SOMC-VIZAG

DRAFT
Standard Operating Procedure
SOP (Title)
SOP No.

: Hydrogen Plant Operation.

: SOMC/OPN/SOP/Hydrogen Plant Operation.
Date:

Issue No.

Revision :00
04.09.2016

Department: Operation & Maintenance

Target group: Hydrogen Plant Operators.

Approved by: Plant Manager / Chief Executive Officer

Released on: 04.11.2016

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Revision history log
Revisio
n
Rev-0
Rev-1
Rev-2

Revision date

Prepared by
Checked by

Name
Sooraj S S
T

Designation
Sr.Engineer
HOD-

Reviewed

Srinivasulu
P S Kumar

Operations
Plant Manager

by

Ref No: SOMC/OPN/SOP/Hydrogen Plant Operation

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Revised by

Signature

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Table of contents
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2.
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4.
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4.
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Description
Purpose of the Document
Scope of coverage
Definitions and abbreviations, specialized terms
used
System description
Process Brief
Approving Authority and Review
Data and Records Management

Approving Authority and Review

Data and Records Management

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1.0 Purpose of the document:

This document intends to provide guidance to operate
Hydrogen plant and handle the cylinders efficiently and
safely.
2.0 Scope of coverage:
The usage of this document is limited only to operate
Hydrogen plant and handle the cylinders by the hydrogen
plant operators.
Target groups shall be advised to use this document along
with the Hydrogen plant P&ID.
3.0 Definitions
used
PPE

and

abbreviations,

specialized

terms

: Personal
Protective
Equipment
: Unit Control Engineer

UC
E
SCE : Shift Charge Engineer
TPP : Thermal Power Plant.
LEL : Lower Explosive Limit

4.0 System description

A 2*10Nm3/hr sized hydrogen plant is envisaged in HNPCL
TPP for the necessary hydrogen gas requirement for the
main plant generator cooling. A uni-polar based M/s Eastern
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Electrolyser make hydrogen plant is constructed near
Desalination Plant for the same with 256+8 cylinders
(BHEL+EEL supplied) storage capacity
4.1

Process Brief:
AC power at 415 Volts is supplied to rectifier. In the Rectifier
the voltage is reduced by the rectifier transformer and
converted to direct current at a voltage of up to 14.5 volts.
DC power from the rectifier is supplied to electrolytic cells
through copper bus bars. When DC current flows through
the cells the water in the cells is converted into hydrogen
and oxygen gases. The rate of evolution of gas is directly
proportional to the DC current. At 4050 amperes (the
maximum allowable current) the six cells will produce 10
cubic meters of hydrogen and 5 cubic meters of oxygen per
hour. The liquid in the cells (called the electrolyte) is a 2830% by weight solution of Potassium Hydroxide in DM
water. The Potassium Hydroxide is not used up when gas is
generated, except for mechanical losses due to spillage and
entrainment. The only raw material supplied to the cells
apart from electric power, powered from FOPH feeder, is
Demineralized water, to replace the water converted to
hydrogen and oxygen. At full current the 12 cells will
require approximately 30 liters per hour of feed water. Each
cell is fitted with two gas coolers, one for each gas. The
gases leaving the cell pass through the coolers before
entering the gas header. In the coolers the gas is cooled
and electrolyte (Mist) vapor is condensed and returned to
the cell through an overflow pipe. The gas coolers are
cooled by water. Water enters at the distribution header,
flows through the hydrogen and oxygen gas coolers of a cell
in series and then flows through a discharge hose to the
cooling water collection header. Attached to the end of each
cell is a cooling jacket. Cooling water from the distribution
manifold flows through a discharge hose to the cooling
water collection header.
From the cells the hydrogen and oxygen gases flow through
collection headers to liquid seal . The liquid seal serves to
equalize the hydrogen and oxygen gas pressures and to
prevent reverse flow of gases from the low pressure
hydrogen gasholder, when the cells are idle. O2 & H2 Gas

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from the cells are first sent to vent. After H2 gas purity has
been checked by on line O2% gas analyzer and purity of H2
gas above 99% H2 gas is diverted to Gas Holder. From the
liquid Seal it goes through Mist Eliminator Gas Holder.
Oxygen is sent to vent through the Vent pipe.
DM water, conductivity meter/cell is provided for measuring
the conductivity of DM water. Solenoid valve is provided to
dump the water to drain, if the conductivity is high. Once
the purity is found within acceptable limits (< 4 cm) water
is diverted to DM water head tank.
Over a period of time the cell will lose some potassium
hydroxide due to entrainment and spillage. A mixing tank
fitted with a hand operated pump is supplied for use in
adding potassium hydroxide to the cells.

