water electrolysis hydrogen plant overhauling plan, Cilacap power plant

5m3/h WATER ELECTROLYSIS HYDROGEN PRODUCTION EQUIPMENT OVERHAULING PLAN

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

THE CILACAP POWER PLANT PURCHASED 5M3/H WATER

ELECTROLYSIS HYDROGEN PRODUCTION EQUIPMENT, HAS 10 YEARS
OPERATION, NEED COMPREHENSIVE EQUIPMENT OVERHAULING(THE
EQUIPMENT AS FOLLOW)

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

一、设备大修方案 The equipment overhauling plan

1 更换为全新的 5 立方电解槽。
replace for the new 5 cubic electrolysis.
2 制氢框架碱液过滤器更换为配套、全新的。
Hydrogen production framework lye to form a complete set, a new filter
replaced
3 提供 2 台全新气动薄膜调节阀（美国 mark708）
provides two new pneumatic regulating valve(US mark708)
4 提供 2 台新的减压阀
provides two new reduing valve
5 制氢系统控制系统程序完善。(提供一台工控机)监控画面可同时在工控机上实现。
Hydrogen production system for program control system upgrade.（supply a
computer）。Monitor picture can also indicate in the computer.
6 控制柜内电缆重新铺设、排列整齐。
Control cable laying, contained in the order.
7 制氢框架、整流柜、控制柜、配电柜重新喷涂防锈漆。
Hydrogen production framework, rectifier cabinets, control cabinets,
distribution cabinets to spraying antirust paint.
8 除盐水冷却设备除水箱外全部更换。(含板式换热器 2 台，除盐水泵 2 台，阀门、
管道等)
In addition to salt water tank, cooling water equipment change the
new(including the 2 set heat exchange, cooling water pump 2 set, valve
and pipes)
9 运行备件，见供货范围
operation spare parts, see scope of supply
10 氢气储罐安全阀等配套阀门，更换为全新的.
Hydrogen tank safety valve and so on change the new.

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

1 更换为全新的 5 立方电解槽
change for the new 5 cubic electrolysis

从电解槽出来带着氢气和氧气的碱液在氢（氧）分离器中分别靠重力的作用与氢（氧）分
离，在分离器下部停留期间，得到初步冷却。然后二路汇合进入碱液循环泵，泵在这里提供
了碱液循环的动力，我们采用了两台碱液循环泵，一用一备确保制氢系统的稳定运行。碱液
经过过滤器时，机械杂质被除去。经过滤的碱液进入电解槽下部，并通过特殊的通道均匀分
配到各个电解小室。电解液在各个小室内（二块极板之间）自下而上流动，不断得到电解，
从而形成了电解液的内循环系统。

Lye mixed with hydrogen and oxygen coming out of the electrolyzer enters into
hydrogen (oxygen) separator and separate from hydrogen (oxygen) . Lye is
preliminary cooled during the period of stay in the separator. Then two streams
of lye coming out of both bottom of separators converges and enters into lye
circulation pump (two lye pumps, one operating and one standby). Through lye
filter, the lye is sent to the lower part of electrolyzer and evenly distributed
into each cell of electrolyzer through special passage. The electrolyte is
continuously electrolyzed while flowing from the bottom to the top in each cell
of electrolyzer, and thus form the electrolyte’s inside circulation system.

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

2 制氢框架内碱液过滤器更换为配套、全新的

Hydrogen production framework the lye filter to change a new one

制氢装置进碱（进水）系统
Lye feeding (water feeding) system
制氢装置由电解槽和框架Ⅰ组成。碱液箱中的电解液通过碱液循环泵抽入框架Ⅰ，经碱
液过滤器过滤后注入电解槽，注满电解槽后碱液分别进入氢（氧）分离器。该系统在首
次开机时适用。
原料水的抽入同碱液。该系统在清洗设备时适用。
Hydrogen generator is composed of electrolyzer and auxiliary frame.
Electrolyte in the lye tank is pumped into auxiliary frame by the lye
circulation pump, through lye filter, and inject into electrolyzer. After
electrolyzer is full with lye, the lye enters into hydrogen (oxygen)
separator respectively. This system is applicable during first start-up of
the hydrogen generator.
The injection of DM water is the same as aforesaid lye, and is applicable
during equipment cleaning.
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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

