Cavitations in a Compressor
A hydrogen compressor had a major malfunction resulting in serious cavitations, vibrations and dead heading of the 1st stage. The incident resulted in 5 of the 8 lower head bolts on the first stage to snap, oil losses and damage to the 1st stage diaphragms. No breaches of hydrogen or contamination took place. The situation was noticed if a remote log in when reviewing the compressor pressures. The system was safely shut down and followed up by an on site investigation an hour later.
Event Date
January 10, 2013
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
The root cause is still to be determined based on manufacturer investigation. The likely component was the high pressure inlet valve that is used for top off filling. This valve potentially leaked and allowed high pressure into the interstage when it was not expected. This caused the 1st stage to dead head which likely lead to the bolts breaking, oil loss, further cavitations high vibrations. All repairs have been completed and the compressor is back in operation as of 26.01.2013.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
Compressor
Storage/Process Medium
Location Type
Location description
Unknown
Operational Condition
Consequences
Number of Injured Persons
8
Currency
Lessons Learned
Lessons Learned
This problem was not 100% determined. A few changes were made in the program logic to add a HIGH INTERSTAGE PRESSURE shutdown which may have shut the system down in time to prevent damage. Trending information for the station history was updated to see the details of future incidents and operational efficiency of the compressor. Reduction of the inter-stage safety valve is also in future plans.
Event Nature
Emergency Action
The system was shut down followed by an on site investigation an hour later.
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
Report provided but confidential