Haskel Helps a Leading Fluid Systems Provider Drive Innovation

When you’re a leading fluid systems products and services provider, known around the globe as the inventor of fluid system components that revolutionized the space—you rely heavily on your robust research and development (R&D), production, and testing operations. As do your 1,000’s of employees. Not to mention your countless customers who rely on you to lead the pace of innovation, particularly in the growing hydrogen industry.

A heavy R&D environment like this one at this leading company requires the distribution of nitrogen and helium throughout the plant to effectively conduct a variety of tests, such as pressure tests, including leak tests. For example, the company engineers valves that are tested to maintain pressures of up to 5,000 PSI with nitrogen, throughout a network of different test benches, in order to ensure the equipment can reliably sustain that level of pressure in the field. That high-pressure nitrogen is also utilized to test final products and prove out design concepts.

Recently they began facing a major problem. One of their two, over-20-year-old hydraulically driven gas boosters, used for pressurization of compressed nitrogen and helium gasses for pressure testing, started failing and impacting timelines and budgets, as can be the case with older equipment. For an engineer or maintenance technician without much experience with hydraulics, troubleshooting a hydraulic problem can be tricky—failure modes can be caused by things like inadequate filtration, worn-out valves, leaky seals, and electrical operators that give out without indication. Additionally, as the industry grows so does the need to test at pressures greater than what their existing hydraulic boosters were designed to produce.

Recognizing the greater issue before them, especially with the hydraulic boosters approaching the end of their useful lifespan, the decision was made to replace them. So, they contacted the experts at Haskel for guidance, who had just what they needed to get the job done while automating their operation, improving productivity, and reducing costs: the Q-Drive gas compressor. Powered by an electric servo motor, this IoT enabled gas compressor delivers high efficiency, precision and accuracy. It enables seamless plug-and-play installation and easy integration with existing control systems, while providing cleaner, quieter, and more sustainable solution to traditional gas compressors. It also offers impressive features like three programmable operating modes, predictive maintenance and over 30 built in sensors to prevent overheating or over-pressurization, enable remote monitoring and operation.

Upon installation of their new Q-Drive system, the company immediately took advantage of Q-Drive's wide variety of automation features and advanced communication–items that they hadn’t been able to utilize until now. They also noted the incredible space savings, noise reduction, and lack of oil droplets as Q-Drive offers a much smaller footprint and cleaner operation than other types of gas compressors.

On top of that, the company was able to realize higher pressures with much greater accuracy and control from their new Q-Drive, allowing for additional advantages for the company in terms of operational savings. In fact, the company estimates that the Q-Drive unit will pay for itself based on the cost-savings in energy consumption of running the equipment alone.

Ultimately, Haskel’s Q-Drive solution has allowed the company to revolutionize their production process by replacing aging hydraulic systems with a smart, connected electric solution that offers unprecedented control over their test processes. As Q-Drive can be controlled using a 24Volt DC High/Low signal to start, stop, and pause the pump, the unit was easily integrated into their established plant infrastructure. Which meant little to no interruptions during the upgrade, and as well even more compression power and control over the pressure flowing to each individual testing bench.

This also helped in significantly reducing costs and increasing productivity. The new Q-Drive allows them to more efficiently innovate, while remaining adaptable to changing market conditions.

To learn more about how the Q-Drive can also help you reach your operational goals, contact us today.