Equipment Considerations for Hydrogen Applications
Due to the inherent dangers of working with pressurized hydrogen, it is important to utilize high-pressure equipment that is reliable even in hazardous conditions. An understanding of the specific considerations for these types of applications helps ensure workplace safety and compliance with industry standards.
Importance of Using the Right High-Pressure Equipment
When compared to other types of fuel, hydrogen has a very wide flammability range. It is therefore vital that high-pressure equipment used in hydrogen applications does not have any weak points, as hydrogen may press against these points to create cracks or leakage. If the equipment cannot safely contain hydrogen, there are several hazards to be cognizant of.
When pressurized hydrogen causes a crack in the piping system, it may lead to explosions. This is particularly dangerous because hydrogen requires such low amounts of energy to ignite. Hydrogen flames are difficult to see in daylight and do not produce smoke, making them challenging to identify without getting hazardously close.
In addition to the risks surrounding hydrogen explosions and flames, other hazards to note include:
Hydrogen embrittlement. When hydrogen causes a material to lose ductility and become brittle.
Hydrogen permeation. A phenomenon wherein hydrogen ions penetrate thin diaphragms, leading to inaccurate measurements.
Hydrogen asphyxiation. A significant risk when hydrogen accumulates during a leak.
Factors to Consider When Selecting High-Pressure Equipment
When selecting the appropriate high-pressure valves, fittings, and tubing, there are many factors to consider:
High Pressure Valves
High pressure hydrogen valves must meet strict industry standards to ensure high performance even in harsh environments. Factors to consider when choosing a hydrogen gas valve include:
Temperature range. The valve must be able to operate well at a wide range of temperatures.
Regulating stem design. A regulating stem controls the flow of gas.
Seat material. Metal seats create a tighter shut-off, resulting in improved equipment longevity.
Valve body patterns. There is a range of patterns available depending on the needs of the application.
Sizes and ratings. Choosing the appropriate size ensures the valve will perform well under the required pressure.
High Pressure Fittings
Factors to consider when choosing high pressure fittings include:
Types of fittings. There are a range of fitting types to choose from, including adapters, couplings, and elbows.
Sizes and ratings. Depending on the size, fittings may have a pressure rating of standard, medium, high, or ultra high.
Quality control and industry standards. High pressure fittings should meet quality control standards such as those set by ASME.
High Pressure Tubing
When choosing high pressure tubing, it is important to consider both the diameter size and the pressure ratings. Tubing with a smaller diameter will generally withstand higher pressures than tubing with a larger diameter.
When paired with the proper equipment, hydrogen has a vast array of applications, including:
Power plant generator cooling
Oil and gas
Hydrogenation of unsaturated fatty acids in vegetable oils
For over two decades, MAXPRO has been providing industry-leading hydrogen solutions for customers across a range of industries. We are ISO 9001:2015 certified, with a strong commitment to quality. Our equipment meets the standards of both the American Society of Mechanical Engineers (ASME) and European Pressure Equipment Directive 97/23/EC, and is TUV certified and CE Mark compliant.
High-Pressure Equipment from MAXPRO
Choosing appropriate equipment is vital when working with pressurized hydrogen. Our experienced team will work with you to determine the options that best suit the needs of your project. Find more information in our brochure, or request your quote today to begin working with us on your next project.
Maximator® dry air spools (DAS) can be used for liquid pumps, gas boosters, and air amplifiers. They are suitable for dry air, nitrogen, and other severe operating conditions (e.g., air dew point below 0° F and ambient temperature below 0° F). The following article covers how to repair and lubricate the spool valve.
Spool tool remover – Sold by Maxpro
Hammer or mallet
Repair kit- Includes O-rings and a snap ring
Grease – We recommend Kluber Lube, Polylub GA 352 P High Temperature Grease. This grease has good long term adhesion and water resistance.
Overview of the Spool Valve Repair & Lubrication Process
Loosen four cap screws that hold the spool housing to the end cap to release any air trapped in the spool valve.
Remove the snap ring from the spool valve housing.
With a long screw driver or wooden dowel, from the ½” FNPT side of the housing, push out the spool plug and spool from the housing.
Clean the spool and bore of the housing sleeve. Check the O-rings for wear and the spool sleeve for scratches. Replace if necessary.
Put a light coat of grease on the O-rings and in the bore of the spool sleeve.
Insert the spool into the spool sleeve, small side first, gently moving the spool from side to side with very little pressure on the end of the spool. DO NOT FORCE. The O-rings fit loosely on the spool and can be cut if they are forced in.
