Instrument air headers are designed to handle large volumes of air at high pressure. They are constructed from high-quality materials that can withstand harsh environmental conditions and provide long-term durability. The header is usually installed at the beginning of the air supply line and is connected to the air compressor. If you are in the market for instrument air headers, you are in the right place. Instrumxx Industries is the leading instrument air header manufacturer, stockist supplier, and exporter in India.
In this blog post, we will dive into the details of what an instrument air header is and why it is essential for your operation.
What is an Instrument Air Header?
An instrument air header is a system that distributes compressed air to various instruments, control valves, and other devices in an industrial facility. These headers are typically used in industries such as oil and gas, petrochemicals, power generation, and others where precision control is critical. The header provides a constant supply of clean, dry, and regulated compressed air, ensuring that the instruments and devices function correctly.
Types of instrument air header
There are two main types of instrument air headers: single-line and dual-line. A single-line system consists of one main header that supplies air to all the instruments. In contrast, a dual-line system has two separate headers: one for high-pressure instruments and the other for low-pressure instruments. The dual-line system ensures that high-pressure instruments receive adequate air supply without affecting the low-pressure instruments.
Properties of Instrument air headers
Instrument air headers are designed to deliver compressed air to various devices and systems used in industrial processes. To ensure optimal performance, instrument air headers are designed with certain properties that make them suitable for their intended applications. Here are some of the key properties of instrument air headers:
- Pressure rating: Instrument air headers are designed to withstand high pressure. They are typically rated for pressures ranging from 150 psi to 1000 psi, depending on the specific application. The pressure rating of the instrument air header must match the requirements of the devices and systems it will be supplying compressed air to.
- Material: Instrument air headers are typically made of materials such as
Stainless Steel, Carbon Steel, Hot Dip Galvanize Carbon Steel. The choice of material depends on the application and the specific requirements of the process. For example, stainless steel may be used in corrosive environments to prevent rust and other forms of degradation.
- Size: Instrument air headers are available in various sizes to accommodate different flow rates and pressure requirements. The size of the instrument air header must be chosen based on the maximum flow rate and pressure that will be required for the devices and systems will supply compressed air.
- Quality of air: The quality of the compressed air delivered by the instrument air header is critical to the performance of the devices and systems it will supply compressed air to. Instrument air headers are designed to deliver clean, dry, and oil-free compressed air. This is achieved through the use of filters and other devices that remove contaminants from the compressed air.
- Fittings and connections: Instrument air headers are designed with various fittings and connections to ensure that they can be easily installed and connected to the devices and systems that they will supply compressed air to. The fittings and connections must be compatible with the specific devices and systems that the instrument air header will supply compressed air to.
Benefits of instrument air headers
Instrument air headers are an essential part of many industrial processes, providing a reliable and efficient source of compressed air for various applications.
The benefits of instrument air headers and how they can improve the performance and efficiency of your industrial processes.
- Increased Efficiency:
One of the significant benefits of instrument air headers is that they provide a reliable and consistent source of compressed air for your industrial processes. This helps to ensure that your equipment and machinery are running at optimal efficiency, reducing downtime, and increasing productivity. The compressed air generated by instrument air headers can be used to power a wide range of equipment, including pneumatic tools, actuators, valves, and control systems.
- Enhanced Safety:
Instrument air headers are an essential component of many safety systems in industrial processes. They are often used to power safety valves, which are designed to release pressure from the system in the event of an overpressure situation. This helps to prevent accidents and ensure the safety of personnel working in the area. Additionally, instrument air headers can be used to power emergency shutdown systems, which are designed to quickly shut down the process in the event of an emergency.
- Improved Process Control:
Instrument air headers can also be used to power control systems, which are critical for regulating the flow of fluids and gases in industrial processes. By providing a reliable source of compressed air, instrument air headers help to ensure that control systems are functioning correctly, providing accurate and precise control of the process. This helps to improve the quality of the final product, reduce waste, and increase efficiency.