配碱系统
Lye preparation system
碱箱中的原料水由配碱泵循环，经碱液过滤器，通过阀门的切换回到碱液箱。在原料水
循 环的过程中，不断加入氢氧化钾，氢氧化钾不断溶解，从而形成了配碱循环（外循
环）。此步工作在首次开机时执行。
DM water in the lye tank is circulated by lye circulation pump, after lye
filter, through switch of valve return to lye tank. During the circulation of
DM water, KOH is continuously added in and be resolved, thus form the lye
preparation system (lye outside circulation). This operation is done during
initial start-up.
3. 制氢系统控制系统程序完善(提供一台工控机)监控画面可同时在工控机上实现。
Lye feeding (water feeding) system
制氢装置由电解槽和框架Ⅰ组成。碱液箱中的电解液通过碱液循环泵抽入框架Ⅰ，经碱
液过滤器过滤后注入电解槽，注满电解槽后碱液分别进入氢（氧）分离器。该系统在首
次开机时适用。
原料水的抽入同碱液。该系统在清洗设备时适用。
Hydrogen generator is composed of electrolyzer and auxiliary frame.
Electrolyte in the lye tank is pumped into auxiliary frame by the lye
circulation pump, through lye filter, and inject into electrolyzer. After
electrolyzer is full with lye, the lye enters into hydrogen (oxygen)
separator respectively. This system is applicable during first start-up of
the hydrogen generator.
The injection of DM water is the same as aforesaid lye, and is applicable
during equipment cleaning.

Pressure control system

通过安装在氧侧分离器上的压力变送器进行压力测量并将测量信号变为 4～20mA 的直流
信号送至 PLC，经过与设定值的比较，通过 PID 运算，输出电信号给电气转换器，转换产
生 0.02～0.1Mpa 的气信号，以此控制氧侧气动薄膜调节阀的开度来达到控制系统压力稳
定的目的。系统的压力设定可以在人机界面上进行。
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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

The pressure transmitter mounted on the oxygen separator side measures the
pressure and change the measure signal into a 4 ~ 20mA DC signal to the PLC,
by comparison with the set value, the PID calculation, output signals to
electrical pneumatic converter, convert the signal into 0.02 ~ 0.1Mpa
pneumatic signal, so that the opening percentage of the pneumatic valve on
oxygen separator side is regulated and the stable system pressure is achieved.
System pressure settings can be performed on the man-machine interface.
液位控制系统
Liquid level control system
a 氢分离器液位的控制
Liquid level control of hydrogen separator
在电解过程中，原料水不断消耗，使氢氧分离器液位不断下降，因此需要通过补
水泵补充原料水，以满足电解消耗的需要。
In the electrolysis process, the DM water is consumed little by little,
and the liquid level of hydrogen (oxygen) separator decline, and therefore
DM water needs to be supplemented by feed water pump to meet the needs of
electrolytic consumption.
本系统是通过安装在氢侧的差压变送器进行液位高度测量，并产生标准的 4～
20mA 电流信号，输入 PLC；通过与设定的液位上下限报警和联锁值进行比较，产生输
出信号来控制补水泵的开停及联锁报警。液位上下限报警及联锁值的设定可以在人机
交流界面上进行。
The pressure difference transmitter mounted on the hydrogen separator
side measures the liquid level and change the measure signal into a 4 ~
20mA DC signal to the PLC, by comparison with the set alarm and interlock
value of the maximum and minimum liquid level, output signals to control
the startup/stop and alarm and interlock of the feed water pump. The alarm
and interlock value of the maximum and minimum liquid level settings can be
performed on the man-machine interface.

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

设定 人机界面 补水泵

Setting Man-machine PLC Feed water pump

interface

氢液位 报警联锁

Hydrogen liquid Alarm and interlock

level

B 氢氧侧压力差的控制
Pressure difference control between hydrogen side and oxygen side
本系统的任务是控制系统内氢、氧侧的压力平衡。由安装在氧侧分离器和氢侧分
离器上的差压变送器分别测量氢、氧侧的气、液相压差，两个 4～20mA 测量信号被送
入 PLC。氢侧压力作为给定，氧侧压力作为测量进行比较和 PID 运算（P：比例，I：积
分、D：微分（可选项）正作用运算）。运算结果输出给电气转换器，转换产生 0.02～
0.1Mpa 的气信号，控制安装在氢气出口管道上的气动薄膜调节阀的开度，从而达到控
制两侧压力平衡的目的。
控制方框流程图如下：
The task of this part is to control the pressure balance between
hydrogen and oxygen side of the system. By the pressure difference
transmitter mounted on the hydrogen (oxygen) separator, pressure difference
between gas-liquid phase of hydrogen (oxygen) side is measured, two 4 ~
20mA measuring signals are sent to PLC. Hydrogen side pressure as setting
reference, and the oxygen side as measuring, is compared and PID calculated
(P: proportion, I: integral, D: differential coefficient (optional)).
Calculation result is output to electrical pneumatic converter to be
converted to 0.02 ~ 0.1Mpa pneumatic signals to control the opening
percentage of the pneumatic valve mounted on the hydrogen side. In this way,
the pressure balance between the hydrogen and oxygen side is obtained.
Control block flow diagram as follows:
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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