4.2 Operation of Hydrogen Plant:

From the MCC panel power is made On to the following
equipment.
Rectifier ;Compressor; Vacuum Pump; Dryer; Radiator;
Cooling Water Pump; Air Compressor; Exhaust fan
From ACDB Panel, following equipment is made ON.
PLC panel; Gas Detector Panel; OWS/EWS

Note:
Hydrogen plant is powered by FOPH feeder.
Required DM water is tapped out from the DM make-up
pump discharge line.
Make sure DM water is filled in DM water head tank. Make
sure Cooling water, Instrument air are available. See that
liquid seal has water and mist eliminator water level is
adequate. Also ensure the electrolyte levels are healthy and
gas holder seal water level is adequate.
Ensure that after every 6-7 days of operation the following
equipments should drain completely.
Knock out vessels

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Compressor condensate collection vessels(2 nos
each/compressor)
All filters and catalytic purifier.
4.2.1 LYE PREPARATION

Lye is prepared by mixing KOH flakes with water 290 Litres of Lye
is required for one cell. Safety precautions must be taken while
handling with Lye. Following are the steps to prepare Lye:
1. In 100 litres of DM water Mix 50 kg of KOH flakes. This
proportion can be used as per amount of lye required.
2. Mix the solution thoroughly. Solution will become hot.
3. Allow the solution to cool for 15-20 hrs.
4. Check the concentration of KOH in the solution. It should be
30%.
5. If conc. is not achieved then mix water or KOH as per
requirement.
Note: A lye preparation tank with hand pump is provided for the
same. Filling can be done through any of the gas cooler inlet line.

4.2.2 STARTING PROCEDURE

Check the levels of DM water head tank, Cooling water

sump, electrolyte level, DM water level, Gas Guard
healthiness, Gas holder seal water level and mist eliminator
level are healthy and adequate.
After PLC is ON. Open the Vent valve of cell Skid A and B
and check the instrument pressure it should be >5.5
Kg/Cm2.
Start Rectifier A and B start from PLC (Refer 4.2.3) and
increase the current through increment button up to 500
amps, after 2 minute increase the current up to 700 amps,
after 5 minute increase the current up to 1000 amps.
Now Gas is in venting mode turn on the sample line Valve
and ensure the vent valves are open and gas holder feed
valves are closed condition.
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After 5 minute turn on the sampling valve. When the purity
of Hydrogen is acceptable, Solenoid Valve SV 303/ SV 304
will be energized which will turn on the diverter valve
PV301/PV302 to divert the gas in to the Gas Holder.
Then increase the load to the required load by a increment
of 500 amps every fifteen minute to max load of 4050
Amps, however during normal operation it is not necessary
to go for full load operation. During this period the O2 %
gas analyser checks the purity of gas and above 99.5% the
gas is diverted from vent to Gas holder(Refer 4.2.5).
Adjust the cell pressure by adjusting the water level in the
seal box (Refer 4.2.4)
Note: Analyser is for oxygen only so 99.5 % hydrogen
purity means 0.5% oxygen reading in analyser.
When the Gas temp should be 35C turn on the cooling
water supply in gas cooler (Scrubber).
When cell temperatures reach 60C turn on cell cooling
water to cell jackets. Maintain cell temperature between 5560C. Do not allow temperature to exceed 65C.----RADIATOR INCLUDE
In normal operation with the electrolyte level at the correct
height and with normal cell pressure it should be possible to
observe 25 to 50 mm electrolyte level in vent tube, if the
level in vent tube is higher than this it could indicate cell
electrolyte level is too high.
Under no condition should Hydrogen with purity less than
99% be turn into Gas Holder. Make sure Vent Valve of each
skid kept open before start the plant.
Line -up the hydrogen compressors, two at a time and
purification skid (Refer 4.2.7). Ensure the suction valve and
gas holder outlet valves are open, unless these valves are
open the compressor will not start, it has an interlock with
the compressor (Refer 4.2.6).

