Details

Introduction
The Nitrogen Gas Boosting System is engineered to convert low-pressure nitrogen (20–150 bar) into ultra-high pressures (up to 300 bar) using a single-stage, single-acting Haskel AG-75 pneumatic booster. Its all-pneumatic design eliminates any risk of ignition—no heat, flame, or spark—making it intrinsically safe for use with high-purity and flammable gases. The booster’s 75:1 drive ratio means every 1 bar of plant air generates 75 bar of nitrogen pressure, controlled via a precision air-drive regulator. Housed on a lockable-wheel mild steel frame (750 × 450 × 540 mm), the unit weighs just 27 lb (≈12 kg), ensuring portability for service-technicians and lab environments alike

Key Features
• High Pressure Output: 75:1 amplification ratio delivers up to 300 bar (4 350 psi) nitrogen from a 4–8 bar (60–120 psi) plant-air drive
• Compact & Lightweight: At just 27 lb and with a 750 × 450 × 540 mm footprint, users can roll the system to test bays or fill stations without forklifts
• Hydrocarbon-Free Operation: Complete separation of air and gas sections ensures no lubricants or contaminants enter the nitrogen stream, critical for semiconductor, food, and pharmaceutical processes
• Continuous-Duty Cycling: Infinite variable cycling up to 60 cycles/min, with built-in cooling to prevent gas heating, supports long test sequences or large-volume fills
• Automated Pressure Control: Festo air-drive regulator sets maximum outlet pressure; PLC logic enables hands-free start/stop, fault alarms, and cycle-count monitoring.
• Safety Protections: Pneumatic relief valve at 8 bar drive air prevents over-driving; integrated vent valve allows controlled depressurization.

Applications
• Pipeline & Vessel Purging: High-pressure nitrogen purge removes moisture, oxygen, and hydrocarbons from pipelines or storage tanks before welding or service, ensuring inert atmospheres for safety and corrosion control
• Leak Testing: Pressurizing assemblies (hoses, fittings, pressure vessels) with nitrogen and monitoring decay rates (<1 bar/hr typical) allows non-destructive identification of leaks using soap-solution or helium sniffers.
• Accumulator Charging: Hydraulic accumulators and gas springs require precise nitrogen pre-charge for energy storage; this booster delivers accurate, oil-free gas charges to OEM specifications
• Cylinder Refill & Recovery: Economical topping-up of expensive or specialty-gas cylinders (argon, helium) by drawing down residual low-pressure gas and boosting it back into service.
• Laboratory & R&D: Clean, high-pressure nitrogen supply for materials testing, analytical instrumentation, and prototype component validation.

Technical Specifications

  

    

      
Parameter
      
Specification
    
  
  

    

      
Drive Air Pressure
      
4–8 bar (60–120 psi)
    
    

      
Drive Air Flow
      
10–80 scfm
    
    

      
Drive Ratio
      
75:1
    
    

      
Inlet N₂ Pressure Range
      
20–150 bar (300–2 175 psi)
    
    

      
Max Outlet N₂ Pressure
      
300 bar (4 350 psi)
    
    

      
Displacement per Cycle
      
1.2 in³ (≈19.6 mL)
    
    

      
Max Cycle Rate
      
60 cycles/min
    
    

      
Weight
      
27 lb (12.2 kg)
    
    

      
Frame Dimensions (L×W×H)
      
750 × 450 × 540 mm
    
    

      
Gas Connection
      
Interchangeable 3/8″ SAE or 1/4″ H/P
    
    

      
Material
      
Stainless-steel booster; MS frame
    
    

      
Control Elements
      
Festo filter, regulator, ball valves
    
  


Operating Procedure
1. Air Quality Prep: Ensure plant air meets ISO 8573-1 Class 2.4.3 (≤5 μm particulate, ≤0.5 mg/m3 oil) to protect booster seals and valves.
2. Setup & Leak Check: Connect drive air and nitrogen supply hoses; tighten fittings to 25 Nm; apply leak-check fluid to all joints.

  Startup Sequence:
  • Open drive-air ball valve; adjust regulator to 6 bar.
  • Open nitrogen inlet valve slowly; observe inlet/outlet gauges for stable rise.
  • Increase drive air to raise outlet pressure; do not exceed 300 bar.

3. Pressure Hold & Monitoring: At target pressure, close drive-air valve, isolate circuit, and record pressure at 0, 15, 30, and 45 minutes. Acceptable leak rate is <1 bar/hr.
4. Shutdown & Venting: Close nitrogen inlet, open vent valve to depressurize gas side, then bleed drive air. Stow hoses and lock the unit frame.

Quality Assurance & Inspection
• Dimensional Audit: Verify frame square-flatness and component alignment per P0938 QA drawing.
• Functional Test: Sequential boosting to 100 bar, 200 bar, and 300 bar with 30-min hold-time leak test, documented in the Pre-Dispatch QA Report.
• Calibration Certificates: All pressure gauges and relief valves carry NIST-traceable calibration, valid within ±1% accuracy.
• Documentation: Includes circuit diagrams (P0938-REV-00), operating procedure manual, and maintenance log sheets.

Pneumatic Circuit & Fitting Layout
• The A4-sized circuit plate (P-PED-MDWG-CIRCUIT-FITTING-DIAGRAM-P0938-REV-00) shows:
• Color-Coded Tubing: Blue (1⁄2o drive air), red (1⁄4o nitrogen feed), green (1⁄4o boosted N2).
• Component Tags: F1.0–F11.0 for filters, regulators, valves, and sensors.
• Flow Path: Air-drive enters at F1.0, passes through regulator (F2.0), into booster drive port, then boosted gas exits F8.0 to the outlet manifold.
• Maintenance Access: Quick-disconnect fittings at all valves for rapid replacement of filters and valves.

Conclusion
The P0938 Nitrogen Gas Boosting System combines Haskel’s robust AG-75 booster with precision Festo controls and Wika instrumentation to deliver reliable, oil-free nitrogen up to 300 bar. Its compact mobility, automated controls, and rigorous QA make it an ideal turnkey solution for purging, leak testing, accumulator charging, and cylinder fills in demanding industrial and laboratory settings.