How to choose a gas booster for high pressure - Interfluid Blog

Author: Jesse

Jun. 23, 2025

20 0 0

How to choose a gas booster for high pressure - Interfluid Blog

How to choose a gas booster? Before performing testing or maintenance operations of components, as well as other activities that imply the usage of gas at high pressure, it is necessary to consider some parameters that affect the pressure multiplying operations, such as the usage of flammable gases, working pressures and temperatures, purity and efficiency.

SUNCENTER contains other products and information you need, so please check it out.

Testing or maintenance operations on valves, fittings, cylinders and pipes that require the use of gas at high pressure require technical measures in order to always be efficient and safe: these should never be underestimated, both as regards selecting the most appropriate technology and in its use in the field. In addition, there are also seal tests, accumulator charging, gas transfer, loading and testing of airbags, tyre inflation and the refilling of gas cylinders.

For all of these applications, the most suitable instrument is a gas booster, a pressure multiplier that converts compressed air into high pressure (up to bar) by using the principle of differential areas, without any electrical connection or lubrication.

However, there are some important details to keep in mind before the selection and use of your gas booster, which are discussed below.

Gas boosters and flammable gases

For operations in which gas boosters use potentially explosive gases, it is necessary to ensure that components that come into contact with process gases are properly cleaned and degreased. Additionally, all vents and component vents must be routed and vented to a safe area.

Our recommendations. For the use of all non-inert gases, clean, degrease and respect the maximum pressure limit to avoid the risk of combustion.

Gas boosters and high temperatures

When gas is pressurised, a gas booster must be used that has standard seals in Viton, a material capable of withstanding temperatures up to approximately 190° C. Seal duration also increases with an external cooling sheath in the high pressure section (intercooler), which can recycle and use compressed air used by the pneumatic motor to cool the gas.

Our recommendations In order to keep the gas temperature from elevating too high, it is preferable to use a gas booster for all applications, with a compression ratio as low as possible. For applications with a high compression ratio, it is recommended to instead use a series of multiple boosters with different ratios, or two-stage models, to avoid the danger of the gas overheating.

Gas boosters and work safety

Unlike liquids, gas can be compressed at very high pressures. The systems that use it, such as gas boosters, therefore hold an enormous amount of energy within them that are capable of expanding quickly, which must be kept under control in order not to cause serious damage to people and things. For safe operation, it is therefore necessary to insert a booster downstream of the overflow valve, or, even better, a pressure relief valve. For greater control and safety, it is advisable to insert a pneumatic pilot valve in the circuit for minimum/maximum pressure.

Our recommendations. Above a certain pressure, it is better to use MPCT or HPCT connections to avoid dangerous leaks, i.e. connections for medium pressure or high pressure, both coned and threaded. It is also important to choose boosters with components that provide ample safety margins for pressure management, and to use low volumes when possible to minimise the risk of use. Lastly, remember not to use a gas booster indoors without suitable mechanical ventilation.

Gas boosters and gas purity

In order not to compromise the correct execution of use and operator safety, gases used must be as clean, dry, and uncontaminated as possible. The gas booster has a non-lubricated high pressure section, and is therefore does not have any contaminating hydrocarbons. This special feature allows complete asepticity of the device and the surrounding environment.

Our recommendations. The selection of dynamic seals made of inert material (PTFE) is preferable. The gas booster has a separation between the air motor and high pressure section through three gaskets, enhanced with two vent ports (conveyable) to ensure that the process gas cannot be contaminated by air from operations. One-way valves in the high pressure section that are in contact with the process gas are also made of inert material, i.e. stainless steel, bronze, PTFE and Viton, and are therefore free from hydrocarbons.

So: what is better, a gas booster or traditional mechanical compressor?

What do you need to know to avoid accidental gas booster pump ...

The booster valve can output multiple high-pressure gases, and the role of the gas booster pump is to input it, which can reach 2 times or 5 times the high-pressure gas. Manual adjustment is possible for output pressure and drive, with straightforward operation and excellent practicability. Let’s discuss other needs and how to choose the right gas booster pump.

