The reciprocating hydrogen compressor at the Shiraz Oil Refinery, as the first domestically manufactured hydrogen gas compressors in the country, designed and produced by the engineers of the Havayar Industrial Group, have been prepared for operation and delivered to the employer after successful completion of all pre-commissioning tests.
These compressors, equipped with a 110 kW motor, will provide a discharge pressure of up to 45 bar.This project marks a milestone for the Havayar Industrial Group as it signifies the country’s entry into a new phase of self-sufficiency in the refining industry, which has been achieved within a year.
The use of indigenous knowledge and reverse engineering of previous imported equipment has prevented the outflow of more than 1 million euros per compressor per year and is considered one of the steps towards the country’s self-sufficiency in this industry.
The start-up of the reciprocating hydrogen gas compressor is a sensitive and complex process that requires high precision and adherence to safety principles. Hydrogen, being a highly flammable gas with small molecules that can easily leak, requires special considerations during the installation and start-up of the compressor. The general stages of the start-up process for the reciprocating hydrogen gas compressor are described below:
Initial preparation and equipment inspection
– Equipment inspection: Before anything else, make sure that all compressor components, including cylinders, pistons, valves, and fittings, are in proper condition without any defects.
– Safety system inspection: Ensure that all safety systems, including emergency shutdown systems, leak alarms, and pressure sensors, are functioning properly.
– Pipeline and fitting inspection: Check the pipelines and fittings for leaks. Due to the small size of hydrogen molecules, it can pass through even small leaks.
Site preparation
– Adequate ventilation: The compressor should be installed in a well-ventilated area to reduce the risk of gas accumulation and explosion in case of hydrogen leakage.
– Safe distance: The hydrogen compressor should be installed at a safe distance from ignition sources. Also, equipment confinement should be avoided to allow hydrogen to disperse freely in case of leakage.
– Personal Protective Equipment (PPE): Personnel involved in the installation and start-up process of the compressor should use appropriate PPE, including gloves, goggles, and fire-resistant clothing.
Start-up process
– Leak testing: Before injecting hydrogen into the compressor, the pipelines and fittings should be tested for leaks using nitrogen or another inert gas. Any leaks should be fixed before hydrogen injection.
– Initial hydrogen injection: Hydrogen is initially injected into the system at low pressure to ensure proper compressor performance. The pressure should gradually and accurately increase.
– Parameter control: During start-up, key parameters such as pressure, temperature, and compressor speed should be closely monitored to ensure proper system operation.
Initial inspection and maintenance
– Re-inspection for leaks: After start-up, the system should be re-inspected for leaks to ensure the absence of new leaks.
– Calibration and adjustment: If necessary, control and safety systems should be calibrated and adjusted to function properly under different operating conditions.
– Continuous monitoring: During the initial operating period of the compressor, operational parameters should be continuously monitored to quickly identify and address any issues or abnormalities.
Training and awareness
– Employee training: Employees involved in the operation of the reciprocating hydrogen compressor should receive comprehensive training on system operation, maintenance, and safety.
– Process documentation: All start-up stages should be accurately documented to facilitate the investigation and prompt resolution of any issues that may arise.
Conclusion
The start-up of the reciprocating hydrogen gas compressor requires strict adherence to technical and safety guidelines. This process should be supervised by experts to ensure safe and efficient system performance.
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