Nitrogen Gas Boosting Station, rated to 300 bar.

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

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.
• 3. Startup Sequence: open the drive-air ball valve and adjust the regulator to 6 bar; open the nitrogen inlet valve slowly, observing inlet/outlet gauges for stable rise; increase drive air to raise outlet pressure, never exceeding 300 bar.
• 4. Pressure Hold & Monitoring: at target pressure, close the drive-air valve, isolate the circuit, and record pressure at 0, 15, 30 and 45 minutes. Acceptable leak rate is <1 bar/hr.
• 5. Shutdown & Venting: close the nitrogen inlet, open the vent valve to depressurize the gas side, then bleed drive air. Stow hoses and lock the unit frame.

Quality assurance & inspection

• Dimensional Audit: frame square-flatness and component alignment verified per the P0938 QA drawing.
• Functional Test: sequential boosting to 100 bar, 200 bar and 300 bar with a 30-minute 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) documents the full pneumatic layout.
• Color-Coded Tubing: blue (½″ drive air), red (¼″ nitrogen feed), green (¼″ boosted N2).
• Component Tags: F1.0–F11.0 for filters, regulators, valves and sensors.
• Flow Path: air-drive enters at F1.0, passes through the regulator (F2.0), into the 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.