Session: 20-05 Operation and testing in Oil and Gas Applications

Submission Number: 179132

Safety Management Related to Upgrading an Existing Natural Gas-Fueled Gas Turbine to Hydrogen 

The transition from natural gas to hydrogen as a primary fuel for existing gas turbines represents a critical step toward decarbonizing industrial energy systems and achieving global climate targets. Hydrogen offers significant environmental benefits due to its zero-carbon combustion; however, its integration into legacy turbine infrastructure introduces complex safety challenges. These challenges stem from hydrogen’s unique physical and chemical characteristics, including high diffusivity, extremely low ignition energy, and an exceptionally wide flammability range, which collectively increase the likelihood and severity of hazardous events. This paper proposes a comprehensive safety management framework specifically designed for retrofitting natural gas turbines to operate with hydrogen or hydrogen-rich blends. The framework encompasses systematic risk identification and mitigation strategies across key subsystems such as fuel handling, combustion chambers, exhaust systems, and enclosure ventilation. Methodologies employed include ISO 12100-based risk assessment, hazard and operability studies (HAZOP), and quantitative risk assessment (QRA). Special emphasis is placed on material compatibility, advanced leak detection technologies, ventilation performance, and control system adaptations to maintain operational integrity under varying hydrogen concentrations. The proposed approach is validated through a mid-scale industrial case study, demonstrating its effectiveness in ensuring safety while enabling a scalable transition to low-carbon energy. The findings aim to guide stakeholders in addressing safety complexities and inform future industry standards for hydrogen-fueled turbine systems.

Presenting Author: Nicola Vanni Baker Hughes

Presenting Author Biography: Principal Product Safety Engineer with more than 10 years experience in Baker Hughes rotating equipment, leading safety reviews for the new product development: PHA, HAZOP and Risk Assessment, QRA and SIL management. Certified Functional Safety Engineer in Safety Instrumented Systems since 2008.

Authors:

Nicola Vanni Baker Hughes
Claudio Caruso Baker Hughes
Lukasz Zakrzewski Baker Hughes
Gianluca Ronsichi Baker Hughes
Elena De Leo Baker Hughes