Install the spool plug and snap ring, then tighten the four cap screws that hold the housing to the end cap.
Spool Valve Installation and Repair Services at MAXPRO
At MAXPRO Technologies, we stand behind our line of quality high-pressure products with after-the-sale support. Our after-the-sale services include testing, evaluation, inspection, cleaning, and repair by factory trained technicians.
Need assistance repairing or rebuilding your dry air spool? Contact us today. We provide quick and quality solutions at a competitive price. To learn more about our in-house and field repair services, contact us today. For pricing details, request a quote.
MAXPRO® offers quality Maximator® valves, fittings and tubing, delivering lasting performance under even the most extreme operating conditions. Our engineers leverage more than 325 years of combined experience to match customers with competitively priced components that meet their application’s exact requirements. MAXPRO’s offerings include high-pressure valves, fittings, and tubing with pressure ratings ranging from medium to ultra-high. Maximator® equipment can accommodate applications up to and above 100,000 PSI.
MAXPRO’s line of Maximator® valves includes medium-, high-, and ultra-high-pressure valves with standard coned and threaded connections that facilitate tight and reliable seals. Maximator’s facilities are ISO 9001:2015- and TUV-certified, and extensive quality assurance processes ensure reliable valves and fittings.
Maximator high-pressure valves offer several key features:
Wide temperature range. All Maximator valves can operate at temperatures reaching 450°F, while our extreme temperature products suit applications ranging from -423°F to 1200° F.
Non-rotating stem design. Maximator valves feature a non-rotating stem design to eliminate stem-to-seat galling and provide smooth operation. Options include a simple on/off Vee stem or a regulating stem for more precise flow control.
Metal-to-metal seat. Designed for maximum seal strength, Maximator valves use a metal-to-metal seat for an airtight shut-off. This feature also improves the longevity of both the stem and the seat.
Variety of pattern options. We strive to offer a valve for every high-pressure application, with six valve body patterns available, including an optional replaceable seat for the two-way angle body pattern.
Versatile pressure ratings. Our medium-pressure valves withstand up to 22,500 PSI, while our ultra-high pressure valves can endure 101,000 PSI, so there is an option for every industrial need.
These features have made MAXPRO’s Maximator valves a trusted option since 2006.
High-pressure operations occur in many industries, including chemical processing, oil and gas, and industrial manufacturing. Some common applications include:
Waterjet. High-pressure needle valves control the extreme water pressure that waterjet cutting equipment needs to slice through metal, granite, and other hard materials.
Oil and gas. Facilities that extract, refine, or transport oil and gas all rely on specialty valves to control operations.
Food processing. Many food processing applications involve transporting various slurries, liquids, or powders. A range of high-pressure control valves aid in food processing and sanitizing operations.
Chemical processing. Chemical plants and power generation facilities rely on high-pressure ball valves, needle valves, and check valves to safely move volatile materials.
The experts at MAXPRO can help your team identify the right valve for your application.
High-pressure valves and tubing must be used with fittings with the same pressure rating. Maximator high-pressure fittings have been engineered to provide reliable performance and maintain system integrity in hazardous working environments. The complete line of fittings includes:
Adapters. Available in male/male or male/female configurations, our adapters allow users to connect components of different sizes.
Anti-vibration collet/gland assemblies. Provides extended support and rotational grip for the tubing that is entering the connection fittings with the use of a secondary compressor-type fitting. In doing so, they shield the coned and threaded connection from excessive tube loading and vibration.
Couplings. Couplings can connect components of either similar or dissimilar sizes.
Elbows. Elbows add two common connections to a tubing line, also forming a right angle.
Tees. These T-shaped fittings add three common connections to a tubing line.
Crosses. Named for their cross shape, these parts fit four common connections to a tubing line.
Nipples. Nipples connect two common male connections to tubing.
Safety head assemblies. Safety head assemblies are used for overpressure protection
These fittings offer reliable connections in high-pressure industrial settings.
Any fluid process that calls for high-pressure tubing or valves also requires suitable fittings. Some equipment that may require high pressure fittings include:
Oil and gas control panels and skids
Chemical injection skids
Hydraulic power units
Waterjet cleaning and cutting units
MAXPRO’s high-pressure tubing is produced from thick walled, high tensile strength stainless steel. Our quality, cold-drawn tubing is available in medium-, high-, and ultra-high-pressure ratings. Autofrettaged tubing with enhanced fatigue life is also available for high-pressure production applications.
