CASE STUDY OVERVIEW
When a publicly traded oil & gas operator needed a major infrastructure change at their research and development center, they faced a critical operational challenge – transitioning hydrogen supply. More than eight laboratories relied on this continuous hydrogen supply to support ongoing research and testing.
The transition required a temporary compression solution while existing equipment was refurbished and returned to service. The customer could not risk operational downtime and needed a solution deployed within a four-day window for a 6-month rental period. The temporary solution also needed to integrate with existing hydrogen infrastructure while meeting stringent hydrogen safety requirements.
Total Hydrogen Solutions (THS) deployed its mobile hydrogen refueler, a portable hydrogen chilling, compression, storage, and dispensing system originally designed for vehicle fueling applications. Working alongside the customer, THS modified the unit for a stationary industrial application and served as the temporary solution during the transition between hydrogen providers, maintaining hydrogen delivery throughout the six-month transition period.
PROJECT SCOPE
Located in Texas, the research and technology center of the publicly traded oil & gas company operates multiple laboratories conducting research and testing that require a dependable hydrogen supply. As the facility transitioned to a new hydrogen provider, existing compression equipment required refurbishment before the permanent system could resume operation.
The customer needed an interim solution capable of maintaining hydrogen delivery while the permanent equipment was offline. Because hydrogen supports ongoing research activities across more than eight laboratories, any interruption to supply could affect facility operations. The temporary system was required to support approximately 20 kilograms of hydrogen per day at pressures up to 6,000 psi while maintaining reliable delivery to the facility’s hydrogen distribution network.
The project presented several operational and technical challenges:
- Four-day deployment window with no tolerance for operational downtime
- Continuous hydrogen requirements supporting more than eight laboratories
- Temporary integration between a new hydrogen supplier and existing facility infrastructure
- Modifications required to adapt vehicle-fueling equipment for a stationary industrial application
- Compliance with stringent hydrogen safety requirements and HAZOP review processes
- Seamless transition back to the permanent compression system upon project completion
The customer selected THS because the refueling unit was mobile, immediately deployable, and already permitted as a temporary solution. The unit was conveniently contracted on a rental basis.
TURNKEY SOLUTION
THS deployed its mobile refueling unit, a self-contained hydrogen system featuring two-stage compression, chilling, storage and dispensing capabilities within a portable platform.
While originally designed as a mobile hydrogen fueling station for vehicle applications, the system was modified to support a stationary industrial hydrogen supply application. The unit received hydrogen from a low-pressure tube trailer and boosted pressure to approximately 6,000 psi while maintaining a consistent hydrogen supply to the site’s distribution system.
The turnkey solution included:
- Mobile hydrogen refueler rental unit with two-stage compression
- Integrated hydrogen compression system
- Equipment chiller package
- Onboard hydrogen storage
- Site-specific dispensing & connection modifications
- Control system programming updates
- Check valve & tubing modifications
- HAZOP participation & safety review
- Installation, commissioning, and startup support
- Service & operational support throughout the 6-month rental period
Several engineering modifications were required to adapt the system from a vehicle-fueling application to a building-supply application. THS reconfigured portions of the dispensing system, modified piping connections, added check valves and updated system programming to accommodate the facility’s operating requirements.
Originally developed as a mobile hydrogen fueling station, the unit has been described as a “hydrogen gas station on wheels” capable of supporting temporary fueling and industrial hydrogen supply applications.
IMPLEMENTATION
Initial Evaluation and Planning: THS worked with customer personnel to understand hydrogen demand requirements, evaluate site conditions and determine the modifications necessary to adapt the mobile refueling unit for a stationary facility application.
Safety Review and HAZOP Process: Before deployment, THS participated in a comprehensive HAZOP review with the customer’s engineering personnel to evaluate hydrogen safety considerations and confirm system design acceptance.
Site Modifications and Mobilization: THS modified the temporary mobile hydrogen unit to accommodate facility connections and operating requirements. Installation and commissioning activities were completed within the customer’s four-day deployment window.
Commissioning and Startup: The system was connected to the facility’s hydrogen infrastructure, tested and commissioned. Minor startup adjustments, including vent line modifications and the addition of a check valve, were completed to satisfy site requirements.
Ongoing Support: THS provided weekly support throughout the six-month rental period, ensuring reliable operation until the permanent compression system returned to service.
OUTCOMES
Executed within a four-day deployment window, the mobile refueling unit maintained hydrogen supply during a 6-month critical infrastructure transition while supporting uninterrupted facility operations.
Rapid deployment: THS installed, modified and commissioned the system within four days
Six-month temporary solution: Maintained hydrogen supply throughout a six-month transition period while permanent equipment was refurbished
100% facility uptime after commissioning: Following startup activities, the facility remained operational throughout the project
Adapted for industrial use: Modified a vehicle-fueling platform to support a stationary building application
Hydrogen safety compliance: Completed a full HAZOP review and met customer safety requirements
Up to three days of buffer capacity: Onboard storage provided hydrogen supply flexibility if a temporary issue occurred with the compression system
Reliable transition support: Enabled refurbishment and return-to-service for permanent compression equipment without interrupting hydrogen availability
Originally developed to support hydrogen vehicle fueling applications, the mobile platform has since been deployed for temporary industrial hydrogen supply projects, demonstrating the flexibility of the platform across transportation, research and industrial environments.
Total Hydrogen Solutions provides hydrogen creation, compression, storage, fueling and integration solutions for industrial, transportation and energy applications. From temporary rental equipment to permanent hydrogen systems, THS helps customers maintain reliable hydrogen supply across a wide range of operating environments. Learn more at https://pneumaticandhydraulic.com/total-hydrogen-solutions.