Regular manifold maintenance maximizes downstream operations, gas efficiency
A manifold gas distribution system improves efficiency in many ways, mostly making maximum use of gas cylinder contents with few trips to replace them. Just like any other component of a gas distribution system, manifolds need to be a part of a regular inspection and maintenance program.
Manifolds have a design life expectancy but environmental exposure, high-pressure operation, and regular use can alter that lifespan. When you build manifold operation checks into your maintenance program, your operations will be more efficient. As always, safety comes first.
Manifold safety top of mind
The manifolds don’t operate independently of other components. Focusing on the maintenance of the manifolds only could be costly.
Manifolds attach multiple gas cylinders to your distribution system and work in conjunction with a control box and regulators to ensure proper, consistent pressure among all downstream operations. Since the three components really function as a system, each must be included in regular inspections and maintenance protocols.
Increase safety by including a flashback arrestor, which prevents fire from reaching the gas source in the lines, with annual replacement of the fluid inside the arrestor. Safety measures such as these and regular preventive maintenance go a long way in maximizing uptime and operator job satisfaction.
Control panels and regulators
While most of the focus regarding the control panels is on the pressure regulators, don’t overlook the panel and/or box itself. Control panel and box inspections should look at the housing. Is it in good condition? Do all elements fit tightly? Are all connections tight? Also check the age. Boxes and panels also have an expected lifespan that can be affected by exposure to elements and other operational conditions.
Regulators inside the control box need to be replaced on a regular basis. Regular testing will help avoid emergency replacements. And when you do make replacements, it is imperative to know connector sizes are there are not set standards.
Rob Moyer, president of Rexarc International, a global leader in acetylene plants and gas distribution systems noted that regulators in a white enclosures have aged out. Some stainless steel enclosure boxes are also reaching maximum serviceable age. Be sure to check your service records or give Rexarc a call to get a recommendation on replacing your control box or panel.
What are the signs?
So what should you be looking for when inspecting your manifolds, control boxes/panels, and regulators?
- Leaks, especially at connectors. This could indicate non-matching connectors or failure of the connector.
- Inconsistent pressure downstream, typically most noticeable with fuller tanks or ones that are almost empty.
- Hose damage or weak spots. Keep a watchful eye on places where hoses may come in contact with other elements or are exposed to harsh operating conditions. Also, cylinder leads may become brittle over time.
When to replace an aging manifold
Manifolds are designed for a service life of 7 to 10 years. That lifespan could be impacted by working conditions. One way to make maintenance easier is to keep tabs on installation dates. If you manage your maintenance processes electronically, be sure to record dates that system components are changed and if they are installed new or were repaired. Otherwise tag the component with the install date and make sure that date remains legible. Know your equipment’s lifespan and be sure to replace before it ages out.
Physical damage to the manifold and regulators could necessitate replacement. If you experience an accident where equipment is damaged do not wait for your regular maintenance cadence to inspect and make repairs or replacements. It is far better to be up and running safely than to experience an accident.
Rexarc is your manifold partner
With our experience in acetylene plants and gas distribution systems, Rexarc International can be your trusted partner for system maintenance, parts knowledge and replacement. Contact our experts for help with getting the right parts and setting up a spare parts inventory to help alleviate unexpected downtime on your gas distribution system.