High-pressure tubing is used in the same industries that rely on high-pressure valves or fittings:
Oil and gas. The oil and gas industry utilizes high-pressure tubing in down-hole control systems, hydraulic and pneumatic piping, chemical injection modules, vacuum systems, and others.
Waterjet cutting. MAXPRO stocks high pressure tubing for use with waterjet cutting machines.
Food processing. MAXPRO’s ultra-high-pressure rated tubing easily manages the 87,000 PSI required by various food processing applications.
Whatever the industry, any high-pressure fluid application can benefit from MAXPRO’s trusted high-pressure tubing. Our sales team will help you find the right combination of tubes, valves, and fittings to enhance your application’s safety and efficiency.
High-Performance Products for High-Pressure Applications
MAXPRO’s comprehensive range of tubing, valves, and fittings includes components for virtually any high-pressure application. As experts in high-pressure valves, fittings and tubing, we help customers choose the best items for their application. Whether you need a standard or custom set of high-pressure components, our team is here to help. Contact us today to learn more how our high-pressure engineering expertise can benefit your application.
More Control – More Efficient – Endless Possibilities
What is a Hydraulic Intensifier?
Can You Benefit from an Intensifier?
What is a Hydraulic Intensifier?
A hydraulic intensifier system is quite simple in principle, the system uses hydraulic power to increase the pressure of a liquid or gas. Pressure multiplication occurs because of the dissimilar areas between the hydraulic piston and the process media piston. The ratio of the area between the hydraulic piston and process media piston is known as the pressure ratio.
(Ex: a 10in³ hydraulic piston pushing a 5in³ process media piston had a ratio of 1:2). A ratio of 1:2 can multiply the process media pressure by two times the hydraulic pressure.
Single Stage Intensifier
With a single stage intensifier both the left and right sides have the same ratio resulting in one pressure discharge from the intensifier for every stroke as shown in the picture.
Two Stage Intensifier
With a two-stage intensifier the left and right sides have different pressure ratios, this is also known as a multiple ratio intensifier. Multiple ratio intensifiers allow for a larger pressure multiplication than with a single stage. This style of intensifier only produces a pressure discharge every other stroke as shown in the picture.
Maxpro Technologies has recently designed a new generation of intensifiers to seamlessly integrate with modern and advancing technologies. Our intensifiers now have the option of using electronics and integration to bridge the gap of the mechanical and digital world.
With our latest generation of intensifiers, we are now able to have real time monitoring and feedback of all machine parameters right at your fingertips. For example, the machine is constantly analyzing inlet pressure, outlet pressure, hydraulic flow rate and temperature, coolant flow rates and so much more.
You might wonder why it is so important to continuously analyze all this data, after all our previous generation did not do this. The reason is simple, More Control – More Efficient – Endless Possibilities.
Our automated intensifiers with process monitoring have user programmable recipes to keep your process on point. Minimum and maximum process media pressures can be defined along with specific flow rates to dial in your process like never before.
In today’s world manufacturing is about being lean. Companies are constantly striving to increase productivity while simultaneously decreasing process waste. In the case of our intensifier, we were able to significantly reduce electrical waste. Running motors can be expensive especially under high load. Our control and monitoring system gives you on demand power when you need it and idles without load or powers down when not in use.
No one knows your process better than you; this is why our system is programmed to be flexible. Recipes allow the user to have different process setups saved in the controller, all of which are continuously monitored to keep everything running safely.
In modern times people are accustomed to being connected to their devices. Our latest intensifier is set up to be no different. Our controls system can remotely interface where an internet connection is available as well as receive email notifications of critical machine events. An auxiliary plug prewired to be integrated with other pieces of equipment is also included.
Can You Benefit from an Intensifier?
Hydraulic Intensifiers can be used any time the available liquids or gases are at pressures lower than what is required by the process. Intensifiers will take low pressure liquid or gas and boost them to a specific pressure and flow rate depending on the intensifier configuration and horsepower. Some common pumping media and applications are as follows.
Gas Foaming of Polystyrene
Gas Cylinder Filling
Supercritical CO2 Extraction & Cleaning
Gas Assisted Injection Molding
Gas Supply to Sintering Furnace
Gas Tube Trailer & Cylinder Scavenging
Gas Vapor Reclaim from Cryogenic Storage
Supply Gas to Hot Isostatic Pressing (HIP)
Cold Isostatic Pressing (CIP) of powdered metals and ceramics
Hydrostatic pressure testing
Maxpro Technologies offers three system levels; manual, control and monitoring, and also control and monitoring with tubing.
