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Hydraulic Pressure Intensifiers – How to Select

Since, we have decided we want to use a pressure intensifier to get that needed pressure to finish the job in a hydraulic application. Now, we need to select the right intensifier to install in your systems. But first, do we know what intensifiers do?

What does a pressure intensifier do?  In short, the pressure intensifier does exactly what the name says—it boosts hydraulic pressure. This can be done in new systems or used in existing systems to increase the available pressure. In new systems, you can design the HPU for low / standard pressures and add the intensifier to handle the high-pressure situations. In refit applications, the intensifier can be installed inline, near where the increased pressure is needed without expensive replacement of the power pack. Hydraulic pressure intensifiers generate a higher pressure from a low-pressure hydraulic power source. They always work powered by a pump, which is operating at a set pressure and from this the intensifier generates a higher output pressure.

So, what information do I need to select the right intensifier?  I need to know the required output pressure. What is the inlet flow and pressure and how are you going to mount it in the system?

So, let’s determine the pressures ratios we need, For this example, we have a 2,500 psi system  And need to boost it to 5,000 psi we will need an intensifier with a ratio of 2.0. We will also have an inlet flow of 13 GPM.

The design of the intensifiers is very compact, and they are very easy to install. They are offered as in-line models, which fit standard pipe clamps used throughout the industry. They can also mount as flange mounts. There are options for cetop models and as cartridge type intensifiers. For this application we will be choosing to mount our intensifier in-line.

In high flow applications, we may need to restrict the flow to keep from damaging the intensifier. You can do this by adding a flow control and a p.o. check valve to prevent excess flow.

Once the pressure intensification is reached, we are going to need to know how you are going to plumb the return flow. There are two versions. If you plan to plumb around the intensifier – you will need an S-Version. If you are going to allow the return flow from the component to flow through the intensifier – you will need a P-Version. The P version has a POV valve integrated into the intensifier.

So, we have an in-line application that we need to boost to 5000 psi from a current pressure of 2,500 psi. The system has a flow rate of 13 GPM and the return line will be plumbed through the intensifier. We will need a MP-L-P-2.0. The L in the MP-L stands for large flow intensifier series. We are using the large series because we have a high flow rate of 13 GPM. The P designates a POV to be included because we are routing the return line through the intensifier. If we were routing the return around the intensifier that letter would be S. And the 2.0 designates the intensification ratio.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – Troubleshooting

Most problems concerning the ScanWill Pressure Intensifiers are caused by the following 7 factors:

1. Contamination of the Fluid

If the oil is contaminated it has the possibility of 1, particles could be caught between the seat and the ball check valves. This will result in the intensifier continuously working but will not be able to build pressure.

Also, particles in the oil may be moved along the ground bores 2, and destroy the surface, which will lead to internal leakage through the pistons.

To avoid these problems, a 10µ pressure filter should be added before the intensifier.

2. Large volume under pressure

In applications with a large volume of flow under pressure, the activation of the internal p.o. check valve will cause a very high flow rate in a very short time inside the intensifier.

This high flow rate might be many times the max allowable flow rate of the intensifier and due to the compact design of the ScanWill intensifiers, the flow passes by the internal check valves which will be damaged due to excess flow.

3: Too high of an inlet flow

If the maximum flow rating is exceeded, the internal check valve springs will be compressed too much, and the check valve will be damaged. In addition, excess flow will cause the piston speed to be too high and cavitation may occur. To avoid these problems the inlet flow for both the T and P should be controlled.

4: Too high of an inlet pressure

Exceeding the max inlet pressure for the ScanWill intensifier will result in the screws holding the body parts together to stretch. This will result in the static O-rings between the body parts to be pushed out, and the intensifier will leak. Also, if the screws stretch, the internal leakage will increase, and the intensifier will not be able to increase pressure.

5. Heat

In situations where you have excess heat, the fluid could get thin and lose its lubricity. This will result in the pistons inside getting stuck in the bores and the intensifier will not work. To avoid this, sufficient cooling should be applied. You should also set up your circuit to have your return oil route back to tank when relieving pressure.

6. Return pressure

The ScanWill intensifiers intensify the differential pressure between the P and T inlet ports. In applications with high back pressure in the T line, the expected end pressure might not be obtained. In these situations, a separate T line for the intensifier should be considered.

7. Air in the oil

Air in the oil is unwanted. This will result in the damage of internal parts such as valves and pistons and the performance of the intensifier will be unpredictable. To avoid this the system should be designed so no pockets of trapped air can occur.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Reciprocating-Style Pressure Intensifiers – Accessories

Mounting nut: The M-Nut is a M28 x 1.5 Nut used for mounting the MP-T pressure intensifier.

