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:

Parameter Traditional Field Piping Samvay Pre-Assembled Manifold
Installation Time 2-3 days 2-3 hours
Leak Points 20-30 threaded connections 2-4 connections
Labor Cost High (skilled fitters) Low (simple mounting)
Space Required Extensive Compact
Future Expansion Difficult, costly Simple (blanked ports)
Appearance Cluttered, unprofessional Neat, organized
Quality Control Site-dependent Factory 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

Feature Technical Benefit Operational Benefit
Custom Configurations Built to your P&ID, not off-the-shelf compromises Perfect fit every time
Pre-Assembled & Tested 100% pressure tested before dispatch Reduced site installation time and cost
Individual Outlet Isolation Ball or needle valves on each outlet Maintain or add instruments without system shutdown
Compact Footprint Space-efficient design for crowded panels More instruments in less space
Full Material Traceability EN 10204 3.1 certification Complete documentation for quality audits
Multiple Pressure Ratings From 150 PSI to 6000 PSI One source for all applications
Wide Temperature Range -54°C to +232°C Suitable for any environment
Mounting Flexibility Wall, panel, or free-standing Adapts to your facility layout
Future Expansion Ports Blanked and capped outlets Easy addition of new instruments
Identification Tags Stainless steel tags on each outlet Clear labeling, reduced errors

Technical Specifications

Specification Details
Material of Construction AISI 304/L, 316/L Stainless Steel; Carbon Steel (A105), Duplex, Super Duplex, Monel, Inconel on request
Inlet Connection 1/2″ to 4″ NPT / BSP / Flanged (ASME 150# to 2500#) / Socket Weld / Butt Weld
Outlet Connections 1/4″, 3/8″, 1/2″, 3/4″, 1″, 1-1/4″, 1-1/2″, 2″ NPT / BSP Female
Maximum Operating Pressure Standard: 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 Outlets Customizable: 2 to 40 outlets (even numbers typical, odd available)
Outlet Spacing Standard: 40mm / 1.5″; Custom: 30mm to 100mm as required
Valve Options Ball valves (on/off), Needle valves (throttling), Blanking plugs, Check valves
Valve Materials SS316 barstock body, PTFE seats, Viton®/FKM seals
Valve Pressure Rating 3000 PSI (standard), 6000 PSI (high-pressure)
Mounting Options Wall-mount brackets, panel-mount flanges, free-standing base plates, DIN rail mount
Body Construction Barstock (solid), Pipe & weld (fabricated), Forged (compact)
Surface Finish As-machined, pickled, passivated, electropolished, painted
Cleanliness Oil-free assembly for instrument air; Oxygen cleaning available
Identification Stainless steel tag with P/N, pressure rating, material, customer tag number
Documentation IFC drawings, MTC, pressure test reports, NDT reports

Complete Product Range

By Valve Type:

Manifold Type Valve Description Best For Pressure Rating
Ball Valve Manifold Quarter-turn on/off isolation, full port Quick shut-off, high cycle life, minimal pressure drop 3000-6000 PSI
Needle Valve Manifold Multi-turn throttling control, fine adjustment Precise flow adjustment, metering applications 3000-6000 PSI
No-Valve Manifold Blanked ports only, customer adds valves Future expansion, customer preference N/A
Mixed Valve Manifold Combination of ball and needle valves Multi-function requirements, different services 3000 PSI
Check Valve Manifold Integral check valves on outlets Preventing backflow, critical applications 3000 PSI
Regulator Manifold Pressure regulators on selected outlets Zone pressure control, different pressure requirements 300 PSI

By End Connection Type:

Connection Type Standard Size Range Pressure Rating Application
Threaded (NPT) ASME B1.20.1 1/8″ to 2″ Up to 3000 PSI General purpose, easy installation
Threaded (BSP) ISO 228 1/8″ to 2″ Up to 3000 PSI European/Asian markets
Socket Weld ASME B16.11 1/8″ to 2″ Up to 6000 PSI High-pressure, permanent installations
Butt Weld ASME B16.9 1/2″ to 4″ Up to 6000 PSI+ Severe service, high temperature
Flanged (ASME) ASME B16.5 1/2″ to 4″ 150# to 2500# Large manifolds, frequent dismantling
Flanged (DIN) EN 1092 DN15 to DN100 PN16 to PN400 European projects
Flanged (JIS) JIS B2220 15A to 100A 10K to 40K Japanese/Asian projects
Tube Fitting Ends Various 1/4″ to 1″ Up to 3000 PSI Direct tube connection

By Body Construction:

