Industries that rely on high-pressure gas systems like energy, oil & gas, and advanced manufacturing, face ongoing challenges in ensuring process safety and cost efficiency. One such challenge is maintaining a steady, high-purity supply of nitrogen gas for leak testing and other critical operations.
 

OMB Valves, a leader in engineered valve solutions for harsh environments, faced high operational costs and logistical complexity tied to nitrogen supply. Their solution? Transitioning to on-site nitrogen generation with a fully integrated plug-and-play skid system from Pneumatech.

Here’s how this innovative setup transformed their operations.

OMB routinely conducts high-pressure leak testing on its valves using inert nitrogen gas, ensuring they meet extreme safety and performance standards. Until recently, this involved a cryogenic nitrogen supply chain—liquid nitrogen stored in tanks, compressed by cryogenic pumps, then evaporated for use.

This setup posed several problems:

• High gas and transportation costs
• Significant nitrogen losses from natural evaporation
• Limited flexibility in supply logistics
• Complex handling and safety concerns

A nitrogen generator separates nitrogen from oxygen in ambient air (which is ~78% nitrogen and 21% oxygen), delivering high-purity nitrogen on demand. This approach is:

• More cost-effective than purchasing gas cylinders or liquid nitrogen
• Environmentally sustainable
• Highly flexible and scalable for industrial needs

Pneumatech’s generators use Pressure Swing Adsorption (PSA) technology with carbon molecular sieves to achieve nitrogen purity levels as low as 10 ppm oxygen.

The nitrogen generation system installed at OMB is mounted on a robust steel skid (6m x 2.4m) and includes all necessary components for high-pressure, ultra-pure nitrogen production, including:

• Variable-speed compressor (15kW) delivering air at 8 bar
• Refrigeration dryer reducing moisture to a dew point of 3°C
• Coalescing filters to eliminate oil aerosols
• Adsorption dryer (PDP -20°C) using advanced ceramic Solides material—ideal for outdoor installations
• Activated carbon tower for vapor removal
• Dust filtration before storage

Once purified, nitrogen is compressed to 300 bar using dual boosters and stored in a 240 Nm³ high-pressure cylinder pack—all housed within the same plug-and-play unit.

One of the standout features of Pneumatech’s nitrogen skid is its plug-and-play design. The system is preassembled, pretested, and preconfigured, reducing installation time and minimizing potential disruptions.
 

Every major component is equipped with IoT connectivity for remote monitoring, predictive maintenance, and real-time alerts, giving operators full control and peace of mind.

OMB’s experience is a clear example of how on-site nitrogen generation can enhance efficiency, sustainability, and safety for industrial operations. With lower costs, fewer risks, and greater control, it's a smart move for companies looking to future-proof their production processes.