HySTAT Indoor (10 Bar)

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HySTAT Manual

Revision: 09

Revision date: 25/01/2011

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WARNING AND DISCLAIMER

This manual is designed to provide tutorial information about the HySTAT electrolyzer. While
every effort has been made to make this manual complete and as accurate as possible, no guar-
antee of its suitability is given.

Hydrogenics Europe NV shall have neither liability nor responsibility to any person or entity with
respect to any loss or damage in connection with or arising from the information contained in
this manual. In case of doubt, please contact us.

Hydrogenics Europe NV

Nijverheidsstraat 48c

B-2260 Oevel, Belgium

Tel.: +32.14.46.21.10

Fax.: +32.14.46.21.11

www.hydrogenics.com

CONFIDENTIALITY
The information contained herein is proprietary information of Hydrogenics Europe NV and shall
not be copied and/or reproduced in any matter, nor used in any purpose whatsoever except as
specifically permitted pursuant to a written agreement with Hydrogenics Europe NV.

Page 4
HySTAT MANUAL

Revision: 09 - Revision date: 25/01/2011

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Page 1
HySTAT MANUAL

Chapter 1: Safety .............................................................................................................8

1.1. Conventions used in this publication ................................................................... 8
1.2. Registered trademarks ........................................................................................ 8
1.3. The Hydrogenics Safety Philosophy ...................................................................9
1.4. Hydrogenics general safety guidelines ..............................................................10
1.5. First aid equipment ............................................................................................11
1.5.1. First aid kit................................................................................................... 11
1.5.2. Eye wash station......................................................................................... 11
1.5.3. Emergency shower ..................................................................................... 11
1.6. Hydrogen properties ..........................................................................................12
1.7. Oxygen properties .............................................................................................13
1.8. Explosion hazard ...............................................................................................14
1.8.1. Hydrogen risks ............................................................................................ 14
1.8.2. HySTAT hazardous area classification ....................................................... 14
1.8.3. Safety guidelines......................................................................................... 14
1.9. Fire hazard ........................................................................................................ 16
1.9.1. Hydrogen risks ............................................................................................ 16
1.9.2. Oxygen risks ............................................................................................... 16
1.9.3. Safety guidelines – prevention.................................................................... 16
1.9.4. Safety guidelines – effect mitigation ........................................................... 17
1.10. Chemical corrosion hazard ..............................................................................18
1.10.1. KOH risks.................................................................................................. 18
1.10.2. Safety guidelines – prevention.................................................................. 18
1.10.3. Safety guidelines – effect mitigation ......................................................... 19
1.11. Asphyxia hazard ..............................................................................................20
1.11.1. Inert gases risks........................................................................................ 20
1.11.2. Oxygen risks ............................................................................................. 20
1.11.3. Safety guidelines....................................................................................... 20
1.12. Skin burn hazard .............................................................................................21
1.12.1. Hot surfaces risks ..................................................................................... 21
1.12.2. Safety guidelines....................................................................................... 21
1.13. Electrocution hazard........................................................................................ 21
1.13.1. General ..................................................................................................... 21
1.13.2. Residual voltage risk................................................................................. 21
1.13.3. Safety guidelines....................................................................................... 22
1.14. Power outage .................................................................................................. 23

Chapter 2: Environmental information ............................................................................26

2.1. Environmental, Health & Safety policy .............................................................. 26
2.2. Material safety datasheets ................................................................................ 26
2.3. Vented gases ....................................................................................................27
2.3.1. Oxygen........................................................................................................ 27
2.3.2. Hydrogen .................................................................................................... 27
2.3.3. Nitrogen ...................................................................................................... 27
2.4. KOH ...................................................................................................................27
2.4.1. Loss during normal operation ..................................................................... 27
2.4.2. KOH spills ................................................................................................... 27
2.5. Chemicals disposal ...........................................................................................27

Revision: 09 - Revision date: 25/01/2011

Page 2
HySTAT MANUAL

Chapter 3: Installation (indoor units) .............................................................................. 30