Manual systems are the simplest form of the hydraulic intensifier. These systems consist of the intensifier, hydraulic power unit and a motor starter with on/off control. This style of system must either be manually operated or integrated into other equipment due to the absence of process feedback. This is a great style of system for someone who wants to do all their own integration and controls or wants a budget system to operate manually.
Control and Monitoring
The control and monitoring system is a plug and play system recently designed to fill a rapidly increasing market demand. This style of Intensifier is a closed loop system meaning it constantly watches your upstream and downstream processes and makes decisions on how to operate based on that data. The advantage of this style of system is that it takes all the guess work out. The integrated recipe page allows you to set up custom process parameters that the system can safely operate within.
Control and Monitoring with Tubing
Systems that incorporate the addition of external plumbing are turnkey systems. These systems not only control the intensifier as described in the control and monitoring system, but they also control any upstream and downstream plumbing as specified by the customer. At Maxpro, our engineers and designers are dedicated to designing custom systems to your specifications.
Maxpro Technologies also has traveling technicians to complete your system install.
If you are completing your own install, check out our patented Coning and Threading Machine to greatly cut down on install time. The Coning and Threading Machine can be purchased or rented.
For more information regarding our line of Hydraulic intensifiers or other quality products from Maxpro Technologies, please contact sales at firstname.lastname@example.org or speak with one of our engineers (814-474-9191).
Pressure relief valves are intended to protect system components from over pressurization. The pressure relief valve is often set at 10% over maximum system operating pressure to allow the system to operate up to the maximum working pressure rating. The maximum allowable working pressure for the system is based on the lowest rated system component. The size must be chosen to allow the rate of relief flow to equal or exceed the potential various sources of over pressurization. Materials of construction must be chosen to be compatible with the fluid or gas that will be encountered. Poor material choices could lead to faulty operation of the relief valve and failure to relieve overpressure as intended.
Features of MAXPRO®’s High Pressure Relief Valves
Proportional high pressure relief valves from MAXPRO® are designed with simplicity in mind. The goal is to support long term reliability, performance, and serviceability, while providing the safety relief valve function. The relieving function is accomplished by an adjustable spring force acting upon a stem that presents two unequal areas for inlet pressure to act upon, causing stem lift off the seat. The higher the spring force, the higher the relieving pressure. With the proportional relief valve design, higher system pressure causes higher stem lift, resulting in higher relieving flow. This “unbalanced stem” design also provides for smoother operation over those that simply lift from the stem area under the seat and minimizes the reseating pressure window as well as hysteresis of the set pressure. These valves are not poppet style relief valves. At a preset pressure, poppet style relief valves “pop” full open for maximum flow, and then snap closed at some reseating pressure. Poppet style valves tend to be more complex to achieve the pop-open action.
MAXPRO® offers proportional relief valves with four minimum/maximum set pressures to support most applications. Choose from:
Note: The sensing pressure enters the side port and exits the bottom port. MT3RV and MT10RV have two standard side ports. The second port can be for a tee for a gauge or vent line, or the extra side port can be plugged if preferred. MT25RV and MT66RV have one sensing port.
Speak to a MAXPRO® Engineer
Please contact us today to discuss your overpressure protection application with one of our helpful engineers.
MAXIMATOR high pressure valves are designed to safely operate at pressures of 15,500 psi for a 1-½” medium pressure valve up to 101,000 psi for an Ultra-High Pressure Valve. High pressure valves are used to regulate flow in various fluid handling operations across a wide range of industries, including aerospace, automotive, military, and mining industries. Selecting the best, high pressure valve for your application is crucial.
There are many factors to consider when choosing a high pressure valve. Below, we highlight some key factors to consider when choosing the right high pressure valve for your application.
Factors to Consider When Evaluating Your High Pressure Valve Needs
Important factors to consider when evaluating whether a particular high pressure valve is right for your fluid handling application include:
Process medium: The valve should be able to handle the process medium, whether it is in gas, liquid, or steam form, inert, abrasive, or corrosive, and hot or cold.
Pressure rating: It should be rated to handle the range of pressures expected in operation. Consider upstream and downstream pressure for the maximum, normal, and minimum flow rates.
Temperature: The valve should be rated to handle process medium temperatures.
