ENHANCING RELIABILITY AND OPERATIONAL INTEGRITY OF HYDROGEN COMPRESSION SYSTEMS SUPPORTING THE US ENERGY TRANSITION

Uju Emmanuel

doi:10.5281/zenodo.21783328

Abstract

Hydrogen compression systems are essential to the production, storage, transportation, and dispensing
infrastructure required for the United States energy transition. However, high operating pressures, cyclic loading,
hydrogen embrittlement, seal degradation, leakage, thermal instability, and component fatigue can undermine
equipment reliability, safety, and operational continuity. This study proposes an integrated reliability and
operational integrity framework for hydrogen compressors combining condition monitoring, digital twins,
physics-informed artificial intelligence, prognostics, and risk-based maintenance. The framework captures realtime vibration, pressure, temperature, acoustic, and leakage data to identify developing faults, estimate remaining
useful life, and support timely maintenance decisions. It also links material degradation, operating severity, failure
probability, and consequence assessment to improve asset prioritisation. The proposed approach is applicable to
reciprocating, diaphragm, centrifugal, and electrochemical compressors deployed across hydrogen production
facilities, pipeline networks, storage terminals, industrial hubs, and refuelling stations. By enabling earlier fault
detection, reducing unplanned downtime, improving maintenance efficiency, and strengthening safety assurance,
the framework supports dependable hydrogen infrastructure expansion and contributes to a resilient, scalable, and
lower-carbon future United States energy system.

Keywords

Hydrogen compression systems; Operational integrity; Predictive maintenance; U.S. energy transition

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