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Compressed gas is sent to vent through its vent valve for 1
minute. This has to be done whenever the compressor is
starting first time during the day. This will remove any
impurities (air) from the crank case. After venting open
compressor discharge line valves and vent valves closed.
As the purification system (Refer 4.2.7) is getting
pressurized, open MV 401, MV 402 valves at the manifold.
This will vent the impurities from the purification system.
Purge the system by filling the gas to 10 Kg/cm2 and vent it
to atmosphere and bring the pressure to 5 Kg/cm2, repeat
this operation for 3 times.
Close vent valves and open the cylinder of cylinders to be
filled at the manifold with the pig tails provided.
Gas can be filled, in any one bank of manifold and other
bank will be made ready for filling.
Once cylinders filled, numbers of these cylinders are noted,
with pressure and purity.
Prior to filling hydrogen gas cylinder should be first
vacuumed and then filled (Refer 4.2.8).
Note:
Online Dew point and PPM analyzer panel is provided. Once
dew point of -40C and O2 PPM <1000 are achieved, gas
can be filled in the cylinders, till such time gas is sent to
vent from the manifold.
Prior to filling offline purity check should be checked and
confirmed by the chemistry department.
Monitor following equipments;
Compressor, for stage pressures, catalytic purifier for
inlet and outlet temperature. In normal operation inlet
temperature is less than outlet temperature, and
would be in the range of 5 to 50C. Temperature
would increase if oxygen content in hydrogen gas is
more. If outlet temperature goes to 80C then we will
have to check for leaks at the suction of compressor
line or check the purity of gas with the help of manual
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gas analyser ( Call to chemical department to check
the purity through ORSAT) at the cell generation and
at the gas holder.
Sensor provided gives an alarm if the hydrogen
concentration is above 20% of LEL (lower explosive limit is
4 %), and trip the rectifier and compressor if the
concentration is above 40% of LEL.
Manifold should not be used for storing filled hydrogen
cylinder. After filling it has to be shifted back to cylinder
storage room.
Note: Operators shall check leaks by applying soap water
across the joints once in 3 months and record has to be
maintained for the same.
4.2.3 Before the rectifier on please check the following;
Selector Switch Position on Control Panel (Local/Remote)
Switch on the MCC Feeder for Rectifier A & Rectifier B.
Check in the Cell Skid Vent Valve it should be open DV-302/
DV 307/DV301/DV 306 always should be closed. Only then
operate this Valve when you want bypass the PV- 301/ PV
302.
Cell Skid DM Water shall be open when Rectifier is on
The entire KOH Sampling Valve should be closed.
The entire inlet Valve of Feed Water Bowl should be open.
The entire outlet Valve of Feed Water Bowl should be open (
operate manually)
The entire Equalizing pressure Valve should be open
The entire KOH Level Tube Valve should be open.
Control Supply charged from the MCB in PLC Panel.
Check the Instrument Air Pressure it should be > 5.5
Kg/cm^2.
Check the Cooling Water pressure it should be > 2.5
Kg/cm^2.
Note: Before starts the Rectifier make sure the potential
meter should be Zero

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If all condition above mention, checked then you can start
the Rectifier for increasing the current there is a increment
& decrement button provided in PLC.
4.2.4 WATER SEAL ADJUSTMENT:

Fill the water seal with water to a depth of 50mm. set the
overflow pipe to maintain this level and throttle to obtain a
slight continuous water flow. Gas will thus be prevented
from escaping into the room but no pressure will be
imposed upon the cells. For increase pressure, by raising
the level of water seal overflow pipe and adding the DM
water (open the DM Water Valve No-BV 806/ BV 809). For
Gas Holder and Cell pressure differential should be 2530MMWC.
When the Gas temp should be 35C turn on the cooling
water supply in gas cooler (Scrubber).
When cell temperatures reach 60C turn on cell cooling
water to cell jackets. Maintain cell temperature between 5560C. Do not allow temperature to exceed 65C.
In normal operation with the electrolyte level at the correct
height and with normal cell pressure it should be possible to
observe 25 to 50 mm electrolyte level in vent tube, if the
level in vent tube is higher than this it could indicate cell
electrolyte level is too high.
After 5 minute turn on the sampling valve V-310, V-360 &
then V-340.When the purity of Hydrogen is acceptable,
Solenoid Valve SV 303/ SV 304 will be energized which will
turn on the diverter valve PV301/PV302 to divert the gas in
to the Gas Holder.
Under no condition should Hydrogen with purity less than
99% be turn into Gas Holder. Make sure Vent Valve V-352
kept open before start the plant.
4.2.5 GAS HOLDER:
When the Gas Purity achieved at 99.5 then PV 301/PV 302
operated and H2 Gas diverted on Gas Holder.
In the Gas Holder there are Four Limit Switch provided Low,
Low- Low, High, and High-High.

