Details
Introduction
The Gas Distribution System is a turnkey solution designed to supply ultra-pure gases— Zero Air (ZA), Nitrogen (N2), Hydrogen (H2), Helium (He), and Methane (CH4)—from high-pressure cylinders to laboratory instruments with precision, safety, and uninterrupted operation. It integrates automatic cylinder changeover, multi-stage purification, point-of-use regulation, stainless-steel distribution, and real-time gas detection into a modular, scalable assembly that fits neatly into standard panel layouts.
Key Features
• Auto Changeover Dual-Cylinder Manifold: Automatically switches between primary and standby cylinder banks when pressure falls below set thresholds, ensuring continuous supply without manual intervention.
• Multi-Stage Purification Trains: Sequential trap cartridges remove moisture (<5 ppb), hydrocarbons (<15 ppb), and residual O2 (<1 ppb); housed in SS 304 panels with quick-change elements.
• Point-of-Use SS 316L Regulators: Ultra-miniature, single-stage regulators deliver controlled outlet pressures (0–100 psi) directly at instrument inlets, with integrated shut-off valves for safe line isolation.
• Electropolished SS 316/316L Tubing & Fittings: Leak-tight tubing (1⁄4′′×0.035′′, 1⁄8′′×0.028′′) and compression βittings (tees, unions, reducers) ensure inert βlow paths; custom-length pigtails and flexible braided hoses complete the distribution network.
• Gas Detection & Safety System: ATEX/CE-certified multi-channel detector panel monitors O2, combustibles, and toxic gases via SS 316 transmitter heads; provides 4–20mA outputs, programmable relays, and RS-485 Modbus communications with visual/audible alarms.
• Custom Control Panels: Powder-coated MS enclosures arranged per the full-layout drawing, panel-mounted with process regulators, dual-scale gauges, relief valves, and isolation valves for ergonomic operation and straightforward expansion.
Applications
• Analytical Instrumentation: Supplies carrier and calibration gases to GC, GC-MS, and FID detectors, where ultra-pure zero air (<0.1 ppm THC) prevents baseline drift and enhances sensitivity.
• Catalyst R&D: Feeds ultra-clean reactant gases for kinetic studies in microreactors or fixed-bed setups, where trace impurities can poison catalysts and skew activity measurements.
• Process Simulation: Supports pilot-scale reactors requiring precise ratios of H2, N2, or CH4 under controlled pressures for scale-up validation in chemical or petrochemical research.
• Safety-Critical Environments: In inerting or blanketing applications (e.g., gloveboxes, Schlenk lines), integrated detection and automatic shutdown protect personnel and samples from asphyxiation or explosion risks.
Technical Specifications
| Parameter |
Specification |
| Overall Dimensions (L×W×H) |
12,600 × 2,000 × 3,500 mm |
| Tank Capacity |
2 × 2,000 L PVC |
| Pump & Motor |
Grundfos CM 15-3, 4 kW (5.36 HP), 3-phase, 50 Hz |
| Flow Rate |
Up to 250 LPM; per-nozzle: 1–2 LPM at 2 bar |
| Working Pressure |
Up to 10 kg/cm²; test pressure typically 1–2 bar |
| Nozzle Material & Size |
SS 304; Ø2 mm holes (8-place) |
| Filter Mesh Size |
60 mesh (250 LPM capacity) |
| Frame Material |
SS 304 square tubing |
| Piping |
Schedule-80 uPVC |
| Mobility |
6 × lockable caster wheels (7,500 N each) |
| Operating Voltage/Temp. |
180–240 VAC; 15–24 °C ambient |
| Weight |
Approximate per GA drawing |
Bill of Materials (Excerpt)
| Item |
Quantity |
| Auto Changeover Dual-Cylinder Manifold |
5 banks |
| Gas Purification Modules |
6 (ZA, N₂, H₂, He, CH₄, spare) |
| Point-of-Use Regulators |
ZA: 17; N₂: 18; H₂: 11; He: 10; CH₄: 4 |
| SS Tubing (¼″×0.035″) |
550 m |
| SS Tubing (⅛″×0.028″) |
25 m |
| Compression Fittings |
>300 |
| Gas Detection Panel & Transmitters |
1 panel; 5 head units |
| Flexible Braided Hoses |
10 (1 m each) |
| Control Panel Enclosures |
17 secondary + junction boxes |
Core Components & Functionality
Auto Changeover Manifold
A pilot-operated valve senses when the primary cylinder bank pressure falls to a preset point, triggering an uninterrupted switch to the reserve bank. This maximizes gas usage and eliminates manual intervention.
Purification Modules
Each gas stream flows through cartridge-type traps in SS 304 panels:
1. Desiccant Stage lowers moisture to <5 ppb;
2. Carbon Bed removes hydrocarbons to <15 ppb;
3. Oxygen Scavenger ensures residual O2 <1 ppb. Cartridges snap in/out via quick-release clamps.
Point-of-Use Regulation
Compact SS 316L regulators positioned at instrument inlets maintain stable 0–100 psi pressures. Their diaphragm-sensed design and integrated filters deliver contaminant-free gas with optimized flow characteristics and isolation valves for maintenance.
Distribution Network
Electropolished SS tubing ensures smooth, inert flow with minimal dead volume. Compression fittings provide versatile routing; flexible braided hoses accommodate movement and vibration isolation. All connections undergo helium leak testing to <1×10−9 mbar·L/s.
Detection & Control
A 16-channel ATEX/CE panel aggregates analog (4–20 mA) and digital (Modbus RTU) signals from SS 316 sensor heads. Programmable alarms, relay outputs, and visual/audible indicators allow automated shutdown upon hazardous conditions.
Panel Assembly
Enclosures are built per the A1841 layout, with standardized frame sizes, knock-outs, and mounting rails. Regulators, gauges, and valves are ergonomically arranged for visibility and maintenance access.
Conclusion
The system delivers a highly reliable, safe, and modular platform for distributing multiple ultra-pure gases in demanding R&D and analytical environments. Its automated changeover, advanced purification, localized regulation, and integrated safety controls ensure continuous, contamination-free supply tailored to evolving laboratory needs.