3.1. General.............................................................................................................. 30
3.1.1. Checklist ..................................................................................................... 30
3.2. Reception and handling .....................................................................................31
3.2.1. Reception.................................................................................................... 31
3.2.2. Handling...................................................................................................... 31
3.3. Site preparation ................................................................................................. 35
3.3.1. Structural..................................................................................................... 35
3.3.2. Floor trays for cabling ................................................................................. 38
3.3.3. Drains - gully traps ...................................................................................... 39
3.3.4. Connections ................................................................................................ 39
3.3.5. Heating and ventilation ............................................................................... 43
3.3.6. Storage ....................................................................................................... 43
3.3.7. Dehydro dryer ............................................................................................. 44
3.4. Mechanical connections ....................................................................................45
3.4.1. General ....................................................................................................... 45
3.4.2. Hydrogen user line...................................................................................... 45
3.4.3. Hydrogen vent to atmosphere..................................................................... 45
3.4.4. Oxygen vent to atmosphere........................................................................ 46
3.4.5. Feed water connection................................................................................ 47
3.4.6. Water locks ................................................................................................. 47
3.4.7. Drain connections ....................................................................................... 48
3.5. Electrical connections ........................................................................................49
3.5.1. General ....................................................................................................... 49
3.5.2. Cables......................................................................................................... 49
3.5.3. Earthing and bonding.................................................................................. 49
3.5.4. Cable trays.................................................................................................. 50
3.5.5. Lightning protection..................................................................................... 50
3.6. ATEX enclosure ventilation system................................................................... 50
3.6.1. Design flow & pressure ............................................................................... 51
3.6.2. Layout ......................................................................................................... 51
3.7. Electrolyte ..........................................................................................................52
3.7.1. General ....................................................................................................... 52
3.7.2. Specifications.............................................................................................. 52
3.7.3. Filling........................................................................................................... 52
3.8. Utilities............................................................................................................... 52
3.8.1. Purge installation ........................................................................................ 52
3.8.2. Cooling water .............................................................................................. 52
3.8.3. Closed loop cooling water........................................................................... 52
3.8.4. Other ........................................................................................................... 53

Chapter 4: Operation ......................................................................................................56

4.1. Introduction to the HySTAT system................................................................... 56
4.1.1. Product code............................................................................................... 56
4.1.2. Process description..................................................................................... 56
4.1.3. Process flow................................................................................................ 56
4.1.4. System overview......................................................................................... 56
4.1.5. Main components........................................................................................ 58
4.2. HySTAT Electrolyzer operation .........................................................................71

Revision: 09 - Revision date: 25/01/2011

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HySTAT MANUAL

4.2.1. General ....................................................................................................... 71

4.2.2. HySTAT human-machine interface............................................................. 71
4.2.3. HySTAT basic operation principles............................................................. 71
4.2.4. HySTAT start conditions ............................................................................. 71
4.2.5. HySTAT operational phases ....................................................................... 72
4.2.6. Level control, pressure control and current control..................................... 75
4.2.7. Starting the HySTAT ................................................................................... 75
4.2.8. Stopping the HySTAT ................................................................................. 77
4.2.9. Depressurizing the HySTAT ....................................................................... 77
4.3. Deoxo dryer operation .......................................................................................79
4.3.1. Deoxo dryer operational phases ................................................................. 79
4.3.2. Nitrogen purge of the deoxo dryer .............................................................. 80
4.3.3. Depressurization of the deoxo dryer ........................................................... 81
4.3.4. Deoxo dryer into production........................................................................ 81
4.4. Critical alarms ....................................................................................................82

Chapter 5: Maintenance and troubleshooting ................................................................86

5.1. Introduction........................................................................................................ 86
5.2. Generator status ................................................................................................87
5.2.1. Status for maintenance procedures ............................................................ 87
5.3. Inspection of the HySTAT system .....................................................................89
5.3.1. Definitions of inspections ............................................................................ 89
5.3.2. Overview of inspections – HySTAT ............................................................ 90
5.3.3. Overview of inspections – Dryer systems ................................................... 92
5.3.4. Overview of inspections – Auxiliaries.......................................................... 93
5.4. Scheduled maintenance – HySTAT ..................................................................94
5.4.1. Maintenance schedule ................................................................................ 94
5.4.2. Power- and control cabinet maintenance.................................................... 97
5.4.3. Cleaning the outdoor housing ..................................................................... 99
5.4.4. Checking and replacing the 24V UPS batteries........................................ 100
5.4.5. Checking the fixing of the power cables ................................................... 101
5.4.6. Replacing the thyristor cooling fans .......................................................... 103
5.4.7. Replacing the complete thyristor stack ..................................................... 105
5.4.8. Checking the torque on the cell stack ....................................................... 107
5.4.9. Checking leak tightness ............................................................................ 109
5.4.10. Checking the concentration of the electrolyte ......................................... 111
5.4.11. Removing the electrolyte ........................................................................ 114
5.4.12. Filling with electrolyte.............................................................................. 116
5.4.13. Checking the functionality of the temperature switches.......................... 120
5.4.14. Checking the functionality of the level switches...................................... 122
5.4.15. Replacing the level switch floats ............................................................. 124
5.4.16. Replacing the level transmitter floats ...................................................... 127
5.4.17. Checking the level transmitter................................................................. 129
5.4.18. Replacing or recalibrating the safety relief valves................................... 131
5.4.19. Inspecting pressure vessels.................................................................... 132
5.4.20. Checking and cleaning the electrolyzer solenoid valves......................... 134
5.4.21. Replacing solenoid & pneumatic valves ................................................. 136
5.4.22. Cleaning the break tank .......................................................................... 147
5.4.23. The HTO analyzer................................................................................... 148
5.4.24. Cleaning the HTO panel ......................................................................... 153
Revision: 09 - Revision date: 25/01/2011

