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Technical Specifications
TABLE OF CONTENTS
1 INTRODUCTION ......................................................................................................................................................... 3
2 SAFETY ....................................................................................................................................................................... 3
3 QUALITY ASSURANCE ................................................................................................................................................ 4
4 RELIABILITY & AUTOMATION ..................................................................................................................................... 4
5 CONTROL & MONITORING OF THE UNIT .................................................................................................................... 5
6 SCOPE OF SUPPLY ...................................................................................................................................................... 6
6.1 BASIC EQUIPMENT .................................................................................................................................................... 6
6.1.1 Ten (10) Process skids ........................................................................................................................................... 6
6.1.2 Two (2) Control Panels.......................................................................................................................................... 6
6.1.3 Two (2) Power Distribution Cabinets .................................................................................................................... 7
6.1.4 Twenty (20) Power Racks ..................................................................................................................................... 7
6.2 OPTIONAL EQUIPMENT............................................................................................................................................. 8
6.2.1 Two (2) HPS (Hydrogen Purification system) ........................................................................................................ 8
6.2.2 Two (2) Chillers (gas cooling) ................................................................................................................................ 8
6.2.3 Ten (10) ATEX Enclosures for HySTAT Process Parts .......................................................................................... 9
6.2.4 Two (2) Electrolyte cooling systems ..................................................................................................................... 9
6.2.5 Two (2) Feed water treatment systems .............................................................................................................. 10
6.3 ADDITIONAL OPTIONS ............................................................................................................................................ 11
6.3.1 Process options ................................................................................................................................................... 11
7 TECHNICAL SPECIFICATIONS .................................................................................................................................... 12
8 DIMENSIONS............................................................................................................................................................ 13
8.1 TEN (10) PROCESS PARTS ............................................................................................................................................. 13
8.2 TWENTY (20) POWER RACKS ......................................................................................................................................... 13
8.3 TWO (2) CONTROL PANELS ........................................................................................................................................... 13
8.4 TWO (2) POWER DISTRIBUTION CABINETS........................................................................................................................ 13
8.5 TWO (2) HYDROGEN PURIFICATION SYSTEMS.................................................................................................................... 13
9 EXAMPLE OF POSSIBLE LAYOUT ............................................................................................................................... 14
10 CODES AND STANDARDS ......................................................................................................................................... 15
11 DOCUMENTATION ................................................................................................................................................... 15
12 LIMITS OF SCOPE ..................................................................................................................................................... 15
13 EXCLUSIONS............................................................................................................................................................. 16
14 DISCLOSURE ............................................................................................................................................................. 16
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Annex: HySTAT-600/10 Indoor Version
Revision 1106
1 INTRODUCTION
The HySTAT- 600/10 Indoor Version is an all-in hydrogen generator producing 600 Nm/h of
hydrogen at a purity of up to 99,998% (99,999% as an option) and a pressure of 10 bar(g). It is made
out of 10 skids producing 60Nm/h each, grouped in 2 trains of 5 skids each to offer redundancy.
The HySTAT is completely automated, which significantly reduces the time for an operators
attendance. Designed for a fully continuous operation, the hydrogen output flow will be automatically
adjusted to follow the demand of the user. Maintenance requirements are kept to a minimum thanks to
a careful selection of the vital components used.
Hydrogenics has a long history of building indoor solutions for customers all over the world and has
carefully designed a high performance standard, in compliance with the latest international codes and
standards applicable for hydrogen production.
2 SAFETY
At Hydrogenics, we care about our clients safety. The HySTAT is designed taking into account
international standards :
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Annex: HySTAT-600/10 Indoor Version
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Besides, special effort has been made to ensure the highest safety levels for our customers:
PROFISAFE protocol ensuring a safe shut down in case of control failure (PLC)
Continuous Hydrogen in atmosphere detection (HTA)
Fail safe logic for all parameters (over 30 parameters controlled)
Uninterruptible Power Supply (UPS) ensuring a safe shutdown in case of power failure
Constant monitoring of gas purity (HTO)
Inherent safe design (passive safety) allowing the unit to perform emergency depressurization
mechanically when the control features are down
Minimal gas presence in the system (only few Nm3 at full production)
Multiple redundancy on critical safety parameters. In addition to the standard transmitters, each
critical parameter is also controlled by a safety switch which will trigger an alarm or stop the unit
in case of abnormal operation (eg. electrolyte level, cell stack temperature, pressure,).
3 QUALITY ASSURANCE
Hydrogenics is always looking at improving its internal production and quality process in order to
guarantee and deliver the safest and most reliable electrolyser available on the market. Therefore,
Hydrogenics as been granted:
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
The HySTAT is starting and maintaining hydrogen production fully automatically, while the major
safety and production parameters are continuously checked. Following features are included as a
standard on our unit:
Hydrogen Pressure control: the HMI (Human Machine Interface) on the control panel allows
the operator to select the required gas pressure (between 6 and 10 barg). The HySTAT will
automatically adjust its production rate to maintain the setpoint pressure (as an option, a
pressure reduction valve can be added in order to meet the customer requirements).
