Manifold Systems

Overview

As an alternative to the conventional approach of installing individual valve assemblies at each terminal unit, a Marflow manifold system houses all of the valves for a group of, typically up to six, terminal units in a single, insulated box. This has many advantages.

Ordering and installation is simplified and there is less chance of error.

The full bore flushing bypass allows large flushing velocities while considerably reducing the number of locations to be visited during the cleaning and flushing process.

During commissioning, instead of taking measurements at each terminal unit the commissioning engineer can access perhaps up to six units in one space. Clearly, the time savings simply from not having to move from one to another and complying with the Working at Height Regulations at each location are enormous.

With a properly considered control solution the need to revisit each manifold more than once is unnecessary, often reducing the commissioning process to a "read and record" exercise.

The use of a Marflow light weight engineered insulation box enclosing the manifold system greatly improves and simplifies the insulation of the system and provides re-sealable access.

The box also provides a suitable location to store local system information which is used during the commissioning stage and beyond.

When floors are re-partitioned and heating and cooling loads change, extra terminal units can easily be accommodated.

The full benefits of off site pre-fabrication including quality assurance and cost effective manufacturing are realised.

Build Quality

All Marflow manifolds are assembled in our Birmingham factory using components from quality-assured suppliers, with further factory testing to our own ISO 9000 quality system. This virtually eliminates leaks and on-site rectification work.

Push Fit Connections

Marflow manifolds are usually factory fitted with copper tails to every connection, allowing all pipe connections to be accomplished with our PEM series, push on fittings – leading to even further labour savings.

Insulation

The use of a Marflow light weight engineered insulation box enclosing the manifold system greatly improves and simplifies the insulation of the system, as well as providing re-sealable access. This Nilflam box also offers better heat transfer characteristics than traditional insulation materials and is class O fire rated. This offers significant time savings compared to manually insulating the manifold (or traditionally the valve sets) and, of course, preserves the integrity of the insulation during post installation checks and adjustments. When used in conjunction with pre-insulated multi-layered pipe from the manifold to the heat exchanger the entire secondary distribution system is fully insulated.

Faster Commissioning

Commissioning time is reduced as there are fewer control points, with less distance between them. Instead of taking measurements at each terminal unit the commissioning engineer can access perhaps up to six units in one space. Clearly, the time savings from fewer locations, while complying with the ‘Working at Height’ Regulations at each, are enormous. With a properly considered control solution the need to revisit each manifold more than once is unnecessary, often reducing the commissioning process to a ‘read and record’ exercise. The greatest saving in commissioning time can be achieved by using one of our automatic balancing solutions. The flow rate to each heat exchanger can then be preset (in our factory or on site) and maintained regardless of fluctuations in differential pressure. Commissioning is then effectively reduced to flushing and checking that the actual water flow rates equate with the design flow rates.

Ordering & Installation is Simplified

By incorporating a number of “terminal valve sets” into a single unit, with no parts to purchase, store, locate, pick and assemble, installation time is greatly reduced. This reduces errors and material losses and only requires a single part number for the entire assembly, thus greatly simplifying material take-off and reducing administration costs. Installation to the ceiling slab usually only takes minutes. The use of hand bendable Pexal multi-layer pipe allows simple end to end connections to be made from the manifold to the heat exchanger without the use of elbows or other
pipe fittings.

Delivery Scheduling

Marflow manifolds are built to your schedule, so deliveries are managed to provide you with maximum productivity and optimum use of the on-site workforce. Manifolds can be scheduled to arrive in manageable batch quantities ‘just in time’, so that levels of on-site stock storage – and associated security issues - are kept to a minimum.

Longer term Benefits

Longer term benefits include localisation of maintenance procedures around each manifold and easy isolation of terminal units, minimising disruption to building users.

Operating and Maintenance data

The box also provides a suitable location to store local system information which is used during commissioning and right through to operating and maintenance. So each manifold box is pre mounted with valve information and flow rates relevant to the system type and its planned location in the building.

Flushing & Cleaning is Improved

The use of manifold systems reduces flushing and cleaning time by grouping the bypass, drains and air-vents into a central location serving, say, 4 to 6 heat exchangers. Assembly in a controlled, factory environment eliminates the ingress of dirt and debris normally associated with on-site assembly and, when combined with other clean components, significantly reduces flushing and cleaning times. The full bore short route flushing bypass allows the recommended flushing velocities to be achieved. The secondary pipe work to the heat exchangers is inherently clean and may just require a short backflush. Use of the Marflow Filterball integrated ball valve and strainer in the manifold system provides two key advantages. It removes the need to have individual strainers and an associated isolation valve to each heat exchanger, and offers the facility to clean the strainers without significant water loss or any air ingress.

Post Installation Flexibility

When floors are re-partitioned and heating and cooling loads change, heat exchangers can easily be repositioned or extra heat exchangers can be accommodated. Usually some assumptions about this are included at the planning stage. By incorporating a spare connection into each manifold box (which costs very little to do) extra heat exchangers can be added to the system after the initial installation without cutting into or modifying the original pipe work. A further benefit of our automatic balancing solutions is that extra heat exchangers can be added without the extra expense of having the system re-balanced. The use of multi-layered pipe also allows for units such as chilled beams or radiant panels to be moved with ease.