Air-driven. 2689 bar. Zero electrical connection.

Why air-driven boosting matters

High-pressure gas testing is a routine requirement across defence, aerospace, automotive, and industrial manufacturing. However, many environments where pressure testing is needed — fuel handling facilities, gas cylinder stores, field maintenance, explosive environments — carry restrictions on electrical equipment. The Pressure Pac solves this by using compressed air as the sole drive medium, generating nitrogen pressure up to 2689 bar with no electrical connection whatsoever.

The core of the system is a Haskel air-driven booster pump. Haskel is the established standard for air-operated high-pressure gas boosters in defence and industrial applications. The pump uses the input air pressure acting on a large-area piston to develop proportionally higher output pressures on a smaller-area gas piston — generating pressure ratios that allow modest drive air pressures (4 kg/cm²) to produce extreme output pressures.

Inlet and filtration circuit

Drive air supply

The drive air supply must be dry and filtered to protect the booster pump internals. The Pressure Pac requires a minimum drive air pressure of 4 kg/cm² at a flow rate of 60 SCFM. A dew point temperature (DPT) of −40°C is specified for the drive air, which is in the customer's scope — a suitably rated compressed air dryer must be provided at the installation. Drive air purity requirements are 7 micron (for 2.0 class) and 5 micron (for 6.0 class).

Inlet nitrogen filtration

A 5 micron high-pressure filter on the nitrogen inlet protects the booster and test circuit from particulate contamination. Inlet nitrogen is supplied at 17–150 kg/cm², filtered to 5 micron before entering the booster. This purity requirement ensures consistent booster performance and prevents damage to precision valve seats and test article connections.

Pressure generation and control

The Haskel booster amplifies the inlet nitrogen pressure to the required output level. The Pressure Pac supports multiple selectable output pressure ranges — 10, 50, 100, and 200 kg/cm² — configured via precision pressure regulation for different test requirements. Step pressurisation capability allows controlled ramp-up from 0.5 kg/cm² to 7 kg/cm², enabling pressure-step test protocols where the test article must be held at intermediate pressures before proceeding to the full test pressure.

The maximum achievable output pressure from the Haskel booster is 2689 bar. The outlet gas flow rate is variable and configured according to the specific test requirement.

Safety features

Safety relief valve

A safety relief valve provides overpressure protection throughout the high-pressure circuit. It is set to limit system pressure to the rated safe working pressure and activates automatically if the circuit pressure exceeds the setpoint — protecting the test article, connecting hoses, and the booster itself from damage caused by over-pressurisation.

Vent valve

The vent valve allows the pressurised gas in the test unit to be safely released after test completion. Before any disconnect or demount operation, the operator opens the vent valve to depressurise the circuit in a controlled manner. This is a mandatory procedural step in all pressure testing operations and the Pressure Pac incorporates a dedicated vent valve to facilitate safe de-energisation of the circuit.

Portability and installation

The complete system is mounted on a compact trolley with two lockable castors. The trolley design keeps the system footprint minimal, allowing deployment in restricted workshop spaces, on vehicle platforms, or at field maintenance locations. No electrical connection is required at any point — the only utilities needed are a compressed air supply and an inlet nitrogen supply, both via standard high-pressure hose connections.

Neometrix provides site preparation guidance, connection diagrams, and operator training. Standard 12-month warranty covers all manufacturing defects. Annual maintenance contracts and on-site service are available post-warranty.

Multi-gas capability

While nitrogen is the standard working medium, the Pressure Pac can generate pressure for use with other gases including hydrogen, helium, and oxygen, subject to compatibility review of the specific application and connection hardware. Contact our engineering team to confirm suitability for non-standard gas media before ordering.