PRESENTATION ON HYDROGEN

GENERATION PLANT

MAIN TOPICS TO BE DISCUSSED

KNOWING HYDROGEN GAS

WHY GENERATORS NEED TO BE COOLED ?
WHY HYDROGEN IS USED AS COOLANT?
TRADE OFF BETWEEN AIR COOLING AND HYDROGEN
COOLING.
EFFECT OF HYDROGEN PURITY ON GENERATOR
PERFORMANCE.
TYPICAL GENERATOR HYDROGEN COOLING SYSTEM
DIFFERENT HYDROGEN GENERATION METHODS
SAFETY MEASURES TO BE TAKEN WHILE HANDLING
HYDROGEN.
OUR EXPERIENCE REGARDING VISIT TO NTPC
VINDHYACHAL SUPER THERMAL POWER STATION

KNOWING HYDROGEN GAS

Hydrogen Gas Is Dangers
A.At any mixture of Hydrogen and Air, Ranging from 4% to
74%, it is flammable (High Flammability Range). In dry
oxygen, the flammability limits are 4% to 96% by volume.
B.Hydrogen flame is almost invisible to the naked eye. It
burns with a light blue or pale blue flame or no colour at
all. While the flame temperature is very high, relatively little
heat is radiated. It is almost too late before you can detect
a hydrogen flame.
C.Hydrogen being light gas (1st element of the periodic
table) always leaks out. So a minor leakage of hydrogen is
very common.

HYDROGEN FLAMMABILITY RANGE

WHY GENERATORS NEED TO BE COOLED ?

As current flows in a conductor, heat is generated. A
generator has a lot of conductors and a lot of current
flowing through the conductors, generating a lot of heat. If
that heat isn't "removed" then the windings will be
damaged.
In a synchronous generator (alternator), there are high
currents flowing in the rotor windings, which also
generates heat which must be "removed".
So, the purpose of the generator hydrogen cooling system
is to maintain the generator rotor and the stator iron within
their proper operating temperature ranges under all
operating conditions.

WHY HYDROGEN IS USED AS COOLANT?

1.

2.

3.

The density of Hydrogen is only 0.07 compared to that

of air (1). Windage loss and power loss are
minimized, Increase in generator efficiency.
Specific heat capacity of hydrogen is about 14 times
than that of air. less quantity of hydrogen for same
rating of generator Reducing fan power.
Hydrogen does not react with any metals inside the
generator No danger of oxidation of metals inside
the generators.

TRADE OFF BETWEEN AIR COOLING AND

HYDROGEN COOLING.

Generally for small generator up to 100 MW

Air Cooling is preferred Cost of
transport of Hydrogen or Generation of
Hydrogen is much higher than cost of low
Generator efficiency.
For 100 MW and above Hydrogen Cooling
is commercially viable.

EFFECT OF HYDROGEN PURITY ON

GENERATOR PERFORMANCE.
Decrease in Hydrogen's purity results in an increase in
density Increase in generator windage friction losses
Decrease in Generator efficiency
Decrease in Hydrogen's purity results in an increase in
Fan power Increase in Auxiliary Power consumption.
For a 800MW unit with a 1% increase in hydrogen purity
will results in 366kW increase in power output which is
shown graphically.
A 3% increase in hydrogen purity translates to an
additional 1MW output without any increase in fuel
consumption. Considering selling price of $.04/kWh, a
3% purity increase can save $320,000 per year (based on
8000 operating hours).

EFFECT OF H2 PURITY ON GEN EFFICIENCY AND OUTPUT

OPERATIONAL REQUIREMENTS OF THE GENERATOR HYDROGEN

COOLING SYSTEM.
oTo continuously re-circulate the hydrogen gas within

the generator
oTo cool the hydrogen to the required temperature.
oTo dry the hydrogen to the required dew point.
oTo maintain the correct hydrogen gas pressure in the
generator by providing make-up hydrogen to
compensate for leaks.
oTo provide an alarm for liquid oil or water within the
generator cavity.
oTo monitor the hydrogen gas purity.
oTo monitor CO2, Air, and H2 for purging and charging
the generator.

