The during
As part of the conversion process, we conducted a comprehensive Hazard and Operability Study (HAZOP) to assess the specific hazards related to introducing hydrogen into the system. Key risks identified included the formation of explosive atmospheres due to hydrogen’s lower ignition energy and its ability to leak through small gaps more easily than natural gas. Additionally, flame stability issues were a concern, as hydrogen burns hotter and faster than natural gas, potentially affecting furnace performance and creating hotspots that could damage the equipment.
To mitigate these risks, several safety controls were implemented. First, we recommended upgrading the ventilation system to ensure that any leaked hydrogen would dissipate rapidly, preventing the formation of potentially explosive atmospheres. We also introduced hydrogen detection systems capable of identifying leaks early and triggering automatic shutdowns. Furthermore, modifications were made to the burner system to accommodate hydrogen’s unique combustion characteristics, ensuring stable flame operation and reducing the risk of overheating.
The result
Upon completing the safety modifications and conducting thorough testing, the client successfully converted the test furnace to operate safely on a dual-fuel system. We then created the Explosion Protection Document (EPD) to reflect the new controls in place, ensuring compliance with DSEAR and other relevant safety regulations was documented. This trial conversion provided valuable insights into the practical challenges of using hydrogen fuel, allowing the client to better prepare when planning to convert their larger furnaces in the future.
By addressing the unique risks associated with hydrogen, our client was able to take a critical step toward their sustainability goals while ensuring the safety of their operations and workers.