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-------Installation Of

Manifolds
Module 12218

Instrument Trainee Task Module 12218

INSTALLATION OF MANIFOLDS_
Objectives
Upon completion of this module, the trainee will be able to:
1. List the advantages of using manifold type valving.
2. Given a drawing, determine the location of manifolds.
3. Given the system specifications and requirements, identify and select
the following valve manifolds:
Three-Valve Equalizer
Five-Valve Equalizer
Five-Valve Blowdown
Two-Valve
Single-Valve
4. Given the system specifications, and requirements, correctly install
valve manifolds.

Prerequisites
Successful completion of the following Task Module(s) is required before
beginning study of this Task Module: NCCER Core Curricula; NCCER Task
Module 12201, Craft-Related Mathematics; NCCER Task Module 12202,
Instrumentation Drawings and Documents II; NCCER Task Module 12203,
Principles of Welding; NCCER Task Module 12204, Process Control Theory.

Required Student Materials


1. Student Module
2. Required Safety Equipment

Instrumentation Trainee Task Module 12218

Course Map Information


This course map shows all of the Wheels of Learning task modules in the
second level of the Instrument curricula. The suggested training order begins
at the bottom and proceeds up. Skill levels increase as a trainee advances on
the course map. The training order ma y be adjusted by the local Training
Program Sponsor.

Course Map: Instrument, Level 2


LEVEL 2 COMPLETE

Installation of Manifolds Module 12218

TABLE OF CONTENTS
Section Topic .
Page
1.0.0 Introduction .
5
2.0.0 Manifold Valve Identification ...
6
2.1.0 Single-Valve
.. 6

Instrumentation Trainee Task Module 12218

2.2.0 Two-Valve
..
2.3.0 Three-Valve Equalizer
..
7
2.4.0 Five-Valve Equalizer
..
7
2.5.0 Five-Valve Blowdown

8
3.0.0 Manifold Installation
.
9

Installation of Manifolds Module 12218

Trade Terms Introduced in This Module


Blowdown: The process of removing air, water, or sludge from the bottom of
a vessel or in an instrument line to drain or reduce concentration levels.
Differential pressure transmitter: Device which measures the difference in
pressure between any two points of a system or a component.
Equalizer: Device which allows pressure to equalize from one side of the
manifold to the other.
Manifold: A conductor which provides multiple connection ports.

1.0.0 INTRODUCTION_
The intricate systems that are now in use emphasize compactness; therefore,
many manifolds are used, especially on hydraulic and pneumatic and
instrumentation systems. It is often desirable to mount all the valves on a
manifold panel.

Figure 1. Manifold Mounted Directly on Machine

As shown in Figure 1, large numbers of connecting lines can be located in


drilled or fabricated manifold plates. These plates and valves not only
eliminate many fittings and potential leaks but also ensure a minimum

Instrumentation Trainee Task Module 12218

number of errors in plumbing. Although manifolds are relatively expensive,


they greatly reduce assembly time in connecting up a system. The manifold
may be drilled, cored and cast, bolted-on, or brazed-plate construction.

2.0.0 MANIFOLD VALVE IDENTIFICATION_


2.1.0 SINGLE-VALVE
Single-valve manifolds are used in simple systems where it is necessary to
provide a positive shut-off of flow and to throttle flow during operation. They
also provide for two instrument connections and a test connection. Any or all
of these connections may be blocked according to desired use. Figure 2
shows a simplified cutaway view of a single-valve manifold along with its
schematic diagram.

Figure 2. Single-Valve Manifold

2.2.0 TWO-VALVE
Two-valve manifolds are used as a barrier between line pressure and
instrumentation equipment. The second valve and line serves the dual
purpose of providing a vent connection to prevent line pressure from being
locked in the instrumentation and could also serve as a calibration
connection. Figure 3 shows a simplified cutaway view of a two-valve
manifold along with its schematic diagram.

Installation of Manifolds Module 12218

Figure 3. Two-Valve Manifold

2.3.0 THREE-VALVE EQUALIZER


The three-valve equalizing manifold is most commonly used in conjunction
with a differential pressure transmitter. It consists of two block valves
and one equalizing valve. Each side of the equalizing valve body usually has
been ported and plugged for either vents or test connections. Figure 4 shows
a simplified cutaway view of a three-valve equalizing manifold along with its
schematic diagram.

Figure 4. Three-Valve Equalizing Manifold

2.4.0 FIVE-VALVE EQUALIZER

Instrumentation Trainee Task Module 12218

The five-valve equalizing manifold provides two mainline block valves and a
double block and bleed arrangement for the equalizer line. Static pressure
and calibration connections are also provided. This manifold is primarily
intended for gas service and is used to connect differential pressure
transmitters to system flow meters. Figure 5 shows a simplified cutaway view
of a five-valve equalizing manifold along with its schematic diagram.

