Helium Charging Station, rated to 400 bar helium and 690 bar hydrotest.

Introduction

The Neometrix Helium Charging System is engineered as a comprehensive skid-mounted solution for the safe recovery, hydrostatic testing and high-pressure refilling of helicopter emergency flotation bottles. Leveraging proven pneumatic-driven technology, it accommodates bottle volumes of 9 L and 18 L, delivering helium at up to 400 bar for refilling and up to 690 bar water pressure for hydrostatic certification. This turnkey system streamlines depot-level maintenance workflows by integrating decanting, testing and charging in a single, mobile unit.

System overview

1. Decanting module

Utilizes a pneumatic gas booster to transfer residual helium from flight bottles into recovery cylinders at approximately 125 bar, minimizing gas loss and contamination. An air-driven equalization process ensures smooth pressure balancing before boost operations commence.

2. Hydrostatic test module

Employs a Haskel ASF-100 air-driven liquid pump to pressurize plain water up to 690 bar, subjecting bottles to controlled over-pressure for integrity checks. The system auto-stops at preset test pressures to prevent over-stress.

3. Refilling module

After successful hydrostatic testing, bottles are charged with high-purity helium up to 400 bar using the pneumatic gas booster. Automated shut-off valves and precision regulators ensure accurate fill pressures and prevent overcharging.

Key features

• Pneumatic-driven boosters: Haskel gas and liquid boosters operate without heat, flame or sparks, offering infinitely variable cycling speed and continuous-duty operation.
• High-efficiency filtration: multi-stage filtration protects boosters and valves from particulates and moisture, ensuring long component life and consistent performance.
• Precision instrumentation: gauges, pressure switches and audible/visual alarms provide real-time monitoring and automatic safety cut-outs at predefined thresholds.
• Modular design: stainless-steel tubing, high-pressure hoses and Swagelok fittings simplify maintenance and ensure leak-free connections.
• User-centric controls: a central control panel with intuitive toggle switches reduces operator workload and prevents sequencing errors.
• Integrated bottle handling: accommodates 9 L and 18 L helicopter emergency flotation bottles with decanting, testing and charging in one place.
• Clean dry air supply: a 20 HP / 10 bar compressor with refrigerated and desiccant dryers achieves a −40°C dew point for the booster drive circuit.
• Sequenced valving: Festo and Swagelok isolation and needle valves with DOT/ISO relief valves precisely sequence all operational phases.

Core components & functionality

• Haskel pneumatic gas booster AGT-32/62: area-ratio pneumatic drive with hydrocarbon-free separation, up to 400 bar fill pressure.
• Haskel ASF-100 air-driven liquid pump: 100:1 ratio, 0.4 in³ stroke, stainless-steel construction, UHMWPE seals, up to 1,138 bar output.
• Air supply & drying: 20 HP, 10 bar compressor with refrigerated and desiccant dryers to achieve a −40°C dew point.
• Valves & regulators: Festo and Swagelok isolation valves, needle valves for fine control, and relief valves per DOT/ISO standards.

Operational workflow

Decanting

• Connect bottle adapters and recovery cylinder; isolate vent valves.
• Equalize pressures at approximately 125 bar via panel valves.
• Engage the gas booster; monitor transfer until gauges indicate completion.
• Vent residual gas and disconnect.

Hydrostatic testing

• Fill the bottle with water from the 150 L reservoir.
• Start the liquid pump; auto-stop at 450 bar (adjustable up to 690 bar).
• Depressurize, drain water and inspect for leaks or deformations.

Refilling

• Connect the helium supply; open the booster inlet and bottle valves.
• Activate the booster to pressurize the bottle to 400 bar; automatic cut-off.
• Vent the line, isolate the valves and remove the bottle.

Technical specifications

Safety measures

• Pressure safety: relief valves and pilot switches guard against over-pressure; never bypass factory settings.
• Area requirements: operate in well-ventilated, obstruction-free zones; ensure floor support for skid weight.
• Personal protection: use full-face shields, gloves and hearing protection; follow lock-out/tag-out procedures.
• Fluid handling: drain and dispose of hydrotest water per local regulations.

Applications

• Military & aerospace: depot-level maintenance of helicopter flotation and escape system bottles.
• Industrial gas suppliers: high-pressure cylinder certification and refill services.
• Research & calibration labs: precise pressure testing and gas handling for high-purity applications.
• Emergency services: rapid recovery and refill of fire-suppression cylinders in the field.

Maintenance & support

• Routine service: replace filter elements every 6 months or after 1,000 operating hours; inspect seals quarterly.
• Booster overhaul: exchange seals and diaphragms annually or after 500 cycles.
• Pump maintenance: lubricate per manufacturer guidelines; monitor stroke counts for seal replacement.
• Neometrix support: spare-parts provisioning, on-site training and remote diagnostics.

Advanced helium charging systems for aviation and maintenance applications

Reliable helium handling is critical for aviation and depot-level maintenance operations. Helium charging systems and helium charging machines provide safe and efficient refilling of helicopter flight bottles, ensuring readiness and operational reliability. Integrated helicopter bottle testing and hydrostatic test benches allow high-precision evaluation of pressure integrity and safety compliance.

Modern systems leverage Haskel gas boosters, high-pressure helium refill units and skid-mounted helium systems to support depot-level maintenance and flight bottle decanting operations. High-pressure testing ensures all bottles meet stringent performance and safety standards, maintaining aircraft operational readiness while reducing risk.

These advanced helium charging solutions deliver reliable, high-throughput and precise operations for aerospace maintenance, enabling safe handling, testing and replenishment of high-pressure helium systems.

Conclusion

By integrating industry-leading pneumatic boosters, precision instrumentation and robust safety systems, the Neometrix Helium Charging System delivers a safe, efficient and fully mobile solution for decanting, hydrostatic testing and high-pressure refilling of gas cylinders. Its modular design and comprehensive support ensure operational reliability and global standards compliance.