人机界面 PID 设定

Man-machine interface
PID setting

氧差压变送器

Oxygen pressure difference

transmitter 电气转换器 气动薄膜调节阀

Electrical Pneumatic
diaphragm valve
conversion
valcontrol valve
氢差压变送器 PLC
Hydrogen pressure
difference transmitter

C、制氢系统的重要参数检测点
Major parameter checking point of the hydrogen generator
(1)系统压力 system pressure
(2)氧液位 liquid level of oxygen separator
(3)氢液位 liquid level of hydrogen separator
(4)碱温 lye temperature
(5)氢、氧压差 Pressure difference between hydrogen and oxygen separator
(6)碱液循环量 circulation lye quantity
(7)出电解槽氧含氢量 Hydrogen content in oxygen out of electrolyzer
(8)出电解槽氢含氧量 Oxygen content in hydrogen out of electrolyzer

4. 整流柜电压 voltage of rectifier cabinet

警报 连锁
Alarm Interlock
序 号 监控参数 下下限
下限 上限 上上限
No. Monitoring parameters Lower
Lower Upper Up upper
lower
limit limit limit
limit

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

制氢系统操作压力 YES YES

1
Working pressure of hydrogen generator
制氢系统操作温度 YES YES
2
Working temp. of hydrogen generator

碱液流量 YES YES

3
Lye flow rate
氢分离器液位 YES YES YES YES
4
liquid level of hydrogen separator

氧分离器液位 YES YES YES YES

5
liquid level of oxygen separator

干燥塔 I 顶部运行温度 YES YES

6 Working temperature at top of adsorption
dryer I
干燥塔 I 底部运行温度 YES
7 Working temperature at bottom of adsorption
dryer I
干燥塔 II 顶部运行温度 YES YES
8 Working temperature at top of adsorption
dryer II
干燥塔 II 底部运行温度 YES
9 Working temperature at bottom of adsorption
dryer II

微量氧含量 YES YES

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Oxygen micro-ananlysis
产品氢露点 YES YES
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Dew point of product hydrogen

冷却水操作压力 YES YES

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Operating pressure of cooling water

仪表气操作压力 YES YES

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Operating pressure of instrument gas

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

二、 改造后实现技术参数
Technical data for hydrogen generator:
1、设备型号 equipment model： DQ5-/3.2
2、额定氢气产量 rated hydrogen output: 5m3/h
3、额定氧气产量 rated oxygen output: 2.5m3/h
4、出口氢气纯度 outlet hydrogen purity: ≥99.999%
5、出口氧气纯度 outlet oxygen purity: ≥99.3%
6、氢气含湿量 H2 Dew point: ≤4g/m3H2
7、氧气含湿量 O2 Dew point: ≤4g/ m3O2
8、系统工作压力 working pressure： 3.2Mpa
9、额定直流电耗 rated consumption of DC electricity： ≤4.8kw.h/Nm3

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

三、翻新工作范围：Project work scope

1.工艺划分界线为制氢车间外 1 米，买方负责将工艺所需的合格的水，仪表气接到工艺划分
界限处。制氢车间外 1 米以内的设备由卖方负责。
Process battery limit is 1 meter outside of the hydrogen generating workshop. The
buyer shall provide eligible water and instrument gas that is needed by the
process to the battery limit position. Equipment within the battery limit is in
Seller’s scope of supply.
2. 配电柜内。
The buyer shall connect voltage power to the end of the rectifier, and connect
low voltage power to the inside of power cabinet.
3. 当安装材料在卖方供货范围内时，卖方提供的安装材料为界区内的安装材料。当安装材料
不在卖方供货范围内时，界区内的安装材料由买方提供。
When installation material is in Seller’s scope of supply, the Seller shall
supply installation material that is within the battery limit. When installation
material is not in Seller’s scope of supply, the Buyer shall supply installation
material that the process needed.