Mounting kit: The M-Kit consists of two mounting brackets, used to fasten the intensifier to a base plate.

Connection kit: Connection Kits are available for mounting the intensifiers directly to a hydraulic block. The P and T connection is then supplied directly through the Connection Kit, eliminating the need for tubing.

Cetop D03 / NG06 top plate: The Cetop D03 / NG06 top plate is for closing the top of the MP-C intensifier.

High Pressure Fittings

High Pressure Filters: In-line Filters grant a high protection to the most delicate components in a hydraulic system.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MP-2000-XP Series

The MP-2000-XP pressure intensifier is made for installation in smaller power packs, where a higher end pressure is required, e.g. for a bolt tensioner.  The available ratios of 7:1, 10:1 and 13:1 allows end pressures proportionally of up to 37,700 psi / 2,600 bar to be generated, from a power pack laid out for 200 bar / 2,900 psi max. and a flow rate from 2 to 13 LPM / 0.5 to 3.96 GPM. When the XP-intensifier is connected to P and T, it will automatically increase the supplied pressure proportionally to the required end pressure. For evacuation of the high pressure side a pilot operated check valve is integrated, and when activated, the flow from the high pressure side is led through a separate side port directly to tank, where it will be cooled and filtered before being pumped back in the hydraulic circuit. Below the dimensions and circuit of the intensifier with the oil flow direction is shown.

Ratio Min. Inlet Flow Max. Inlet Flow Outlet Flow Q1 Outlet Flow Q2 Min. Supply Pressure Max. Supply Pressure Max. Output Pressure
(i) (GPM / LPM) (GPM / LPM) (GPM / LPM) (GPM / LPM) (PSI / BAR) (PSI / BAR) (PSI / BAR)
7.0  0.5 / 2 3.4 / 13  0.29 / 1.1  0.05 / 0.2 218 / 15 2,900 / 200 20,300 / 1,400
10.0  0.5 / 2 3.4 / 13  0.18 / .07  0.05 / 0.2  218 / 15 2,900 / 200 29,000 / 2,000
13.0  0.5 / 2 3.4 / 13  0.13 / /05  0.02 / 0.1  218 / 15 2,900 / 200 37,700 / 2,600

Weight: 5.94 lbs / 2.7 KG

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MP-CT Series

The MP-CT pressure intensifier is made for installation in hydraulic stacking systems, where a higher end pressure is required for a specific job. The MP-CT will increase the pressure exactly and only where required, and supply the higher pressure through a separate female port G1/4″. End pressures in the range 1,400 to 11,500 psi / 100 to 800 can be achieved, and the end pressure is proportionally to the supplied pressure, which can be in the range 145 to 2,900 psi / 10 to 200 bar. The supply   circuit will not be affected by the higher pressure, and will not have influence on other functions in the chain. The MP-CT is designed for inlet flows from 0.5 to 3.96 GPM / 2 to 15 LPM dependent on the ratio chosen. For evacuation of the high pressure side a pilot operated check valve is integrated. This is operated by a directional valve on the supply side, and will activate the high pressure side to tank. Using the MP-CT in a hydraulic system offers the advantage, that the system pressure can be kept as low as possible, as any higher pressure can be obtained where needed. This way pressure reduction in the whole system and energy wasting can be avoided.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MP-T-XP Series

The MP-T-XP Series hydraulic pressure intensifier is based on the MP-T and is identical to it, except that the MP-T-XP adds a dedicated radial G1/4” port for returning the flow from the high pressure side to tank. This ensures the oil from the high pressure side is returned for filtering and cooled before entering the intensifier circuit again. This is used frequently in small power packs and provides for more clean and cool oil flow through the intensifier and the connected tools by allowing the oil to circulate through the tank.  

