Details

Introduction
The Oxygen Gas Boosting System is a compact, skid-mounted unit designed to elevate oxygen pressures up to 350 bar (≈5,000 psi) using only plant air (3–7 bar), eliminating electrical ignition risks and ensuring intrinsic safety for oxygen service. Its oxygen-clean construction (ASTM G-93), multi-stage compression, and integrated control logic make it suitable for cylinder filling, rebreather top-off, emergency backup, and continuous feed in critical medical, industrial, and defense applications.

Key Features
▹ Multi-Stage Compression with Intercooling: Three- to five-stage piston arrangement with stainless-steel intercoolers to maintain gas integrity and manage temperatures < 80 °C.
▹ Variable Drive-Air Control: Optional proportional valve or hybrid electric drive for soft-start and optimized air consumption.
▹ Purity & Dew-Point Monitoring: Inline oxygen analyzer (> 99.5 % purity) and moisture sensor (dew point < –40 °C) for medical and semiconductor standards.
▹ Oxygen-Clean Design: All wetted parts, hoses, gauges, and vessels cleaned and certified to ASTM G-93; hydro-test-certified hoses and calibration certificates included.
▹ Explosion-Proof Operation: Fully pneumatic (or ATEX-rated electric) design approved for Zone 2 hazardous areas.
▹ Integrated PLC/HMI Interface: 7′′ touchscreen with recipe storage, SCADA/Modbus connectivity, event logging, and self-diagnostics.
▹ Automated Purge & Relief: Post-shutdown purge clears residual O2; safety-relief valves set at 210 bar protect against over-pressure.
▹ Modular Skid-Mount Construction: Forklift pockets, lifting eyes, shock mounts, and pre-piped skid for rapid deployment.

Technical Specifications

  

    
Parameter
    
Specification
  
  

    
Drive Medium
    
Plant air (3–7 bar) / Optional electric motor
  
  

    
Gas Inlet Pressure
    
20–120 bar
  
  

    
Max. Outlet Pressure
    
350 bar (≈5,000 psi)
  
  

    
Flow Rate
    
Up to 20 Nm³/h @ 200 bar; 5 Nm³/h @ 350 bar
  
  

    
Dew Point
    
< -40 °C (post-filter)
  
  

    
Purity
    
> 99.5 % O₂
  
  

    
Drive-Air Consumption
    
100–200 Nm³/h
  
  

    
Noise Level
    
< 75 dB(A) at 1 m
  
  

    
Weight & Footprint
    
~250 kg; 1.5 m × 0.8 m skid
  
  

    
Safety Relief Setting
    
210 bar
  
  

    
Certifications
    
CE, ISO 13485, ASTM G-93, ATEX Zone 2
  


Applications
▹ Cylinder Filling & Gas Transfer: Rapid, safe topping-off of industrial, medical, and emergency O2 cylinders.
▹ Medical & Life-Support: ICU backup, hyperbaric therapy charging, mobile field-hospital carts.
▹ Aviation & Defense: Aircraft emergency O2, pilot rebreather top-off, EVA ground support.
▹ SCUBA & Rebreather Industry: Dive-shop fill stations, military dive teams.
▹ Industrial Manufacturing: Laser cutting, welding, glass-melting, reactor purges, semiconductor oxidation.
▹ Environmental & Research: Waste-water aeration, hypersonic wind-tunnel injection, combustion tests.

System Architecture & Control
▹ Air-Drive Section: Piston assembly isolated by stainless membranes; two-stage filtration (coalescing + carbon) for pneumatic valves.
▹ Oxygen Compression Block: Oxygen-service pistons with intercoolers to limit temperatures; dynamic seals for leak-free operation.
▹ Control & Safety Subsystem: PLC monitors pressures, executes PID loops; redundant transmitters and mechanical relief valves ensure fail-safe operation.
▹ Human-Machine Interface: 7′′ touchscreen for setpoints, alarms, maintenance countdown; Ethernet/Modbus TCP for remote SCADA integration.

Principle of Operation
▹ Startup: Drive-air signal or electric motor engages booster at low stroke, ramping to full flow.
▹ Compression: Oxygen passes through staged pistons; intercoolers remove heat to protect gas quality.
▹ Pressure Regulation: Outlet transducer closes drive-air valve at setpoint; excess pressure is bled safely.
▹ Shutdown & Purge: Drive-air venting and purge valve operation clear residual oxygen, avoiding stagnation.

Maintenance & Lifecycle
▹ Monthly/500 h: Inspect filters, hoses, relief-valve settings.
▹ Quarterly: Calibrate transmitters and dew-point sensor; test interlocks.
▹ Annual: Full oxygen-clean re-certification; dynamic seals and hose hydro-test to 1.5× MAWP.
▹ Spares Kit: O-rings, filters, relief cartridges, transducer module, PLC backup.

Optional Modules & Customization
- Redundant Booster Skid: Auto-switchover for uninterrupted operation.
- Gas Blending Package: Precise O2–N2 mixtures via mass-flow controllers.
- Remote Monitoring: Cloud telemetry with SMS/email alerts, dashboard analytics, MQTT/OPC-UA.
- Climate-Controlled Enclosure: IP55 cabinet with heater/AC for –20 °C to +55 °C environments.
- Mobile Configuration: Wheel-mounted frames, fold-down skid arms, shock isolation.

Installation & Commissioning
- Plug-and-Play Piping: ISO 8434 quick-connect fittings, reducing hook-up time to < 2 hours.
- Factory Acceptance Testing: Pneumatic endurance run, PSIP report, witness video.
- Site Survey & Layout: 2D/3D CAD for placement, ventilation, and service access.
- Operator Training: Two-day on-site course covering operation, maintenance, and emergency procedures.

Environmental & Efficiency Considerations
- Optimized Air Consumption: Piston timing logic cuts drive-air use by up to 30%.
- Noise Reduction: Acoustic enclosure and chamber muffler achieve < 70 dB(A), meeting OSHA standards.
- Heat Recovery: Optional exchanger captures waste heat for process or building heating.
- Compact Footprint: 1.2 m × 0.8 m skid; modular stacking of dryers or buffer tanks.

After-Sales Support & Warranty
- Standard Warranty: 12 months on parts and labor; extendable to 24 months with annual maintenance contract.
- Service Agreements: Bimonthly inspections, 24×7 hotline, 48-hour spare-parts delivery.
- Spares Availability: Kits stocked for 5 years post-sale, distributed via Neometrix Defence Limited.
- Software Updates: Free firmware enhancements and cybersecurity patches via USB or remote download.

Conclusion
This turnkey Oxygen Gas Boosting System combines ultra-safe pneumatic compression, smart controls, and scalable modules to meet the most demanding requirements in medical, industrial, and defense sectors. With its oxygen-clean design, robust safety features, and comprehensive lifecycle support, it delivers unmatched reliability, purity assurance, and total cost of ownership optimization.