How to choose the right gas booster pump type

Nitrogen, oxygen, and hydrogen are among the gases that the booster valve can pressurize. When choosing the type, the client should take the initiative to specify the necessary pressure and flow if the gas is corrosive, such as H2S, SO2, etc.

Gas Booster Pump Filtration Requirements

Compression serves as the booster valve’s power source, and it requires clean air and particles smaller than 5 um. The factory’s air source is typically quite polluted. If it is linked to the valve directly without filtering, the pump will build up dirt over time, which will eventually cause the one-way valve to malfunction. The sealing ring has significant wear.

Additional reading:
How to Choose an Inline Filter for Your Compressed Air System?

The company is the world’s best pneumatic chemical injection pump supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Gas booster pump installation requirements

The driving air source should be installed using a PU air pipe since it is simple to set up and operate and won’t corrode. If the metal pipe is used, it must be compressed before installation in order to prevent welding slag from blowing into the reversing valve and causing it to become stuck. Its service life may be impacted by the driving air source’s medium and purity. Normal compression will include some moisture and contaminants in the absence of a cold dryer or filter. The booster pump’s performance will be hampered by the moisture and pollutants that enter it. Its sealing ring and cylinder will become scratched with usage and efficiency.

Safe operating procedures for gas booster pump

1. The operator must be familiar with the equipment’s general layout and capabilities; using the equipment in any way other than as intended is strongly prohibited.

2. Before the operator, look for air leaks in the air pipe, couplings, and filter.

3. Integrate the air valve and modify the air pressure regulating valve to set the output air pressure to the desired level (tank pressure 0.95Mpa).

4. Check to see if the booster pump can operate normally.

5. Check to see if the gas storage tank’s pressure gauge reaches the preset level and whether the booster pump turns off when it does.

6. After the booster pump stops operating, confirm once more that the regulator’s pressure setting and the tank gauge pressure are in agreement.

7. When the job is done, shut off the air valve and clean the equipment.

Requirements for the use of gas booster pumps

The gas booster pump needs to be used and maintained in a number of ways in order to function better while in use and prevent mishaps.

Gas circuit boosting, pressure maintenance, and pressure stabilization are tasks that gas booster pumps are employed for in various industries. The natural gas industry is one example of a specific industry, which also includes pipeline transportation and pressure and static testing of valves, pipes, cylinders, etc.

When the air pressure needs to be increased because it is insufficient in the hot runner business. testing of brake systems and other parts for leaks in the auto parts industry. Transport via pipeline, instrumentation, and high-pressure gas testing are all related to the petrochemical sector. Additionally, there is the sewage industry, electrical industry, chemical industry, fire prevention industry, industrial robot industry, and so forth.

It is required to set the driving air pressure to between 3 and 8 bar while utilizing the gas booster pump. The driving air pressure’s 6 bar economic use pressure. Additionally, in order to ensure that the driving cylinder and the reversing valve function normally and that the sealing ring lives a long time, the driving air pressure needs to be kept clean, dry, and free of moisture.

A filter is installed at the IN (inlet) pressure of the gas booster pump’s booster section to maintain the purity of the pressured gas medium and serve as secondary protection. In addition, it is advised to install a bursting disc and other safety protection measures if the pressure of the high-pressure outlet is too high. It is important to purchase a pressure vessel (with a pressure vessel certificate) whose pressure value is higher than the rated output pressure of the pump body if the high-pressure outlet needs to be equipped with a buffer tank.

Gas Booster Pump Maintenance Requirements

Before performing maintenance on the gas booster pump, it must be maintained without air pressure, the drive must be stopped, the intake pressure must be stopped, and the high-pressure output pressure must be unloaded. Additionally, it is advised to interact with technical staff or carry out maintenance while being guided by video.

How to Choose an Inline Filter for Your Compressed Air System?

5 Things to Know Before Buying inline compressed air filter

Comments

More Categories You Might Be Interest