Vehicle Refueling Dispenser Revitalization
Industry: Vehicle Refueling
Location: USA
Timeline: Several months
Client: Hydrogen-electric vehicle manufacturer
Utilizing our expertise in delivering turnkey aftermarket service solutions for complex OEM equipment Fluitron successfully revitalized a hydrogen dispensing system for a hydrogen-electric vehicle manufacturer.
Our customer faced significant challenges with an outdated hydrogen dispensing system that had been idle for years and was now required to be brought back into safe and efficient operations.
Fluitron carried out a comprehensive system assessment, refurbishment, modernization, and on-site commissioning, over a period of several months,
- 5+ years of inactivity for the hydrogen dispensing system.
- 3 key system components: compressor skid, electrical panel, and storage/dispensing conex.
- Installation of 3 major safety upgrades: flame detectors, strobe light, and gas detectors.
- Replacement of the non-functional HMI and rewritten operational code.
- Comprehensive Factory Acceptance Testing: leak testing, helium compressor tests, and controls validation.
The project encompassed a complete and comprehensive system assessment, followed by refurbishment, modernization, factory acceptance test (FAT) and then on-site installation and commissioning.
The rebuild of the hydrogen dispensing system included:
- Addition of flame detectors
- New strobe light and gas detectors
- Mechanical components repair
- Replacement of the Human Machine Interface (HMI) with a modern unit
- Rewriting of the HMI’s code.
Comprehensive System Refurbishment and Modernization
Fluitron approached the project methodically, delivering a tailored end-to-end solution which identified and addressed the challenges and met our customers’ requirements.
- Assessment and Planning:
- Dispatched field service experts for in-situ system evaluation and prepared a detailed refurbishment proposal.
- System Overhaul:
- Rebuilt and modernized the compressor skid, electrical panel, and conex.
- Added safety features, including flame detectors, gas detectors, and strobe lights.
- Control Upgrades:
- Replaced the non-functional HMI with a modern unit and developed new operational code.
- Testing and Validation:
- Conducted extensive FAT, including leak testing, helium compressor trials, and controls validation.
- Installation and Commissioning:
- Provided on-site support for seamless system installation and startup.
Revitalized Equipment for a Safer, Sustainable Hydrogen Future
The project successfully restored the hydrogen dispensing system to like-new condition, with key outcomes including:
- Operational Efficiency: Fully functional system meeting industry standards.
- Enhanced Safety: Modern safety devices reduced operational risk and improved compliance.
- Extended Equipment Life: Zero-hour rebuild maximized the value of existing assets.
The project’s success was marked by:
- Improved Safety: New safety devices and systems reduced operational risk.
- Operational Longevity: Refurbishment extended the system's usable life.
- Quality Assurance: Comprehensive FAT ensured reliability and performance.
Key Takeaways:
- Proactive planning and thorough testing are critical in restoring aging equipment.
- Incorporating modern safety features enhances the long-term viability of hydrogen systems.
This project showcased Fluitron’s end-to-end aftermarket service capabilities, specifically on hydrogen dispensing system. Fluitron carried out a detailed inspection, reported the findings and reinstatement measures, completed the system rehabilitation and then undertook testing and installation.
By working closely with our customer and understanding their desired project outcomes Fluitron was able to deliver a tailored solution and successful outcome.
