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.