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Green Hydrogen Dispensing System with Enhanced Safety Control System in High-Risk Zones

About the Client

One of India’s major energy leaders with manufacturing sites spread across Gujarat and Maharashtra, including one of the world’s largest refining and petrochemical complexes.
As part of their move towards cleaner energy, they were building their first-ever green hydrogen refueling station— a completely new project for them, with strict safety and performance expectations.

Requirements

Working with hydrogen demands extremely stringent safety measures. The client needed a SIL2-certified safety control system  capable of managing critical operations such as hydrogen compression, dispensing, decanting, and fire & gas detection—without fail.
In addition to this, the system had to seamlessly communicate with multiple third-party devices. All design, engineering, testing, and deployment work needed to be completed within an ambitious five-week timeline.
They were looking for a partner who could not only navigate the complexities of a highly flammable environment but also deliver the project at the required speed.

The Solution

We built a complete SIL2-compliant safety system designed specifically for hydrogen operations. This included:
  • A Safety CMX SIL-2 system as the core of the setup
  • Fully wired enclosures with 100+ safety I/Os
  • Integrated engineering and operating stations for smooth monitoring
  • Reliable networking devices for secure communication
Every part of the system was engineered to work seamlessly with hydrogen compressors, dispensers, decanters, and fire & gas detection equipment.

Key Outcomes

Greater Safety
The hydrogen refueling station now runs with a robust SIL2-based safety framework, reducing the chances of failures, leaks, or hazardous incidents.
Smarter Monitoring
Operators can now view and monitor the entire station from a centralized interface,giving them faster control and better insights.
Lower Operating Costs
Early fault detection and predictive alerts have helped the client reduce downtime andcut down maintenance expenses.
Stronger Environmental and Safety Compliance
The improved safety layer supports their clean-energy vision and ensures the stationmeets all required safety standards.

Why the Client Chose MIPL

Proven Experience
With years of experience in automation and control systems, we’ve delivered several similar projects—especially in high-safety environments like LNG and fuel dispensing.
Strong Industry Understanding
Our team understands Oil & Gas processes deeply. This helps us refine SOPs and recommend practical automation enhancements.
On-Time, Every Time
Even with tight timelines, we ensure quality engineering and seamless execution.
A Commitment to Doing Things Right
We follow global safety standards and adopt advanced technologies so clients can trust the systems they operate.