Major Components of the Generator Hydrogen

Cooling System:Centrifugal Fans
The centrifugal fans located at each end of the rotor draw
hydrogen from the air-gap between the rotor and stator and
blow it through the coolers located within the generator yoke.
From the coolers the hydrogen is directed to both the stator
iron and to the rotor. The cool hydrogen passes through the
ducts in the stator irons and enters the air gap from the centre
portion of the stator iron.

Major Components of the Generator Hydrogen Cooling System:-

Hydrogen Coolers
The hydrogen coolers are long, finned, U-Tube units mounted
axially in compartments located in the generator yoke. The hot
hydrogen passes over the finned tubes, losses its heat to the
service water and then flows on to cool the stator iron and rotor
conductors.
Gas Supplies H2, CO2 and Air
Hydrogen from a bulk storage system is fed to the generator via
a pressure regulating valve. The H2 pressure within the
generator is held relatively constant by the hydrogen makeup
system. CO2 from the portable bottles is used to purge
hydrogen or air from the generator when required. The CO2 is
then displaced by clean, dry air if the generator is to be opened
for maintenance.

MajorComponentsoftheGeneratorHydrogenCoolingSystem:

Hydrogen Dryer
Typically, hydrogen dryer will be a twin tower type using beds
of activated alumina. Cycle times are adjusted to suit the
drying load. Cycle times are adjusted to suit the drying load.
Hydrogen Gas Analyzers
The gas analyzer unit analyzes the H2 purity when the
generator is at operating speed. A low purity alarm is
provided. A portable gas analyzer is used when charging and
discharging the generator. The primary significance of the
hydrogen purity is the requirement to avoid an explosive
H2/Air Mixture, i.e. H2 content must be above 80% or below
3%.

DIFFERENTHYDROGEN
GENERATIONMETHODS

The three Methods used in Power Industry

for generation of Hydrogen are: Unipolar Design
Liquid Bipolar (Potassium Hydroxide as
Electrolyte) Design
Solid Bipolar Design (Proton Exchange
Membrane Technology)
The three methods are discussed briefly :

Unipolar Design:In unipolar design electrolysis of water uses the tank

electrolyzer in which a series of electrodes, anodes and
cathodes alternately, are suspended vertically and parallel to
one another in a tank partially filled with electrolyte.
A single tank-type cell usually contains a number of
electrodes, and all electrodes of the same polarity are
connected in parallel, electrically, as pictured in Figure.
Advantage : - Extremely simple to manufacture and repair.
Disadvantages of Unipolar Design: - It usually operates at
lower current densities and lower temperatures.

Bipolar Design (Potassium Hydroxide as Electrolyte):-

Bipolar Design (Potassium Hydroxide as Electrolyte):-

The second type of electrolyzer construction is the bipolar

design. Often called the filter-press design, this has
alternating layers of electrodes and separation diaphragms
that are clamped together. The cells are connected in series
and can result in higher stack voltages. Since the cells are
relatively thin, the overall stack can be considerably smaller
than the unipolar design. This method is widely used in the
industry. The space requirement for this type of generation is
more. The H2 Generation plant is often placed outside at
some distance. Hydrogen is supplied by H2 gas cylinders to
the generator.

Bipolar Design (Proton Exchange Membrane) :The other electrolyzer technology is called PEM or solid polymer electrolyte. In a
PEM, the electrolyte is contained in a thin, solid ion-conducting membrane rather
than the aqueous solution in the alkaline electrolyzers. This allows the H+ ion (i.e.,
proton) to transfer from the anode side of the membrane to the cathode side and
separates the hydrogen and oxygen gases. Oxygen is produced at the anode side
and hydrogen is produced on the cathode side. PEM electrolyzers use the bipolar
design and can be made to operate at a high differential pressure across the
membrane. The space requirement in this type of H2 generation is pretty less.
Practically no maintenance is required in this type, neither a full time operator is
required.

