Process manifolds can distribute, isolate, combine, redirect, measure, or sample liquids and gases within industrial systems. Unlike many motion-control manifolds, the primary purpose may not be operating an actuator. Instead, the manifold becomes part of the process-fluid pathway itself.
Material compatibility, corrosion, sealing, contamination, pressure, temperature, cleaning, instrumentation, and valve selection can therefore become major design priorities.
Process Distribution
Routing Liquids and Gases
A process manifold can accept fluid from one source and distribute it among several branches or combine several lines into a controlled common path.
Internal passages may connect pumps, tanks, filters, valves, instruments, sampling equipment, analyzers, heat-transfer equipment, or production processes.
Port arrangement should reflect the actual process layout so external tubing and piping can be routed efficiently.
Pump Integration
Process Pumps and Manifolds
Pumps move process fluids through piping, manifolds, filters, valves, heat exchangers, vessels, and other equipment.
Industrial chemical pumps represent one category where construction and wetted components must be selected with the properties of the handled fluid in mind.
A manifold connected to the same process should receive the same compatibility review for body material, seals, valves, fittings, instruments, and surface treatments.
Pumps & Manifold Systems →Valve Functions
Isolation and Flow Control
Process manifolds can contain or connect to valves used to isolate equipment, redirect flow, prevent reverse flow, regulate a branch, or control process sequencing.
The valve technology should suit the fluid, pressure, temperature, required shutoff behavior, allowable pressure drop, and maintenance strategy.
Wetted Materials
Process Fluid Compatibility
Every wetted material should be appropriate for the process medium and expected operating conditions.
Stainless steel, aluminum, brass, carbon steel, seals, polymers, coatings, valve internals, tubing, and instrumentation can all respond differently to particular fluids.
Temperature can further change corrosion behavior, seal performance, viscosity, and chemical compatibility.
Fluid Compatibility →Corrosion
Stainless Steel Process Manifolds
Stainless steel can be considered where process conditions require corrosion resistance, mechanical strength, cleaning capability, or compatibility with the surrounding environment.
The specific stainless grade should be evaluated according to the actual medium rather than assuming that all stainless materials behave identically.
Stainless Steel Manifolds →Measurement
Instrumentation Ports
Process manifolds can provide dedicated connections for pressure, flow, temperature, sampling, or other measurements.
Integrating these ports into the manifold can reduce the number of separate tees and branch fittings required in the external piping system.
Sensor placement should correspond with the actual portion of the process engineers need to monitor.
Filtration
Protecting Process Equipment
Filtration can remove contaminants from process streams or protect pumps, valves, instruments, nozzles, and other components from unwanted particles.
Filter material and construction should suit the process medium and expected operating conditions.
Filter pressure drop should also be included when evaluating pump and manifold performance.
Manifold Filtration →Cleanliness
Cleaning Process Manifolds
Manufacturing debris should be removed before a manifold enters service.
Certain process systems may also require cleaning between batches, after maintenance, during commissioning, or before changing the material flowing through the system.
Passage layout, drainability, access, surface condition, and material compatibility can all influence the cleaning strategy.
Deburring & Cleaning →Pressure & Flow
Process Pressure Drop
Valves, filters, fittings, passages, meters, tubing, and other restrictions all influence the pressure available downstream.
Process manifolds should be sized so required flow can reach each branch without introducing unnecessary loss.
Flow distribution becomes especially important where several branches operate at the same time.
Pressure Drop & Flow →Engineering Review
Process Manifold Design Factors
Related Applications
Process Manifolds and Other Industrial Systems
Process manifolds share many design principles with hydraulic, pneumatic, and general industrial machinery manifolds, but fluid compatibility and process cleanliness often receive greater emphasis.