The Benefits of an Air Pressure Booster
Air pressure boosters are designed to pressurise pipeline air from ambient to high-pressure levels. They can also be used to manage peak consumption or as back-up compressors.
They use advanced piston technology and cylinder diameters that are specifically designed for higher pressure levels. Moreover, they are available in oil-injected or oil-free versions for various applications and industries.
Energy efficiency
Most industrial applications need different air pressure levels, and a booster system allows you to easily harmonise them. Air boosters allow you to utilise compressed air to its full potential, amplifying your existing supply of compressed air to provide the pressure level needed for the specific application. This means you can increase your production speed without the cost of buying an additional compressor.
An air pressure booster is an integral part of your compressed air system, converting low pressure into high-pressure with no loss of energy. A typical booster unit consists of an inlet check valve, two air power metres (APM), a discharge check valve, and a tank.
Depending on your requirements, you can choose between single-stage or multi-stage booster technology, with models available for both oil-lubricated and oil-free operation. Air is drawn from the inlet and compressed, and then pumped into the drive chamber by a movable piston. The energy from the pulsations generated during this process is recovered in the accumulator or pulsation tank and reused, increasing the air booster’s energy efficiency.
The energy consumption of a compressor is measured by the amount of air it consumes, while the consumption of an air pressure booster is measured using a special method which takes into account energy conservation and the flow rate characteristics. This enables the energy efficiency of an air pressure booster to be precisely assessed.
Reliability
Air boosters offer a reliable way to increase compressed air pressure. Rather than pushing an existing air compressor system to its limits, they add extra pressure until the desired level is achieved. This reduces energy consumption as well as wear and tear on the air compressor.
Another benefit of an air booster is that it can provide a stable air pressure booster supply of air, which can prevent pressure fluctuations for other equipment in your facility. This can improve output and efficiency, as the steady flow of air helps ensure your machines are running at their peak performance levels.
Additionally, most booster systems include a air pressure booster factory receiver and discharge tank to help dampen the pulsations caused by the compressor’s reciprocating movement. These tanks allow the booster to operate with less energy and also add an additional level of storage capacity for the system.
Air boosters can be used for a wide range of applications, from PET bottle production to air pressurisation testing and laser cutting. In fact, they play a vital role in many industrial processes, improving productivity and reducing maintenance costs. The amplified air pressure created by a booster allows pneumatic tools to work with greater precision, helping to produce finer workmanship and higher quality products. They can even be used for power generation, enhancing the operation of turbines and generators.
Maintenance
To ensure a long lifespan, air boosters require regular maintenance. This includes a visual inspection for wear and tear, leaks, and other blockages. A thorough inspection also helps prevent the need for expensive repairs or replacements. To maintain the quality of the driving air, the compressor should be isolated, and the tank pressure gauge should be observed for a drop in pressure. This indicates that there is a problem in the system. Coating the fittings in a soap and water mixture can help locate the source of the problem.
If an air booster is used in conjunction with a pulsation tank or receiver tank, the discharge check valve should be fitted downstream of the receiver to stop high pressure from bleeding back into the booster. This will reduce the amount of maintenance required, especially if the pulsation tank or receiver tank is leaking.
Similarly, Haskel’s pumperblock design is easy to maintain and can be done by one service technician without the need for a crane or special tools within 4 hours. The standard components don’t need any special oils and all of the service points are easily accessible. They also only need a 70 psi shop air supply and don’t require electrical power.
Safety
Air booster systems increase pressure with little energy, consuming no more than the amount of air used to start them up. They also produce minimal heat and do not need any cooling water. These features make them safer to use than air compressors, reducing the risk of injuries or damage to equipment.
Most compressed air tools and equipment work at a low pressure of up to 13 bar supplied by standard industrial air compressors. However, a number of applications require higher pressures. This includes spray painting, PET bottle production and train braking systems.
An air pressure booster can be connected to an existing air compressor system to provide a range of different working levels for various applications. This is more economical than using a separate air compressor and allows you to avoid over-pressurising your facility.
The Sprague booster works rapidly to reach the required working pressure and then stops when it reaches a pressure balance. This reduces energy consumption, prevents a build-up of excessive heat and minimises wear and tear on the unit. It can be controlled precisely by adjusting the pressure control valve on the compressed air inlet line or by connecting a 3/2-way on/off valve on the outlet side of the booster. A pulsation dampening tank (optional) can also be fitted upstream of the booster to prevent high pressure pulsations from going into and coming out of the system.
