Height (mm)Weight (kg)
1/2″1/4″420050752.5
1/2″1/4″628050753.5
3/4″1/4″836060905.0
1″1/4″10440701007.0
1″3/8″12520701008.5
1-1/4″1/2″84408012010.0

Pipe & Weld Manifolds (SS304):

Inlet SizeOutlet SizeOutletsLength (mm)Body Pipe ODWeight (kg)
1-1/2″1/2″660048.3 mm8.0
2″1/2″880060.3 mm12.0
2″3/4″10100060.3 mm15.0
3″1/2″12120088.9 mm22.0
3″3/4″16160088.9 mm28.0
4″1″121400114.3 mm35.0

Why Choose Samvay Fluid Tekniks Inc.?

1. Engineering Excellence:

  • Design Support: We review your P&ID and recommend optimal configurations
  • Custom Solutions: 100% built to your specifications, not off-the-shelf compromises
  • Application Expertise: Decades of combined experience across all industries
  • Value Engineering: We optimize designs for performance and cost

2. Quality Assurance:

  • 100% Testing: Every manifold pressure tested before dispatch
  • Full Traceability: Complete material documentation
  • Cleanliness: Oil-free assembly for instrument air applications
  • NDT Options: DPT, RT, UT available on request

3. Competitive Pricing:

  • Direct Manufacturer: No middlemen, factory-direct pricing
  • Volume Discounts: Tiered pricing for bulk orders
  • Annual Contracts: Long-term pricing agreements available
  • Freight Optimization: Consolidated shipping for cost savings

4. Quick Turnaround:

Order TypeDesign TimeFabricationShipping
Standard Configurations1-2 days5-7 daysAs per mode
Custom Engineered3-5 days10-14 daysAs per mode
Complex Systems5-7 days14-21 daysAs per mode

5. Global Experience:

  • Thousands Supplied: Manifolds in service worldwide
  • International Standards: Familiar with all major codes
  • Multi-Lingual Support: English, Hindi, Arabic, Spanish
  • Time Zone Coverage: Support across global business hours

6. After-Sales Support:

  • Technical Assistance: Installation guidance, troubleshooting
  • Documentation: Complete O&M manuals, drawings
  • Spare Parts: Readily available for all components
  • Warranty: Comprehensive coverage against defects

Ordering Information

How to Specify Your Manifold:

  1. Inlet Connection: Size, type (NPT/BSP/flanged), pressure class
  2. Outlet Connections: Size, type, quantity, spacing
  3. Valve Type: Ball, needle, none, or mixed
  4. Material: SS304, SS316, CS, Duplex, etc.
  5. Pressure Rating: Maximum operating pressure
  6. Temperature: Minimum and maximum
  7. Mounting: Wall, panel, free-standing
  8. Special Requirements: NACE, PED, oxygen cleaning, etc.
  9. Documentation: Required certificates and reports
  10. Quantity: Number of manifolds

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