Case Study: Actuation Lab improves valve leak safety analysis with Gexcon consequence modelling

Actuation Lab shows hydrogen blasts up to 16 barg with Gexcon

Actuation Lab, a UK manufacturing company, faced the challenge of demonstrating the hazards of conventional valve designs by understanding the potential consequences of valve stem leaks from high-pressure methane and hydrogen systems. They partnered with the vendor Gexcon to use advanced consequence modelling to analyze flammable cloud sizes and potential explosion overpressures that could occur inside a containerised electrolyser.

Gexcon conducted dispersion and explosion simulations using their FLACS software. The results showed that even small leaks could quickly create large flammable clouds, leading to catastrophic explosions, with hydrogen presenting a significantly higher hazard than methane. Gexcon provided detailed visualisations that helped Actuation Lab clearly demonstrate the serious risks involved and the safety benefits of their innovative Dragonfly Valve design.

Actuation Lab