The PEM Electrolysis Process

Advantages of Bipolar Design: Reduced stack footprints, higher current densities, and its
ability to produce higher pressure gas.
Disadvantages of Bipolar Design: It cannot be repaired without servicing the entire stack.
Previously asbestos was used as a separation diaphragm,
but manufacturers have replaced or are planning to replace
this with new polymer materials. And since Asbestos is a
carcinogenic material it is important for the manufacturers to
replace them with different materials.

SAFETY MEASURES TO BE TAKEN WHILE HANDLING

General
Precautions:HYDROGEN.
When hydrogen is contained within process and storage
vessels, the concentration should be checked regularly to
ensure the hydrogen is outside the explosion range.
Before hydrogen is introduced into a process or storage
vessel, a purging or evacuation process must be performed to
remove the oxygen.
Before a process or storage vessel containing hydrogen is
opened to atmosphere, perform a hydrogen purge using an
inert gas. (e.g:- Nitrogen)
Maintain a positive pressure in the hydrogen vessel to
prevent the introduction of air.
Open Flames, smoking or welding is not permitted in areas
where hydrogen is present.

StatorCoolingWaterConductivity
Sincethelargegeneratorsoperateat18000voltsACorabove,itis
absolutelyessentialthatthestatorcoolingwaterconductivitybekept
lowenoughtoprovideadequateelectricalinsulation.
Hydrogen/AirConcentrations
Thehydrogen/airconcentrationmustbekeptoutsidetheexplosion
range(474%)toavoidseriousdamagetoequipmentandpossiblefire
injurytopersonnel.
HydrogentoSealOilDifferentialPressure
ThesealOilpressuremustbegreaterthanthehydrogenpressureto
preventtheleakageofhydrogenfromthegenerator.

Hydrogen

to Stator Water Differential Pressure

To prevent leakage of liquid Water from the stator system into
the hydrogen, the hydrogen pressure must be greater than
the stator cooling water pressure.
Hydrogen Dryness
To prevent condensation and possible ground faults within the
generator, the hydrogen gas which is circulating in the
generator must be kept dry enough to always above the dew
point.
Drains
Any leakage of liquid, oil or water in to the generator can
cause severe physical damage. The drains from the bottom of
the generator must be in operation.

SAFETY PRECAUTIONS RELATED TO LAYING OF H2 PIPE LINES.

H2 Pipelines should not preferably be underground. If it is in a

trench, care should be taken that the trench is properly
ventilated.
H2 Pipelines should preferably run on the top of all the other
pipelines and not along with them.
All the H2 pipes to be properly earthed.
Flanged and screwed joints to be avoided. Welded joints shall
be used.
Provision for thermal expansion to be kept.
The H2 piping shall be coloured as per code and at regular
interval distance shall be marked with a warning.

OUR EXPERIENCE REGARDING VISIT TO

NTPC VINDHYACHAL SUPER THERMAL
NTPC ranked 341st in the 2010, Forbes Global
POWER STATION

2000 ranking of the Worlds biggest companies.

With a current generating capacity of 34,194 MW,
NTPC has embarked on plans to become a 75,000
MW company by 2017.
The plant is located on the north western bank
of Govind Ballabh Pant Sagar (GBPS) at
Vindhyasagar of Sidhi district in the state of
Madhya Pradesh.

The observations
electrolyzer for Stage
Our
: I have been replaced 2-3

times duo to leakage in the vessel and through adjoining

fittings.
For Stage II and III no of Hydrogen Cylinder required is
7 per 500 MW Unit per day.
For Stage I (6X210 MW) Hydrogen is fed to Generator
through direct Pipe line.
Temperature of DM Water after electrolysis is 48 C
For Stage II and III there was no need of Mechanical
maintenance of the Hydrogen Generation Plant (using
PEM Technology).
For Stage II and III no UPS was provided.

Some Photos from the Vindhyachal

NTPC Visit H2 generator PEM

Diaphragm Compressors

Inside the PEM Unit

Electrolysis Cell - PEM

Hydrogen Tank Yard

Electrolysis by KOH

Hydrogen and Oxygen Seperator

Tanks

KOH leakage from Electrolysis Cell

KOH Electrolyzer Cell

Hydrogen Filling Manifold

Generator

THANK
YOU!
GOOD