Figure 5. Five-Valve Equalizing Manifold

2.5.0 FIVE-VALVE BLOWDOWN


The five-valve blowdown manifold combines a three-valve equalizing
manifold with two special blowdown valves. This system provides an
extremely compact, reliable, and economical unit eliminating eight nipples,
four tees, and two shut-off valves. There are two block valves and one
equalizing valve on the manifold and the two blowdown valves are designed
with left and right hand block valves. The blowdown outlets are on the
bottom of the two valves after the block valves. Figure 6 shows a simplified
cutaway view of a fivevalve blowdown manifold along with its schematic
diagram.

Installation of Manifolds Module 12218

Figure 6. Five-valve Blowdown Manifold

3.0.0 MANIFOLD INSTALLATION_


Prior to actual manifold installation several items dealing with manifold
construction and operational parameters must first be verified. The following
items are considerations that can be checked by either a system schematic
or system specifications/requirements.

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Inlet/Outlet Configuration
Pressure/Temperature Ratings
Packing Type
Disc Configuration
Manifold to System Orientation
Figure 7 shows a manifold valve with its typical markings. These markings
give you manifold orientation, pressure/temperature ratings, packing, type,
and materials of construction.

Figure 7. Typical Manifold Valve Markings

Figure 8 shows the common manifold valve inlet/outlet configurations.


Selection and installation of the correct manifold is dependent on existing,
system configurations along with the previous considerations.
The installation of various instruments has been made easy and efficient
by the use of various manifold designs. Some design features include;
adjustable packing for leakproof extended service, integral hard backseats
to prevent stem blow-out, and free swiveling ball end stems that provide
bubble-tight, metal-to-metal valve closure without seat galling.
Two manifold accessories which have proven invaluable components for
installing transmitters are the "Close-Couple Futbol" and the "Rod Out
Device". The Futbol allows for the shortest possible distance between the
orifice flange union and the instrument manifold. It comes complete, from
the manufacturer, with bolts, washers, and a teflon gasket. Two Futbols
are required per installation.
9
The Rod Out is a device to clear orifice passages which have become
restricted. It is designed to be used while the valve is open and under
pressure. It is available in carbon steel, stainless steel, and monel with inlet
connections to fit standard manifold instrument flanges.

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NOTE:

Prior to the installation of manifold, ensure all O-rings are


thoroughly lubricated with manufacturers recommended
lubricant.

Figure 8. Manifold Inlet/Outlet configurations

SUMMARY
Valve manifolds have been widely used in the fabrication of hydraulic and
pneumatic systems. Three valve and five valve manifolds are used for
installation of differential pressure cells. Two valve manifolds provide
connections for indicating devices such as gages. some advantages of these
components include; ease of assembly, compactness, and good

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maintainability. The use of manifolds will save time and minimize the
possibility of rework. This module has provided the necessary information to
ensure that a technician thoroughly understands the construction and
proper installation of a variety of valve manifolds.

SELF-CHECK REVIEW / PRACTICE QUESTIONS


1. List two advantages of using manifolds.
2. List the five manifold selection considerations that must be verified prior
to installing a manifold in a system.
3. What type of instrumentation equipment is a three-valve equalizing
manifold most commonly used in conjunction with?
4. Matching exercise: Select the manifold from the list below that matches
its schematic diagram.
(a)
Single Valve
(b)
Two-Valve
(c)
Three-Valve Equalizer
(d)
Five-Valve Equalizer
(e)
Five-Valve Blowdown

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PERFORMANCE / LABORATORY EXERCISES


1.

Given a system schematic containing manifolds:


Step 1 Identify manifold locations in the system.
Step 2 Identify each type of manifold in the system.
Step 3 Make manifold selection based on each of the following for each
manifold in the system:

Inlet/Outlet Configuration

Pressure/Temperature Ratings

Packing Type

Disc Configuration
Step 4 Identify manifold to system orientation for each manifold in the
system.
Step 5 Install each manifold in the system.

ANSWERS TO SELF-CHECK REVIEW / PRACTICE QUESTIONS


1. Eliminate fittings
Reduce potential leaks
Minimize errors in plumbing
Reduce Assembly Time
2. Inlet/Outlet Configuration

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Pressure/temperature ratings
Packing type
Disc Configurations
Manifold to system orientation
3. Differential pressure transmitter
4. (1)
(b)
Two Valve
(2)
(c)
Three-Valve Equalizer
(3)
(e)
Five-Valve Blowdown
(4)
(a)
Single-Valve
(5)
(d)
Five-Valve Equalizer

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