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

四、 制氢设备供货清单 Scope of supply within hydrogen generator equipment

序 号 名 称 规 格 数 量
备 注 remarks
NO. name specification quantity
电 解 槽
1 5m3/h 1 set 全新 new
electrolysis
碱液过滤器
2 配套 mating 1 pie 苏州竞立 suzhoujingli
Lye filter
除盐水冷却设备
3 Cooling water 配套 mating 1 set 不含水箱 no water tank
equipment
除盐水泵 cooling
3.1 配套 mating 2 set 上海三星 shanghai sanxin
water pump
板式换热器
专 业 厂 家 special
3.2 heat exchange 配套 mating 2 set
manufactory
quipment
管 道 、 阀 门 pipe
3.3 配套 mating 1 set
and valve
气动薄膜调节阀
4 Pneumatic Mark 708 2 set 美国乔丹 Us
regulating valve
减 压 阀 reducing 3.2MPa 减 压 至
5 2 set 上海减压器厂 shanghai
valve 0.6MPa

6 工控机 computer 24 寸 1 set 戴尔 DELL

安 全 阀 safety
7 开启压力 3.4MPa 3 set 上海 shanghai
valve
安全 阀 safety
8 开启压力 1.1MPa 1 set 上海 shanghai
valve
截 止 阀 globe 满足 3 套氢气罐及 1 套空气
9 配套 1 set
valve 罐 数 量 要 求 the quantity

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

fit 3 hydrogen tank and 1

air tank
13X 分 子 筛
10 100 kg 备件 spare parts
molecular sieve
手动球阀 ball 备件 spare parts 美国
11 DN15 PN4.0 2 pie
valve SWAGELOK
温 度 变 送 器
备件 spare parts 上海自仪
12 temperature 0-400℃ 1 pie
shanghai ziyi
transmit
温 度 变 送 器
备件 spare parts 上海自仪
13 temperature 0-150℃ 1 pie
shanghai ziyi
transmit
先 导 电 磁 阀
14 配套 mating 2 pie 备件 spare parts
solenoid valve

15 中间继电器 relay 配套 mating 2 pie 备件 spare parts

碱液过滤器滤网
16 net for the lye 配套 mating 1 set 备件 spare parts
filter

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

五、 工艺、系统、安装设计规范
Regulation codes for process, system and installation
《氢气站设计规范》GB50177-2005
The design regulation for hydrogen station
《水电解制氢设备》 JB/T5903-96
Water electrolysis hydrogen generator
《水电解制氢设备质量分等》JB/TQ584-87
Quality classification for water electrolysis equipment
《水电解制氢设备技术条件》ZB J76 009.1-88
Water Electrolysis Hydrogen Production Equipment Technical Conditions
《水电解制氢设备性能试验方法》 J76 009.2-88
Performance test method for hydrogen production equipment by water
electrolysis
《氢气使用安全技术规程》GB4962-85
Safe technology regulation of hydrogen using
《工业用气态氧》 GB 3863-83
Industrial gas oxygen
《工业氢》 GB/T 3634.1-96
Industrial hydrogen
《金属管道设计规范》GB50316-2000
Design regulation of metal pipeline
《氢氧站安装工程施工及验收通用规范》
Usual regulation for installation and acceptance of hydrogen and oxygen
station
《建筑设计防火规范》GBJ16-87((2001)
Fire-fighting regulation for building design
《机械设备安装工程施工及验收通用规范》GB50231
Usual regulation for installation and acceptance of mechanical equipment
《工业金属管道工程施工及验收规范》GB50235
Construction and acceptance of industrial metal pipe
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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

《现场设备、工业管道焊接工程施工及验收规范》 GB50236
Construction and acceptance of onsite equipment installation and industrial
pipe welding
《钢制压力容器》GB150-2005
Steel pressure vessel
《钢制化工容器制造技术要求》HG20584-1998
Manufacturing technical requirement for steel chemical-engineering vessel
《压力容器安全技术监察规程》1999 年版
Pressure vessel safety and technical supervision regulation (1999 version)
《连接法兰标准》 HG20592-2005
Connecting flanges standard
压力容器制造标准符合 GB 标准
Steel pressure vessel standard according to GB

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 water electrolysis hydrogen plant overhauling plan, Cilacap power plant

CONFIRMED BY
PT. S2P

PT.D&C

TEAM O&M

VENDOR SUZHOU JINGLI

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