Hydrogen Flow Control: Based on the pressure, the hydrogen production, and thus the
output flow of hydrogen, is continuously adjusted within the operating range to follow the actual
need. Hydrogen will be (partly) vented to the atmosphere during 20 min max. in case the flow
requirement is below the minimal capacity of the HySTAT.
Cooling automation: The cooling water flow entering the heat exchangers is continuously
adjusted by the PLC (thermostat control). This feature will ensure a constant working
temperature of the electrolysis process.
Remote I/O: using a state-of-the-art profibus connection, we have drastically reduced the
amount of interconnection cables and thus the time needed for installation. Implementing the
profisafe protocol in combination with a safe PLC and safe I/O makes the system compliant
with the most stringent actual safety codes & standards. The PLC will automatically diagnose
any communication errors, not only making the system safer but also minimizing time and effort
for troubleshooting.
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Annex: HySTAT-600/10 Indoor Version
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Remote monitoring: allows the operator to access the EXTER HMI screen located on the
control panel to control and operate the HySTAT electrolyser from a remote connection. It
displays the process parameters, trends, events, alarms,.and allows the operator to
enable/disable individual cell stacks.
A Key switch: will allow the operator to Start/Stop the unit. Safety procedure make it
compulsory to have both inside and outside key switch in the START position in order to start
the unit.
Reset button: resets the safety circuit after a trip. By pushing the reset button, the unit will fully
automatically go into production after having performed the initialization safety procedure.
EMS (emergency stop): by pushing this button, the system will immediately de-energize the
cell stacks and utilities and depressurize the system. By doing so, the system is placed in
safety mode in order to prevent any incident.
EXTER Human Interface (HMI) Touch Screen: the EXTER HMI screen is located on the
control panel and allows the operator to control and operate the HySTAT electrolyser, either
from the screen, or from a remote connection. The EXTER monitoring system includes data
logging on a compact flash card. This also allows our technicians to connect to the electrolyser
to diagnose and troubleshoot events and alarms when needed. The PLC uses the Siemens S-7
software.
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Annex: HySTAT-600/10 Indoor Version
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6 SCOPE OF SUPPLY
6.1 BASIC EQUIPMENT
6.1.1 Ten (10) Process skids
The core component of the system is the IMET pressurized electrolysis cell stack. The IMET cell
stack consists of circular electrolysis cells, each containing two electrodes and an alkaline inorganic
ion-exchange membrane.
This equipment is for indoor installation only. Note that the process part generating the hydrogen is
classified to be only used in a zone II designated area. If however the process part is encapsulated
with the optional ATEX enclosure, one can omit these zone II area requirements. In this case, the
installation area will need to be general purpose.
The Process part comes as a fully assembled skid that includes equipment such as:
Cell stacks
Gas separators
Hydrogen gas rinser, Coalescent filters
Heat Exchangers for Electrolyte and Gas Cooling
Leak detector tray with level switch
Hydrogen detector (HTA), Analyzer panel for hydrogen in oxygen (HTO)
Instrumentation and junction boxes: sensors, transmitters, switches, etc.
Valves, vent headers (H2 and O2)
The control panel cabinet includes the PLC and all related equipment to
ensure an automatic and safe operation of the HySTAT. The Control
Panel will be connected to both the Process Part and the Power Rack by
means of cables. It features:
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The power disctribution cabinet allows you to provide only 1 power supply for the complete electrolysis
system, reducing drastically the cables needed for the complete installation.
Inside the cabinet, a switchgear is present to distribute the power to the control panel, utilities and all
the power racks.
The power rack will convert incoming three phase AC power into regulated DC current required for the
electrolysis process. One power rack can power up to 2 IMET cell stacks and features:
Power Rack
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The Hydrogen Purification System (HPS) is designed to further purify the hydrogen to a minimum
purity level of 99,998%. This purity is reached in 2 stages:
Stage 1: Deoxo stage: to reduce the O2 content in the H2 gas stream by a catalytic
reaction. The output O2 in H2 is less than 10 ppm or, optionally, less than 2 ppm.
Stage 2: Dryer stage: to remove moisture in 2 dryer towers. One tower will be in
operation while the other one will be in standby/regeneration mode. The output hydrogen
will have an atmospheric dew point of less than -60C or, optionally, less than -75C.
The HPS is controlled by the central PLC in the control panel and features:
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Hydrogenics can supply the process skids (and the optional hydrogen purifiers) inside an ATEX
approved enclosure. This enclosure will be equipped with forced ventilation allowing installation in a
General purpose area (non-Ex).