Construction Description Size Range Advantages Typical Application
Barstock Machined from solid bar 1/2″ to 2″ Highest strength, no welds, compact High-pressure, critical service
Pipe & Weld Fabricated from pipe with welded outlets 2″ to 4″ Cost-effective, large sizes General purpose, instrument air
Forged Forged body with threaded outlets 1/2″ to 1″ Compact, high-pressure capability Limited space, high pressure
Modular Interconnected blocks Various Expandable, flexible Control panels, frequent changes

By Mounting Configuration:

Mounting Type Description Best For
Wall Mount Brackets for vertical surface mounting Plant areas, compressor rooms
Panel Mount Flanges for cutout mounting Control panels, analyzer houses
Free-Standing Base plate or legs for floor mounting Large manifolds, dedicated areas
DIN Rail Clip-on mounting for standard rails Electrical/control cabinets
Pipe Stand Clamp mounting on vertical/horizontal pipes Space-limited areas

By Number of Outlets:

Outlet Count Typical Inlet Size Common Applications
2-4 outlets 1/2″ or 3/4″ Small panels, local control stations
6-8 outlets 3/4″ or 1″ Analyzer houses, equipment skids
10-12 outlets 1″ or 1-1/4″ DCS panels, control rooms
14-20 outlets 1-1/2″ or 2″ Large control rooms, plant areas
20-40 outlets 2″ or larger Main plant distribution, multiple zones

By Special Features:

Feature Description Application
Drain Valves Bottom drain for moisture removal Wet air systems, outdoor installations
Pressure Gauges Integral gauge on inlet or outlets Monitoring local pressure
Regulators Pressure reducing on selected outlets Different pressure requirements
Filters Integral filter elements Critical instrument protection
Check Valves Prevents backflow Sensitive instruments
Quick Disconnects Tool-free outlet connections Frequent changes
Color Coding Anodized or painted outlets Service identification
Heating/Tracing Electric or steam tracing Freeze protection

Material Specifications

Stainless Steel Grades:

Grade Chemical Composition Mechanical Properties Applications
SS304/L 18% Cr, 8% Ni, Low C Tensile: 515 MPa, Yield: 205 MPa General purpose, food, water
SS316/L 16% Cr, 10% Ni, 2% Mo Tensile: 515 MPa, Yield: 205 MPa Chemical, marine, pharmaceutical
SS321 17% Cr, 9% Ni, Ti stabilized Tensile: 515 MPa, Yield: 205 MPa High temperature, welding
SS347 17% Cr, 9% Ni, Cb stabilized Tensile: 515 MPa, Yield: 205 MPa High temperature, nuclear
Duplex 2205 22% Cr, 5% Ni, 3% Mo Tensile: 620 MPa, Yield: 450 MPa Offshore, high chloride, sour service
Super Duplex 2507 25% Cr, 7% Ni, 4% Mo Tensile: 795 MPa, Yield: 550 MPa Extreme corrosion, subsea

Carbon Steel Grades:

Grade Chemical Composition Mechanical Properties Applications
A105 C-Mn steel Tensile: 485 MPa, Yield: 250 MPa General purpose, non-corrosive
A106 Gr B C-Mn steel seamless Tensile: 415 MPa, Yield: 240 MPa Piping, high temperature
A350 LF2 Low temp carbon steel Tensile: 485 MPa, Yield: 250 MPa Low temperature, -50°F

Nickel Alloys:

Grade Description Applications
Monel 400 Ni-Cu alloy Hydrofluoric acid, seawater, marine
Inconel 600 Ni-Cr alloy High temperature, oxidizing conditions
Inconel 625 Ni-Cr-Mo alloy Extreme corrosion, high temperature
Hastelloy C276 Ni-Cr-Mo alloy Extreme chemical resistance
Titanium Gr2 Commercially pure Aerospace, medical, extreme corrosion

Quality & Compliance

Design & Engineering:

Quality Parameter Standard / Test
Design Code ASME B31.3 (Process Piping)
Pressure Design ASME B16.34 (Valve Design)
Wall Thickness ASME B36.10 / B36.19
Flange Design ASME B16.5 / B16.47
Thread Standards ASME B1.20.1 (NPT), ISO 228 (BSP)
Socket Weld Dimensions ASME B16.11
Butt Weld Dimensions ASME B16.9

Material Quality:

Parameter Standard / Test
Raw Material Sourcing Prime mills with ISO 9001 certification
Material Certification EN 10204 3.1 Mill Test Certificate
Chemical Composition Spectro analysis verification
Mechanical Properties Tensile, yield, elongation testing
Hardness Testing Brinell or Rockwell
PMI Testing Positive Material Identification on all alloys

