Details

Introduction
The Portable Single Cylinder Nitrogen Trolley with Booster is engineered to provide a rapid, on-demand source of high-pressure nitrogen for field and workshop use. Leveraging a single, standard nitrogen cylinder, the system incorporates a two-stage Haskel pneumatic booster to elevate gas pressures from a typical cylinder pressure of 200–250 bar up to a maximum of 415 bar (6,000 PSI). Mounted on a robust powder-coated steel trolley fitted with industrial-grade swivel casters, this unit combines portability with the performance of stationary boosters—ideal for maintenance teams, R&D labs, and mobile service fleets. Its compact footprint (690 × 645 × 1,150 mm) ensures it navigates through narrow aisles or confined test bays while carrying all necessary controls and gauges within easy reach.

Key Features
▹ High Boost Ratio & Precision Control: The 75:1 boost ratio delivers precise pressure increments. An adjustable high-pressure regulator allows users to set pressures in 1 bar increments, essential for delicate leak tests and burst evaluations.
▹ Dry, Filtered Drive Supply: A built-in 40 μm sintered filter in the drive air inlet ensures contaminant-free operation, extending booster life and preventing damage to sensitive valves and seals.
▹ Integrated Safety Relief: Beyond the primary safety relief valve set at 405 bar, each gauge (inlet and outlet) features a 15%  over-range stop to protect instrument internals, reducing downtime due to gauge failures.
▹ User-Friendly Control Panel: All control valves, regulators, and shut-offs are ergonomically arranged on a front-facing panel. Color-coded handles and clear pictograms minimize operator errors, even in low-light conditions.
▹ Extended Reach & Quick-Connects: Supplied with a 15 m stainless-steel braid hose terminated with ISO 7241 quick-disconnect fittings, enabling fast change-over between different test rigs without tools.
▹ Rugged Mobility: Pneumatic wheels and a textured handle provide secure maneuvering over uneven floors, facilitating deployment in outdoor sites or workshops.

Technical Specifications

  

    
Parameter
    
Details
  
  

    
Boost Ratio
    
75 : 1
  
  

    
Drive Pressure
    
6 bar (min.), up to 16 bar operating range
  
  

    
Drive Air Filtration
    
40 µm stainless steel sintered filter
  
  

    
Drive Flow Demand
    
60 SCFM
  
  

    
Max Outlet Pressure
    
415 bar (6,000 PSI)
  
  

    
Outlet Pressure Accuracy
    
±1 % FS after stabilization
  
  

    
Inlet Pressure Gauge
    
0–280 bar (±2 bar)
  
  

    
Outlet Pressure Gauge
    
0–4,000 bar (±20 bar)
  
  

    
High-Pressure Regulator
    
0–415 bar, micrometer adjustment
  
  

    
Hose Specification
    
15 m × 6 mm OD, 400 bar WP, stainless steel braid
  
  

    
Trolley Dimensions
    
690 × 645 × 1,150 mm (L × W × H)
  
  

    
Weight
    
≈ 75 kg (with hose and gauges)
  
  

    
Materials
    
Powder-coated mild steel frame; SS-316 valves, fittings, and gauges
  
  

    
Operating Temperature Range
    
–20 °C to +60 °C
  


System Description
The system comprises two tightly integrated subsystems:
1. Pneumatic Drive Module:
- Regulator & Filter Assembly: Ensures consistent, particle-free drive air to the Haskel booster, reducing wear.
- Vent & Isolation Valves: Provide safe depressurization without disconnecting hoses, facilitating rapid cycle times.

2. Nitrogen Boost Module:
- Haskel Booster Cylinder: Single-stage, balanced-piston design offers smooth, pulsation-free output.
- High-Pressure Valve Stack: High-cycle stainless steel valves accommodate thousands of operations per hour with minimal maintenance.
- Pressure Gauges & Regulator: Three SS-316 gauges monitor drive, inlet, and outlet pressures; an adjustable micrometer-style knob on the high-pressure regulator provides fine control.

Operation Procedure
1. Setup & Safety Checks: Verify cylinder valve cleanliness and remove any protective caps. Check all hose ferrules for damage; ensure quick-disconnect couplers lock securely.
2. Pressurization Sequence: Open the booster inlet valve; set drive air regulator to ~6–8 bar to start priming. When outlet gauge reads cylinder pressure, close inlet and gradually increase drive pressure until the desired test pressure is reached.
3. Testing & Fine Adjustment: Use the micrometer regulator to adjust ±1 bar around the target. Monitor gauge stability for at least 30 seconds before starting timed leak tests.
4. Depressurization & Changeover: Close drive air supply; open front-panel vent to release residual pressure. Disconnect test hose via quick-disconnect for UUT swap-out.
5. Maintenance Tips: Monthly lubrication of booster piston seals with Haskel-approved grease. Quarterly inspection of drive filter element and replacement if pressure drop exceeds 0.5 bar.

Safety Features
▹ Dual Redundant Relief: Primary relief at 405 bar; secondary burst disc at 430 bar for catastrophic backup.
▹ Over-Pressure Gauge Stops: Mechanical pin stops protect gauge internals from shock loading.
▹ Lockout Provision: Key-operated drive air isolation prevents unauthorized use.
▹ ANSI/ISO Compliance: Meets requirements of ISO 4413 (hydraulic systems) for safe design practices.
▹ Operator Training Module: QR code links to an online safety and operational video, reducing the risk of misuse.

Typical Applications
▹ Industrial Leak Testing: Rapid leak detection in hydraulic manifolds, piping assemblies, and high-pressure valves.
▹ Aerospace Accumulator Charging: Charging nitrogen gas bottles and accumulators to flight-certified pressures with traceable accuracy.
▹ Field Service & Commissioning: Portable platform ideal for oil-and-gas valve testing during commissioning of pipelines and wellheads.
▹ Laboratory Research: Controlled, pulsation-free pressure source for material fatigue and burst-testing protocols.

Conclusion
This Portable Single Cylinder Nitrogen Trolley with Booster stands as a benchmark in high-pressure boosting technology, merging mobility with precision control and robust safety measures. Whether deployed in remote field operations or integrated into quality-control labs, its turnkey design—complete with intuitive controls, comprehensive safety interlocks, and minimal maintenance requirements—ensures users achieve consistent, reliable results with minimal setup time. Offering customizable options for hose lengths, gauge ranges, and remote control interfaces, this booster trolley delivers unparalleled flexibility for diverse industrial, aerospace, and defense testing scenarios.