It features:
Lockable doors
Connections for utilities outside the enclosure
Gas Cooling water in/out
Electrolyte Cooling water in/out
Vent connection out
Process Water in
Drain connection
Purge Gas Connection
Ventilation fan on top of enclosure
Rubber sealing
Powder coated metal sheet panels
Differential pressure switc
This cooling system is used to cool down the electrolyte and the chiller and includes a pump skid and a
dry cooler evacuating the heat to the ambient air. The cooling water circulates in a closed-loop,
through the high performance electrolyte-to-water heat exchangers installed in the HySTAT process
part.
With this closed loop cooling system a full hydrogen output performance of the HySTAT is
guaranteed between -20C and +40C (-40C or +50C as an option) ambient temperature. The Dry
Cooler and pumpskid are controlled by the central PLC in the control panel.
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Annex: HySTAT-600/10 Indoor Version
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The tap water is provided by the customer and must meet or exceed following specs. Note that 1.5 to
2 liters of tap water will produce 1 liter of pure water and that electrolysis reaction requires
approximately 1 liter of pure process water to produce 1 Nm of hydrogen. Keep in mind that part of
the tap water needs to be drained to remove the minerals and part will be sent back to the ROS
membranes.
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Annex: HySTAT-600/10 Indoor Version
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Oxygen Use
As standard the O2 is vented to the atmosphere. Hydrogenics can implement an optional system to
clean the O2 and make it available for further use/purification by the customer.
Mass flow meter: The mass flow meter is a direct measurement of the volume of H2 flowing into the
user line.
Oxygen content in Atmosphere detector (OTA): An Oxygen transmitter in Atmosphere (OTA) can
be implemented in the Process Room to continuously monitor the level of O 2 in the Process Room
atmosphere. An alarm is generated when the oxygen level drops below or raises above the safe limits.
Back pressure regulator: Guarantees the performance of the unit by keeping the generator and the
deoxo dryer at a stable pressure. Variations in the user line will not have an influence on the pressure
in the process part (will be added to the unit if directly connected to a compressor).
Instrument air compressor: a compact but rugged instrument air compressor, installed in the
General purpose room, to eliminate the need of externally supplied instrument air.
Direct coupling to renewable energies: Hydrogenics can offer specific approaches in order to
directly connect the electrolyser to renewables (eg. Power controlled electrolyzer), providing an
efficient and performant system optimized for the application.
Automatic restart (PT-U): This feature allows the HySTAT to continuously detect the actual pressure
in the user line. If the unit is in standby mode, this allows the unit to be automatically restarted once the
user line pressure is below a preset threshold.
Automatic N2 purge: This allows the entire N2 purging sequence of the HySTAT and the HPS to be
performed automatically. Nitrogen purge is required before starting the unit when the internal pressure
is below 15kPa. The systems PLC will sequentially activate the different valves in the system, thus
ensuring that all air is evacuated prior to hydrogen production.
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7 TECHNICAL SPECIFICATIONS
H2 production
Model HySTAT -600/10
Flow range 24 to 600 Nm3/h
Purity (before HPS: Hydrogen 99,9% (H2O saturated)
Purification System) O2 < 1.000 ppm
HYSTAT OUTPUT
Supplied by Chiller
Gas Cooling Loop If not included: Water at 15C
Max. flow 5 m/hr
Feed water Consumption of demin water to process < 1 litre / Nm H2
Consumption of tap water to RO **** 1.5 - 2 litres / Nm H2 (depending on water quality)
Pressure 2 to 4 barg
Instrument Air Min. Pressure 6 bar (Air compressor as an option)
Consumption +- 2500l/min
Electrolyte
FILL
The above data are for reference only and subject to review without prior notice. Performance data are not to be used for guarantee purposes.
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Annex: HySTAT-600/10 Indoor Version
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8 DIMENSIONS
8.1 Ten (10) Process Parts
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Annex: HySTAT-600/10 Indoor Version
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This is an example of a 360Nm3/h installation. The same logic will apply for the quoted 600Nm3/h.
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Annex: HySTAT-600/10 Indoor Version
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11 DOCUMENTATION
Every HySTAT is shipped with a complete set of documentation in English language in 1 hardcopy
and on 1 DVD-ROM:
Electrical drawings
P&IDs
A HySTAT-A manual (reference, installation, operators, maintenance)
Parts list + technical information of components used (DVD-ROM only)
Certificate of compliance
MSDS
12 LIMITS OF SCOPE
Unless stated otherwise in the quote, the battery limits for the HySTAT electrolyser are the:
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Annex: HySTAT-600/10 Indoor Version
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13 EXCLUSIONS
Unless specified otherwise in the proposal, the following items are not included in the scope of this
proposal:
14 DISCLOSURE
This document is strictly confidential. The copyright in this document is exclusive property of
Hydrogenics and may not be copied, translated, modified or disclosed without the written
authorization of Hydrogenics and must be kept in confidence.
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