Flow rate: A high pressure valve should be properly sized to ensure it has the proper flow rate capacity.
Connection type and size: It should have a connection type and size that fits the inlet/outlet piping.
Valve style: Do you need a manual valve or an air actuated valve? If air operated, should the valve be air-to-open (normally closed) or air-to-close (normally open)?
Construction material: A high pressure valve should be constructed of material that can withstand the process medium and operating conditions (temperature, pressure, flow, etc.). For example, stainless steel is suitable for fluid handling operations involving corrosive materials.
Application: It should be appropriate for implementation in the system.
High-Pressure Valve Solutions at MAXPRO®
At MAXPRO® Technologies, our MAXIMATOR® line encompasses a range of manual and air-actuated valves. Key features include:
Non-rotating, rising stem design
316 stainless steel wetted parts with 17-4 PH stainless steel stem
Metal-to-metal seating for bubble-tight shut-off
Optional reversible and replaceable valve seat is available
Combined, these features result in durable and long-lasting valve solutions for repeated open and close cycle operations. Our air-actuated valves come with a piston-style air actuator that is normally closed or normally open. This design offers even better operation and service life. Additionally, mounting the actuator on a yoke keeps it separated from the process fluids, which helps with stem position indication and stem replacement.
Our MAXIMATOR® line includes:
Medium-pressure needle valves: rated to 22,500 psi and available in 1/4″, 3/8″, 9/16″ 3/4″, and 1″ connection sizes. 1-½” valves are rated to 15,500 psi
High-pressure needle valves: rated to 65,000 psi and available in 1/4″, 3/8″, and 9/16″ connection sizes
Ultra-high-pressure valves: rated to 101,000 psi and available in 1/4″, 5/16″, 3/8″, and 9/16″ connection sizes
Both our medium-pressure and high-pressure valves are available with six body patterns:
2-way angle with replaceable seat
Contact the High Pressure Equipment Experts at MAXPRO Today
Need high pressure valves for your fluid handling operations? Turn to the equipment experts at MAXPRO®! We stock a broad selection of quality valves, fittings, and tubing for many high pressure applications. For more information about our MAXIMATOR high pressure valves, fittings and tubing , contact us today or request a quote.
Air amplifiers are industrial equipment designed to increase air pressure to improve pneumatic tool operation. When centralized air pressure systems are insufficient to power air-driven tools, air amplifiers can fill localized demand. Depending on the type of unit, air amplifiers have various pressure and flow capabilities, ranging anywhere from 30 to 4,350 PSI. Because there is such a wide selection of air amplifier designs available on the market, it is important to carefully select the right one for your intended application.
How Air Amplifiers Work
Air-driven air amplifiers use the principle of differential areas to generate pressure. By having a higher ratio of inlet to outlet piston areas, air amplifiers utilize shop air, use some of that air as power to operate the unit (called the ‘drive air’), and intensifies the remainder of the inlet air into pressurized output. Shop air utilizes a four-way spool valve to affect cycling, then exhausts the drive air. There are two main ways MAXPRO® Air Amplifier Systems achieve this:
DLA Series: A large air piston drives a smaller air piston to generate higher pressure levels.
PLV Series: These units have two fixed area pistons. During cycling, the air amplifier utilizes one of the pistons to effectively double the incoming air pressure.
MAXPRO® air amplifier systems include an air control package, the amplifier, air storage tank with drain valve, pressure relief valve and outlet pressure regulator with gauge.
Sizing Air Amplifiers
Consider these factors as you determine the right air amplifier for your application:
Airflow demands are based on the application, environment, and specific equipment involved in each case. Parameters to consider:
Available inlet air drive flow and pressure
Required outlet pressure
Required flow at outlet pressure
What is the highest flow and pressure needed?
Describe typical machine cycle requirements
It is crucial to figure out the highest and lowest air pressure requirement. Remember you will need to store up higher pressure than is needed to provide the delta P needed for airflow.
Duty Cycle (Intermittent demand or 24/7 operation?)
Future expansion of production line (will more volume be needed in the future?)
Future need for higher pressure and flow?
Distance to work (line lengths can become a factor for pressure and flow)
Air Amplifiers From MAXPRO
At MAXPRO, we have concentrated on helping our clients find the right air amplifiers and air amplifier systems for over 25 years. Customer service is our top priority. Our knowledgeable engineers and sales staff are ready to help you select the best MAXPRO Air Amplifier System for your requirements. Contact us today to learn more about our inventory or browse our catalog online.