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HySTAT MANUAL

5.4.25. The HTA analyzer ................................................................................... 154

5.4.26. The OTA analyzer................................................................................... 161
5.4.27. The OTH Analyzer .................................................................................. 163
5.4.28. Replacing the dewpoint transmitter......................................................... 170
5.4.29. Check functionality of door switch power rack ........................................ 171
5.4.30. Check functionality of flooding detection device ..................................... 172
5.4.31. Check functionality of air flow switch ...................................................... 173
5.4.32. Check functionality of current switch for process fan.............................. 174
5.4.33. Changing taps of transformer in power rack ........................................... 175
5.5. Scheduled maintenance – Deoxo dryer .......................................................... 178
5.5.1. Purging the deoxo dryer............................................................................ 179
5.5.2. Replacement of the coalescing filter after deoxo vessel........................... 180
5.5.3. Check instrument air supply...................................................................... 181
5.5.4. Check/Replace filter on instrument air supply........................................... 182
5.5.5. Replacement of the coarse particle filter element..................................... 183
5.5.6. Replacement of the solenoid valves ......................................................... 184
5.5.7. Replacement of the pneumatic valves ...................................................... 185
5.5.8. Exchange catalyst in deoxo dryer ............................................................. 186
5.5.9. Exchange molecular sieve in deoxo/dehydro dryer .................................. 187
5.6. Troubleshooting ...............................................................................................189
5.6.1. The events table ....................................................................................... 190
5.6.2. Investigating start conditions..................................................................... 191
5.6.3. Troubleshooting ........................................................................................ 192

Appendix A: HMI display terminal .................... .........................................................2

A.1.Getting Started..................................................................................................... 2
A.1.1.General ..........................................................................................................2
A.1.2.Using the display terminal ............................................................................. 3
A.1.3.Screen headers .............................................................................................3
A.2.Electrolyzer screens............................................................................................. 7
A.2.1.GGS1 screen .................................................................................................7
A.2.2.Trending Process screen ...............................................................................8
A.2.3.Power screen .................................................................................................9
A.2.4.Enable/Disable cell stacks screen ...............................................................10
A.2.5.Cell stack details screen ..............................................................................11
A.2.6.Production counters screen .........................................................................12
A.2.7.Electrolyzer actions screen ..........................................................................13
A.2.8.Electrolyzer start conditions screens ........................................................... 14
A.3.Utility screens..................................................................................................... 15
A.3.1.Closed loop cooling screen ......................................................................... 15
A.3.2.RO System screen ...................................................................................... 16
A.3.3.Fill calculation screen .................................................................................. 17
A.3.4.Outdoor housing screen .............................................................................. 18
A.4.Deoxo drier screens........................................................................................... 19
A.4.1.HPS screen .................................................................................................19
A.4.2.HPS Nitrogen purge screen .........................................................................21
A.5.Information screens ........................................................................................... 22
A.5.1.Info overview screen ....................................................................................22
A.5.2.Clock & Language screen ........................................................................... 23

Revision: 09 - Revision date: 25/01/2011

Page 5
HySTAT MANUAL

A.5.3.Start conditions overview screen .................................................................24