Welding Quality:

Parameter Standard / Test
Visual Inspection 100% 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 Test 1.5x design pressure for 30 minutes minimum
Pneumatic Test 1.1x design pressure (when specified)

Cleanliness & Surface:

Parameter Standard / Test
Standard Cleanliness Oil-free, debris-free for instrument air
Industrial Cleaning Degreased, washed, dried
Oxygen Cleaning CGA G-4.1 (for oxygen service)
Surface Finish As-welded, pickled, or electropolished
Passivation ASTM A967 for stainless steel
Pickling Removal of heat tint and scale

Testing & Inspection:

Test Type Method Acceptance Criteria
Hydrostatic Test Water at 1.5x design pressure No leakage, no permanent deformation
Pneumatic Test Air or nitrogen at 1.1x design pressure No leakage (soap bubble test)
Dye Penetrant Test Visible or fluorescent dye No indications per ASME V
Radiography X-ray or Gamma ray ASME VIII UW-51 or UW-52
Ultrasonic Test Thickness gauging Per specification
Hardness Test Brinell or Rockwell Within material spec
Dimensional Inspection Calibrated instruments Per drawing tolerances

Certifications & Compliance:

Certification Applicability
ISO 9001:2015 Quality management system
EN 10204 3.1 Material traceability
ASME B31.3 Process piping design
NACE MR0175 / ISO 15156 Sour service (oil & gas)
NACE MR0103 Sour service (refining)
EAC / TR CU Eurasian 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 Type Operation Maintenance
Ball Valve 1/4 turn open/close, do not leave partially open Cycle monthly to prevent sticking
Needle Valve Multi-turn for precise control, do not overtighten Lubricate stem annually

Common Mistakes to Avoid:

Mistake Consequence Prevention
Oversized manifold for flow Pressure drop, insufficient air Calculate total flow requirement
Undersized inlet Starvation of end outlets Inlet at least 2x sum of outlets
No isolation valves Can’t maintain without shutdown Specify valves on all outlets
Poor labeling Operator errors Stainless steel tags on all outlets
Inadequate support Vibration, stress on connections Support at both ends
Wrong material Corrosion failure Verify chemical compatibility

Sizing Guidelines

Selection Guide by Application:

Application Recommended Configuration Material Pressure Class
Control Room Panels 8-12 outlets, ball valves, panel mount SS304 300 PSI
Analyzer Houses 6-10 outlets, needle valves, wall mount SS316L 3000 PSI
Offshore Platforms 10-20 outlets, ball valves, SS tags Super Duplex 3000 PSI, NACE
Compressor Stations 4-8 outlets, no valves, pipe mount CS or SS 300 PSI
High-Pressure Test Stands 2-6 outlets, needle valves, barstock SS316 6000 PSI
Food Processing 6-12 outlets, ball valves, electropolished SS316L 300 PSI, FDA
Pharmaceutical 8-16 outlets, sanitary valves SS316L, electropolished 150 PSI, USP
Mining 10-20 outlets, ball valves, rugged SS304 300 PSI

Global Export Destinations

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

North America:

Country Key Industries Ports of Entry
USA Oil & Gas, Power, Chemical, Pharma Houston, New York, Los Angeles
Canada Oil Sands, Power, Mining Vancouver, Montreal, Toronto
Mexico Oil & Gas, Automotive Veracruz, Manzanillo

Europe:

Country Key Industries Ports of Entry
United Kingdom Oil & Gas, Pharmaceutical Felixstowe, Southampton
Germany Chemical, Automotive Hamburg, Bremerhaven
France Oil & Gas, Nuclear Le Havre, Marseille
Italy Oil & Gas, Manufacturing Genoa, Naples
Netherlands Chemical, Refining Rotterdam
Norway Oil & Gas, Marine Oslo, Bergen
Russia Oil & Gas, Power St. Petersburg

Middle East:

Country Key Industries Ports of Entry
UAE Oil & Gas, Petrochemical Jebel Ali
Saudi Arabia Oil & Gas, Petrochemical Dammam, Jeddah
Qatar Oil & Gas, LNG Doha, Mesaieed
Kuwait Oil & Gas Shuwaikh
Oman Oil & Gas Sohar

Asia Pacific:

Country Key Industries Ports of Entry
Singapore Oil & Gas, Marine Singapore Port
Malaysia Oil & Gas, Electronics Port Klang
Indonesia Oil & Gas, Mining Jakarta
Thailand Automotive, Chemical Laem Chabang
South Korea Shipbuilding, Chemical Busan
Japan Oil & Gas, Manufacturing Tokyo, Yokohama
Australia Mining, LNG Perth, Sydney

Africa:

Country Key Industries Ports of Entry
South Africa Mining, Power Durban
Nigeria Oil & Gas Lagos
Egypt Oil & Gas, Petrochemical Alexandria
Algeria Oil & Gas Algiers

Industry Applications

Oil & Gas – Upstream:

Application Manifold Type Material Special Requirements
Wellhead Control Panels 6-12 outlets, needle valves SS316 NACE MR0175, 6000 PSI
Offshore Platforms 10-20 outlets, ball valves Super Duplex Saltwater resistance, compact
FPSO Vessels 8-16 outlets, mixed valves Duplex Marine approvals
Gas Plants 12-24 outlets, ball valves SS316 Low temp, -50°C

Oil & Gas – Downstream:

Application Manifold Type Material Special Requirements
Refineries 8-20 outlets, ball/needle SS316 Fire-safe valves, high temp
Petrochemical Plants 10-24 outlets, mixed SS316/L Chemical resistance
LNG Facilities 6-16 outlets, extended bonnet SS316 Cryogenic service

Power Generation:

Application Manifold Type Material Special Requirements
Thermal Power Plants 8-20 outlets, ball valves SS304/CS High temp, vibration resistant
Nuclear Power 4-12 outlets, special valves SS316/L Seismic qualified, nuclear grade
Gas Turbine Plants 6-16 outlets, needle valves SS316 High pressure, 3000 PSI
Hydroelectric 4-10 outlets, ball valves SS304 Outdoor, weatherproof

Chemical & Petrochemical:

Application Manifold Type Material Special Requirements
Control Rooms 12-24 outlets, ball valves SS304 Organized, labeled
Analyzer Houses 6-12 outlets, needle valves SS316L Zero dead volume
Batch Processing 8-16 outlets, mix valves SS316 Quick disconnect options
Pilot Plants 4-8 outlets, modular SS316 Flexible, reconfigurable

Water & Wastewater:

Application Manifold Type Material Special Requirements
Treatment Plants 8-16 outlets, ball valves SS304 NSF/ANSI 61, UV resistant
Desalination 10-20 outlets, ball valves Duplex High chloride resistance
Pumping Stations 4-12 outlets, no valves SS304/CS Outdoor, weatherproof
Filter Controls 6-12 outlets, solenoid ready SS304 Panel mount

Food & Beverage:

Application Manifold Type Material Special Requirements
Processing Lines 8-16 outlets, ball valves SS316L Electropolished, FDA seals
Packaging Areas 12-24 outlets, quick disconnect SS304 Washdown capable
CIP Systems 4-10 outlets, special valves SS316L High temp, chemical resistant
Breweries/Dairies 6-12 outlets, sanitary SS316L 3A standards, crevice-free

Pharmaceutical:

Application Manifold Type Material Special Requirements
Cleanrooms 8-16 outlets, panel mount SS316L Electropolished, Ra <0.4μm
WFI Systems 4-10 outlets, sanitary SS316L USP Class VI, drainable
Bioreactors 6-12 outlets, needle valves SS316L SIP/CIP capable
Tableting Areas 10-20 outlets, compact SS304 Oil-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 Size Outlet Size Outlets Length (mm) Width (mm) Height (mm) Weight (kg)
1/2″ 1/4″ 4 200 50 75 2.5
1/2″ 1/4″ 6 280 50 75 3.5
3/4″ 1/4″ 8 360 60 90 5.0
1″ 1/4″ 10 440 70 100 7.0
1″ 3/8″ 12 520 70 100 8.5
1-1/4″ 1/2″ 8 440 80 120 10.0

Pipe & Weld Manifolds (SS304):

Inlet Size Outlet Size Outlets Length (mm) Body Pipe OD Weight (kg)
1-1/2″ 1/2″ 6 600 48.3 mm 8.0
2″ 1/2″ 8 800 60.3 mm 12.0
2″ 3/4″ 10 1000 60.3 mm 15.0
3″ 1/2″ 12 1200 88.9 mm 22.0
3″ 3/4″ 16 1600 88.9 mm 28.0
4″ 1″ 12 1400 114.3 mm 35.0

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 Type Design Time Fabrication Shipping
Standard Configurations 1-2 days 5-7 days As per mode
Custom Engineered 3-5 days 10-14 days As per mode
Complex Systems 5-7 days 14-21 days As 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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