How Gas Distribution System Design and Fabrication Can Improve Plant Efficiency

In a gas processing plant, efficiency is everything. When something goes wrong with a gas distribution system, it has to be fixed as quickly as possible—which unfortunately often means cobbling together a fix or replacement from whatever is available.

The problem is that by using disparate parts from multiple suppliers within a system, it tends to lose efficiency and become more complex than necessary. A more effective solution is a complete system engineered for the specific application from a local vendor specializing in gas distribution system design and fabrication.

Key Aspects of Gas Distribution System Design and Fabrication

In most plants, gas distribution system design and fabrication can be divided into four main subsystems: the source inlet, gas panel, changeover, and point-of-use. It is important that every part of the system operates reliably and efficiently, as a failure at any point has the potential to cause problems downstream.

Swagelok Source Inlet (SSI)

The first stage of the gas distribution system design is the source inlet. The source inlet connects a pressurized gas source to the rest of the system. It can be as simple as a single hose connected to a cylinder or a complex manifold or system of hoses and valves.

The source inlet may seem like a simple set of components, but it’s one of the most critical points in the system. As the most upstream point in the process, any leakage, and pressure loss at the source inlet trickles down to the entire system—so a reliable, engineered solution is essential. A gas distribution system design and fabrication expert can evaluate your process and determine the exact types of components that will ensure reliability and efficiency. These might include isolation valves, individual vent or purge lines, or other options.

Swagelok Gas Panel (SGP)

After the source inlet, gas flows to the gas panel, where the system pressure and flow rate are controlled. The gas panel uses either a single- or double-stage regulator arrangement to control pressure, depending on the application details.

Designing the gas panel—especially the pressure regulator selection—is another critical part of gas distribution system design and fabrication. Because the pressure regulator is the heart of the whole system, it’s very important that it is optimized for the application pressure, fluid properties, and the rest of the system components. Selecting a pressure regulator for a gas distribution system is a sophisticated task that is usually best left to an expert.

Swagelok Changeover (SCO)

The changeover system switches from one gas source to another when it runs out (or reaches a set changeover pressure). Changeovers can be partially or fully automated. The safest, most efficient option is an automatic changeover that keeps the gas flowing at constant pressure as it switches sources, allowing the system to operate continuously.

Of course, the more automated the changeover is, the more critical the engineering details become. This is another point where it’s unwise to cobble together a fix from disparate parts. A gas distribution system design and fabrication vendor will be able to determine the most efficient way to implement a changeover in your system, depending on the source type and process conditions.

Swagelok Point-of-Use (SPU)

The final downstream point of the gas distribution system is at the point-of-use where gas is dispensed. There are usually many point-of-use stations in a plant, and they may have different design and operation requirements. That being said, they are typically the least complex part of gas distribution system design and fabrication.

The point-of-use station is the last point where gas pressure is controlled before it is dispensed. A point-of-use station typically includes a pressure regulator, pressure gauge, and isolation valve to allow precise gas pressure adjustment.

Even though point-of-use systems are relatively simple, they must still provide reliable, consistent, and safe operation. Engineering a station with a compact design and custom mounting options can maximize space while making the station as easy and safe to use as possible.

Gas Distribution System Design and Fabrication Solutions for Northern Alberta

In Northern Alberta gas processing plants, efficiency is critical—and a “Frankenstein” system consisting of disparate parts just doesn’t cut it. Luckily, Edmonton Valve & Fitting has decades of experience in efficient gas distribution system design and fabrication, so custom-engineered solutions are available.

Our Field Advisors can evaluate and optimize your existing gas distribution system and recommend quality Swagelok components that can improve safety and efficiency. Or, we can provide design support for a custom gas distribution system from the ground up to optimize your gas handling applications. Our gas distribution system design and fabrication services include standardized, modular systems and industry-leading Swagelok components customized to your application.