A.5.4.Basic start conditions screens .....................................................................25
A.5.5.Basic delayed start conditions screens ....................................................... 26
A.5.6.Events screen ..............................................................................................27
A.5.7.Analog alarms overview screen ...................................................................28
A.5.8.Analog basic alarms screen ........................................................................29
A.6.Debugging screens ............................................................................................ 30
A.6.1.Debug overview screen ...............................................................................30
A.6.2.Diagnostics screen ......................................................................................31
A.6.3.Counters actuators screen ..........................................................................32
A.6.4.Production limitations screen .......................................................................33
A.6.5.Profisafe overview screen ...........................................................................34
A.6.6.Profisafe UTx screen ...................................................................................35
A.6.7.Profisafe GGS1 screen ................................................................................36
A.6.8.Profisafe HPS screen ..................................................................................37

Appendix B: Tag reference ............................. .........................................................40

B.1.General .............................................................................................................. 40
B.2.HySTAT process................................................................................................ 40
B.3.Deoxo dryer ....................................................................................................... 44
B.4.Deoxo dryer: Full Flow Zero Loss (optional) ...................................................... 46
B.5.Deoxo dryer: Booster pump (optional) ............................................................... 47
B.6.Dehydro dryer .................................................................................................... 47
B.7.Analyzer panel deoxo dryer ............................................................................... 49
B.8.Analyzer panel dehydro dryer ............................................................................ 49
B.9.Instrument air panel ........................................................................................... 50
B.10.Conductivity measurement panel..................................................................... 50
B.11.Frit sparger....................................................................................................... 51
B.12.Chiller............................................................................................................... 51
B.13.Closed loop cooling.......................................................................................... 51
B.14.Cooling water from customer ........................................................................... 53
B.15.Total gas counter ............................................................................................. 53
B.16.Reverse osmosis system ................................................................................. 54
B.17.Hydrogen Cylinder Filling Station..................................................................... 55
B.18.Vacuum Pump for Hydrogen Cylinder ............................................................. 55

Appendix C: Start conditions .......................... .........................................................58

C.1.General Remarks............................................................................................... 58
C.2.Basic start conditions......................................................................................... 58
C.3.Common hydrogen production basic start conditions........................................ 59
C.4.Nitrogen purge start conditions.......................................................................... 61
C.5.Hydrogen deoxo dryer start conditions .............................................................. 62
C.6.Oxygen dehydro dryer start conditions .............................................................. 64
C.7.Hydrogen production start conditions ................................................................ 67
C.8.Cell stack 1 start conditions ............................................................................... 68
C.9.Cell stack 2 start conditions ............................................................................... 70
C.10.Cell stack 3 start conditions ............................................................................. 71
C.11.Cell stack 4 start conditions ............................................................................. 72

Revision: 09 - Revision date: 25/01/2011

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HySTAT MANUAL

Appendix D: Specifications utilities ................ .........................................................76

D.1.Electrolyte .......................................................................................................... 76
D.2.Demineralized water .......................................................................................... 77
D.3.Supply water to reverse osmosis system .......................................................... 77
D.4.Cooling water..................................................................................................... 78
D.4.1.Cooling water purity .....................................................................................79
D.4.2.Ethylene glycol – water solution ..................................................................79
D.4.3.Cooling system capacity ..............................................................................79
D.4.4.Chiller coolant ..............................................................................................80
D.5.Nitrogen gas ...................................................................................................... 80
D.6.instrument air ..................................................................................................... 80
D.7.Calibration gases ............................................................................................... 80
D.8.Electrical power supply ...................................................................................... 81
D.8.1.Grid specifications .......................................................................................81
D.8.2.Power specifications ....................................................................................81

Appendix E: Remote access and data-logging ........................................................84

E.1.Getting started ................................................................................................... 84
E.2.Remote Access Viewer...................................................................................... 84
E.2.1.Introduction ..................................................................................................84
E.2.2.Installation ...................................................................................................85
E.2.3.Connecting to the Operator Terminal .......................................................... 85
E.2.4.Using a Web Browser as a Viewer ..............................................................87
E.3.Beijer Electronics Data Collector (Optional)....................................................... 89
E.3.1.Introduction ..................................................................................................89
E.3.2.System requirements ...................................................................................89
E.3.3.Installation ...................................................................................................91
E.3.4.Using Beijer Electronics Data Collector .......................................................92
E.3.5.Database Tables .......................................................................................102
E.4.Beijer Electronics Viewer (Optional) ................................................................ 103
E.4.1.The Main Window ......................................................................................103
E.4.2.Settings ......................................................................................................103
E.4.3.View Trend ................................................................................................104

Revision: 09 - Revision date: 25/01/2011

HYSTAT MANUAL

SECTION 1: SAFETY

Page 8 Section 1
HySTAT MANUAL SAFETY

Section 1: SAFETY

1.1 Conventions used in this publication