RatioMin. Inlet FlowMax. Inlet FlowOutlet Flow Q1Outlet Flow Q2Min. Supply PressureMax. Supply PressureMax. Output Pressure
(i)(GPM / LPM)(GPM / LPM)(GPM / LPM)(GPM / LPM)(PSI / BAR)(PSI / BAR)(PSI / BAR)
1.5 0.5 / 22.1 / 80.21 / 0.80.08 / 0.3218 / 152,900 / 2004,350 / 300
2 0.5 / 22.1 / 80.21 / 0.80.08 / 0.3 218 / 152,900 / 2005,800 / 400
3.4 0.5 / 24 / 150.58 / 2.20.13 / 0.5 218 / 152,900 / 2009,860 / 680
4 0.5 / 23.7 / 140.47 / 1.80.1 / 0.4 218 / 152,900 / 20011,600 / 800
5 0.5 / 23.7 / 140.37 / 1.40.08 / 0.3 218 / 152,320 / 16011,600 / 800
7. 0 0.5 / 23.4 / 130.29 / 1.10.05 / 0.2 218 / 151,653 / 11411,600 / 800
9 0.5 / 23.4 / 130.19 / 0.70.03 / 0.1 218 / 151,290 / 8911,600 / 800

Weight: 2.86  lbs / 1.3 KG

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers in High Flow Applications

The MP-Intensifiers have a limitation to the maximum permissible flow supplied to the inlet of the intensifier, which depends on the model and intensification chosen. However all MP-Intensifiers can be used in high flow applications if the flow supplied to the intensifier is limited accordingly. The circuit below shows how to install the intensifier in a high flow system. The flow to the intensifier is limited by flow restrictors, and parallel with the intensifier a pilot operated check valve is installed. This pilot-operated check valve is designed to take the full flow and pressure.

At the sequence start the full flow from the pump is delivered through the pilot-operated check valve to the cylinder. When pump pressure has been build up in the cylinder, the MP-intensifier will automatically increase the pressure as required. This setup is also used in the reverse setup, where high pressure is required to initiate the movement of a cylinder, e.g. in core pulling in a plastic injection molding machine.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MP-S Series

The MP-S series is the smallest range of the Scanwill Pressure intensifier range, and is designed for compact applications where the space available is limited, e.g. for pallets on machine tools. The MP-S series is designed for inlet flows from 0.5 to 2 GPM / 2 to 8 LPM and is available with multiple ratios ranging from 2.0 to 9.0 and will increase a supplied pressure (145 to 2,900 psi / 10 to 200 bar) to a required end pressure (1,000 to 11,500 psi / 70 to 800 bar. The end pressure is dependent on the ratio and is always proportional with the supplied pressure. Integrated in the MP-S intensifier is a pilot operated check valve, which allows the high pressure side to be evacuated back to tank through the intensifier. The MP-S series is available in cast iron for industrial applications, and in a Stainless Steel version for marine and offshore applications.

RatioMin. Inlet FlowMax. Inlet FlowOutlet Flow Q1Outlet Flow Q2Min. Supply PressureMax. Supply PressureMax. Output Pressure
(i)(GPM / LPM)(GPM / LPM)(GPM / LPM)(GPM / LPM)(PSI / BAR)(PSI / BAR)(PSI / BAR)
1.50.5 / 22.1 / 80.21 / 0.80.08 / 0.3 218 / 152,900 / 2004,350 / 300
20.5 / 22.1 / 80.21 / 0.80.08 / 0.3 218 / 152,900 / 2005,800 / 400
3.40.5 / 24 / 150.58 / 2.20.13 / 0.5 218 / 152,900 / 2009,860 / 680
40.5 / 23.7 / 140.47 / 1.80.1 / 0.4 218 / 152,900 / 20011,600 / 800
50.5 / 23.7 / 140.37 / 1.40.08 / 0.3 218 / 152,320 / 16011,600 / 800
7. 00.5 / 23.4 / 130.29 / 1.10.05 / 0.2 218 / 151,653 / 11411,600 / 800
90.5 / 23.4 / 130.19 / 0.70.03 / 0.1 218 / 151,290 / 8911,600 / 800

Weight: 1.54  lbs / 0.7 KG

P & T Connections: G1/8″ HP connection: G1/4″ Ordering Code* Example: MP-T-S with POV, intensification 5.0 and BSP connections: MP-T-S-P-5.0-G   *First decide whether the pilot operated check valve, POV, is required, then decide the intensification ratio (i), and finally decide the connections (BSP or UNF). 

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MPL-1400, -2000, -4000 Series

Weight: 19.8 lbs / 9 KG The 1400/2000/4000 series models are hydraulic pressure intensifiers for high flow and high pressure. Please see the technical drawings for each intensifier in the images below: Top: MPL-1400. Middle: MPL-2000. Bottom: MPL-4000.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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Hydraulic Pressure Intensifiers – MPM-F Series

The MPM-F pressure intensifier is a made to meet the space requirements of a customer for hydraulic tongs in the off shore industry. Please contact IC-Fluid Power for more details on this custom application.

ScanWill is a supplier and pressure intensifier manufacturer for various applications including construction, mechanical, marine, and industrial.


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