Strain analysis and non-destructive monitoring of the two-stage hydraulic-driven piston compressor for hydrogen storage

Abstract

High-pressure gas storage is an important means of hydrogen application in the transportation industry, especially in hydrogen refuelling stations. The hydrogen compressor is the most crucial dynamic component for high-pressure gas storage in hydrogen refuelling stations. An effective control system is required to guarantee the compressor operates safely and efficiently, which is based on the safe and efficient monitoring of the operating condition of the compressor. However, significantly limited literature has been provided for the hydraulic-driven piston compressor. In this paper, a non-destructive testing method for monitoring the dynamic pressure by strain gauge in the hydraulic-driven piston compressor is proposed. The relationship between the strain of the cylinder head and key operating parameters is obtained through finite element analysis, based on which the optimal location for the pressure monitoring is identified. The proposed non-destructive testing method is validated by experiments of a two-stage hydraulic-driven piston compressor. The strain analysis indicates that the circumferential strain in the cylinder head has a good linear relationship with the in-cylinder gas pressure with a value above 99.6 %. The deformation of the four monitoring positions is almost unchanged with a maximum deviation of 0.5 % under different piston positions. A high uniformity of the circumferential strain of the cylinder head is observed from the analysis. Experimental results indicate that the proposed non-destructive monitoring method is effective in obtaining the dynamic pressure in-cylinder during the compressor operation with a maximum deviation of 5.13 % and an average deviation below 2.01 %.