Fabricating High Specification Industrial Gas Manifolds for Corrosive Gasses

Industrial gas manifolds are a simple way to supply the gas to the process from multiple sources or transfer it from a high-pressure gas source to the larger distribution system within a laboratory or industrial facility. These manifolds are usually seen as a part of a source inlet where it is connected to multiple numbers of valves and hoses and regulated by a pressure control system. Given the manifold is always in contact with the fluid, its quality and metallurgical properties should be of prime importance during the selection process. 

If reactive or corrosive chemical impurities are present in the gaseous mixture, the gas distribution system at your facility will likely face issues such as leaks and failure. The effect can be exponential at junctions such as the manifolds. Therefore, you will need ultra-high purity and corrosion-resistant industrial gas manifolds for corrosive gases so your operation can run efficiently. 

Industrial Gas Manifolds for Corrosive Gases

Industry experts are aware of the dangers of corrosive gases to new and existing pipelines as well as to production and research facilities. In fact, internal corrosion has been listed as one of the major causes of deterioration for gas transmission and distribution systems with causes being contaminants like carbon dioxide, hydrogen sulfide, nitrogen, moisture, or other reactive chemicals. Manifolds, as a connecting agent to different production and distribution lines, are prone to the negative effects of corrosive gases.

Manifolds have a hollow body with ports that connect to multiple valves and hoses. The highly pressurized gas from one or multiple source cylinders flows through the hose to the manifold where it has direct contact with the metal. When a manifold made of metal such as lower-quality carbon steel grade comes in contact with corrosive gaseous contaminants, it corrodes internally. Corrosion can also be seen when dissimilar metals are used in the manifold assembly. For instance, when a brass hose fitting is used with an aluminum manifold, the corrosive gasses, aided with a moist environment will create galvanic corrosion, eroding the layer of aluminum at the thread and causing the manifold to fail. The corrosion can further lead to:

1. Gradual metal loss and decomposition causing blockage of flow path
2. Erosion reduces the metal thickness, causing leaks and mechanical failure of the manifold
3. Transfer of corrosion beyond the manifold to the metal piping and tubings
4. Stress corrosion cracking when the corrosive nature of gas is combined with high pressure and temperature conditions

Only by using the right metallurgical solution for corrosive gases, industrial gas manifolds can serve its critical function. 

Metallurgical Solution for High-Quality Industrial Gas Manifold

High-quality metallurgical options for manifolds include various metals that are resistant to corrosive elements of the gas and the high temperature of the process. Manifolds comprised of 304 or 316 stainless steel are most prevalently used as an economic solution to corrosion resistance. The 316 stainless steel manifold, in particular, can resist chemicals including sulfur and chloride, even at high temperatures. Many manufacturers may also choose to perform passivation to remove excess iron on the metal surface and improve its corrosion resistance.

For highly corrosive gases, the addition of chromium and molybdenum content can improve the resistance of the metal. Hastelloy, a nickel alloy, is suitable for such requirements. As a high-chrome and high-moly metal, the Hastelloy manifold provides strong resistance against stress corrosion cracking and localized corrosion.  

Fabricating a Corrosion-Resistant System With Swagelok 

When selecting the manifold for your gas distribution system, or when assembling the system itself, it is helpful to have expert advice on the different processes and design conditions and the ideal components needed. Swagelok will help you overcome the challenges by providing custom-designed installations and fabrications for your gas distribution facility.  Depending on the high- or low-pressure requirement at your facility and the nature of gas at your source inlet, we will identify the ideal material requirement for the supporting component like a manifold with attached valve or tubes.

For gas services, Swagelok provides manifolds with traditional, wafer, and compact body designs and compatible fittings. The manifolds are made of standard 316 stainless steel for high corrosion resistance and can be installed to meet your facility’s requirements. The Inconel® or Hastelloy components with industrial gas manifolds for corrosive gases are sure to ensure the safety and reliability of the gas distribution system at your facility.

With Swagelok’s high-quality products and services at the core, the safety of your personnel and process control of operation at your Northern California facility is guaranteed. 

To learn more about Swagelok Northern California’s and how our industrial gas manifolds for corrosive gases can ensure the safety of your facility, contact our team today by calling 510-933-6200.

Morgan Zealear | Product Engineer – Assembly Services

Morgan holds a B.S. in Mechanical Engineering from the University of California at Santa Barbara. He is certified in Section IX, Grab Sample Panel Configuration, and Mechanical Efficiency Program Specification (API 682). He is also well-versed in B31.3 Process Piping Code. Before joining Swagelok Northern California, he was a Manufacturing Engineer at Sierra Instruments, primarily focused on capillary thermal meters for the semiconductor industry (ASML).