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When High limit Switch activated that time Rectifier will Trip
after 5 minute but if Limit Switch High-High will activated
Rectifier will Trip immediately.
When Low Limit Switch (located in Gas Holder A/ B)
activated that time Compressor will be tripped after 2
minute but if Low-Low Limit Switch activated then
Compressor will trip immediately.
4.2.6 COMPRESSOR ON:
Before compressor start check the following permissive Make sure Compressor Suction valve should be open
DV401,DV405,
DV 406.
Compressor Suction pressure should be more than 25
MMWC.
Instrument Air pressure should be more than 5.5Kg/cm2
Gas Holder A/B low Limit Switch should not be activated.
Check the Oil Level also by manually it should be at least
middle level.
Note: The Compressor can also be stopped by depressing Push
Button in Emergency Stop.
4.2.7 Purification Skid
In the purification skid there are Filters, Catalytic Purifier,
water cooler, Desiccant Dryer, Pressure Regulating Valve,
Online PPM Analyzer & On line Dew Point Analyzer.
If any filter will block then you can get the signal through
Differential Pressure Switch, for measuring the temperature
of Catalytic purifier Temperature Element given if the
Catalytic purifier temperature is more than 120C then
Compressor will trip.
Twin tower Desiccant Dryer is provided with 12 Hours cycle
for the dryer, 6 hour Tower 1 shall be in Process and after 6
hour Tower B. The idle dryer will be in regeneration when
other in service.
During regeneration, heating time shall be 180 minute but
if temperature raised up to 120c then heater will off, for
measuring the temperature of Heater Temperature Element
provided.
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Ensure a minimum 4 Nm3/hr. purging gas is flowing through
the drier which is under regeneration.
Back Pressure Regulating Valve providing the purification
Skid setting of this valve shall be 125 Kg/cm2.
If dew point is minus40c then we can fill the cylinder
through Manifold A or Manifold B.
4.2.8 Vacuum Pulling

4.2.9 Permissive and protection

For feed water
Sl.
No

Permissive

Value

Protection

Remarks

Value

Protection

Remarks

Value

Protection

Remarks

Value

Protection

Remarks

For Instrument Air

Sl.
No

Permissive

For Cooling Water with radiator

Sl.
No

Permissive

For Cell skid

Sl.
No

Permissive

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For Compressor

Sl.
No

Permissive

Value

Protection

Remarks

Value

Protection

Remarks

For Purification skid

Sl.
No

Permissive

4.3 SHUT DOWN PROCEDURE:

1. Turn OFF compressor from SCADA.
2. Closed H2 buffer tank storage valve & open H2 purification
vent valve.
3. Let Temp. of the dryer decrease at least to 40 C then
Power OFF heater feeder.
4. Close H2 purification vent valve & open H2 vent valve &
close H2 purification inlet valve of separator.
5. Open 100% of cooling water control valve from SCADA by
changing it from Auto to manual mode to decrease temp. at
least 35C of H2 separator.
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6. Start decreasing Pressure of separator &rectifier current as
follows
7. O2 Pressure

8. Rectifier Current

9. 16

10.

600

11.

15

12.

500

13.

14

14.

450

15.

16.

17.

18.

19.

20.
21.

0
(Stop rectifier unit)

22.
Stop the Rectifier unit.
23.
Maintain the level (Trip at mini. 150 & max. 900
mmWC) of H2 - O2 separator by placing avg. value in the
dialogue box.
24.
Open H2 - O2 gas control valve to 100% by changing it
from Auto to manual from SCADA.
25.
Let the plant come to gravity (i.e H2 - O2 Level should
be approx. same.)
26.
Power off H2 - O2 lye circulating pump.
27.
Again let the plant to achieve gravity level.
28.
Close all vent valves.
29.
Turn of PC.
IN CASE OF EMERGENCY:
30.
Press emergency button on rectifier panel.
31.
Depressurising system by venting gas for H2-O2 vent.

5.0 Health and Safety Considerations

Under normal conditions, hydrogen is a colorless and
odorless gas. Hydrogen is the lightest substance known,
having a specific gravity (referenced to air) of 0.069.
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Hydrogen is non-toxic, however does not support life. When
mixed in the proper proportions with air or oxygen,
hydrogen forms a highly flammable mixture.
In air, the explosive limits are 4.1% to 74.2% per volume. In
dry oxygen, the flammability limits are 4% to 96% by
volume.
Ignition of flammable mixtures can occur with extremely
low energy inputs. An invisible spark can cause an
explosion.
Explosive limit in air is H2 concentration greater or equal to
4.1% H2 = 100% LEL and 1.6% H2 concentration = 40%
LEL.
Always wear PPEs.
Use portable Hydrogen detection meter regularly for joint
leak and other vulnerable areas leak detection.

11.0 Approving Authority and Review

Document shall be reviewed and approved for adequacy by
the Plant Manager /CEO prior to issue.
REVIEW
SOPs should be also systematically reviewed on a periodic
basis, e.g. every 1-2 years or as and when required.
12.0 Data and Records Management
The Master copy of the SOP shall be maintained with MTP
department (library)

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