- Reduced Maintenance:
Another benefit of instrument air headers is that they require minimal maintenance. Unlike other compressed air systems, instrument air headers do not require lubrication, reducing the need for regular maintenance and minimizing the risk of contamination. This helps to reduce maintenance costs and increase the reliability of the system.
- Cost Savings:
Instrument air headers can also help to reduce costs by improving the efficiency of your industrial processes. By providing a reliable source of compressed air, instrument air headers help to reduce downtime, increase productivity, and improve the quality of the final product. Additionally, instrument air headers can help to reduce energy costs by providing a more efficient source of compressed air, reducing the amount of energy required to power the system.
Specifications of Instrument Air headers
Materials of Construction (MOC)
Stainless Steel, Carbon Steel, Hot Dip Galvanize Carbon Steel.
Air Header Pipe constructed from Seamless Pipe, size 1-1/2" & 2" NB schedule 40 and 80. Caps or Reducers welded to the pipe are manufactured from forged material.
Flange or three-piece union-type connection.
4, 6, 8, 10, 12, 16, 18, or as per customer requirement. This outlet Connection is provided with IXX make Ball or Needle valves of 1/4", 3/8", and 1/2" sizes. The nipple used for all the above connections is manufactured from the seamless pipe.
1/2" or 1" Ball Valve, Needle Valve, Gate Valve, and Globe Valve as per customer requirement.
A bracket can be provided as an option.
Air Headers are tested at 150 PSI Pneumatically and 1000 PSI Hydraulically.
Components of instrument air header
The main components of an instrument air header include the air compressor, dryer, filter, regulator, and valves. The air compressor compresses atmospheric air and supplies it to the dryer, which removes moisture from the air. The filtered and regulated air then flows through the header and is distributed to the instruments. Valves are installed in the header to isolate and control the air supply to individual instruments.
Why Choose Instrumxx Industries for Your Instrument Air Header Needs?
Now that you know what an instrument air header is let's dive into why Instrumxx Industries is the right choice for your needs.
Here are a few reasons why our company stands out from the rest:
- Expertise: With years of experience in the industry, we have a deep understanding of the technicalities involved in designing, manufacturing, and supplying instrument air headers. Our team of experts is always ready to assist you in choosing the right header for your operation.
- Quality: At Instrumxx Industries, we prioritize quality over everything else. We use only the best materials and manufacturing techniques to ensure that our instrument air headers meet the highest standards of quality and performance.
- Customization: We understand that every operation has unique requirements. That's why we offer customization services for our instrument air headers. Whether you need a header with a specific size, configuration, or material, we can design and manufacture it for you.
- Competitive pricing: Despite providing top-notch quality, we offer our instrument air headers at competitive prices. We believe that everyone should have access to high-quality instrument air headers without breaking the bank.
- Timely delivery: We understand that time is money, and delays in delivery can cause significant losses for your operation. That's why we have streamlined our supply chain and logistics to ensure the timely delivery of your instrument air header.
Instrument air header installation
Instrument air header installation requires careful planning and execution. The system must be designed to meet the specific requirements of the plant and comply with relevant standards and codes. The installation process involves the selection of appropriate materials, sizing of pipes and fittings, and proper alignment and support of the header.
Applications of Instrument air headers
Instrument air headers have numerous applications in various industries. They are commonly used in industries that require compressed air for process control, such as petrochemical plants, pharmaceuticals, power plants, and many others.
Here are some of the key applications of instrument air headers:
- Industries processes
- Petrochemical Industry
- Safety control
- Pneumatic tools
- HVAC System
- Food and Beverage Processing
- Power Generation Industry
- Oil and Gas Industry and so on.
The instrument air header is a critical component of any process plant, and choosing the right supplier is crucial for the efficient and safe operation of the plant. Instrumxx Industries is a leading manufacturer, stockiest supplier, and exporter of instrument air headers in India. Our products are of the highest quality and are designed to meet the specific requirements of our customers.
If you are looking for a reliable supplier of instrument air headers, look no further than Instrumxx Industries.
Contact us today and explore high-quality Instrument air headers that will fulfill your upcoming project requirements!