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ANNEX 1

Technical Specifications

Alkaline Hydrogen Generator


HySTAT-10/10 (10Nm3, 10bar) indoor version

Hydrogenics Europe NV, On-Site Generation www.hydrogenics.com Hydrogenics Corporation


Nijverheidsstraat 48-C, Oevel, B-2260, Belgium 5985 Admiral Blvd, Mississauga, ON L5T 2N6 Canada
Tel: +32 14 46 21 10 Tel: +1 905 361 3660
Annex: HySTAT-10/10 Indoor Version
Revision 1204

TABLE OF CONTENTS

1. INTRODUCTION ......................................................................................................................................................... 2

2. SAFETY ....................................................................................................................................................................... 3

3. QUALITY ASSURANCE ................................................................................................................................................ 4

4. RELIABILITY AND AUTOMATION ................................................................................................................................ 4

5. CONTROL & MONITORING OF THE UNIT .................................................................................................................... 5

6. SCOPE OF SUPPLY ...................................................................................................................................................... 5

6.1. BASIC EQUIPMENT .............................................................................................................................................. 5

6.2. OPTIONAL EQUIPMENT...................................................................................................................................... 7

6.3. ADITIONAL OPTIONS ........................................................................................................................................ 11

7. TECHNICAL SPECIFICATIONS .................................................................................................................................... 12

8. DIMENSIONS............................................................................................................................................................ 13

9. CODES AND STANDARDS ......................................................................................................................................... 14

10. DOCUMENTATION ................................................................................................................................................... 14

11. LIMITS OF SCOPE ..................................................................................................................................................... 14

12. EXCLUSIONS............................................................................................................................................................. 15

13. DISCLOSURE ............................................................................................................................................................. 15

1. INTRODUCTION
The HySTAT 10/10 Indoor Version is an all-in hydrogen generator producing 10 Nm/h of hydrogen
at a purity of up to 99,998 % and a pressure of 10 bar(g).

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 2 of 15
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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.

Standard HySTAT- 10/10 indoor unit


for a total H2 output capacity of 10 Nm/h

2. SAFETY
At Hydrogenics, we care about our clients safety. The HySTAT is designed taking into account
international standards :

CE (ATEX directive 94/9/EC)


NRTL/UL/CSA (as an option)
GOST/Rostechnadzor (as an option)
New Machine Directive (2006/42/EC)
ISO 22734/1 (onsite hydrogen generation) and ISO 12100 (safety of machinery)
IEC 61508, 62061 and 61511 (Functional Safety of electronic related systems)
Went through a complete risk evaluation process to define the acceptable risk
Successfully completed Hazop studies from major industrial gas companies

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)

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 3 of 15
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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 t, pressure in the system,).

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

4. RELIABILITY AND AUTOMATION


The HySTAT is carefully designed to operate fully continuously with a minimal need for human
attendance while maintaining a reliability level according to the most stringent industrial standards.

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.

Semi automatic nitrogen purge: nitrogen purge is required before starting the unit when the
internal pressure is below 15kPa. The systems PLC will sequentially activate the different

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 4 of 15
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valves in the system, thus ensuring that all air is evacuated prior to hydrogen production. The
only manual action required is changing the position of two valves. This action can be
automated optionally, allowing this action to be performed by a remote operator.

5. CONTROL & MONITORING OF THE UNIT


The control panel features enhanced control & monitoring possibilities:

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.

Exter Visualization Software

6. SCOPE OF SUPPLY
6.1. BASIC EQUIPMENT
6.1.1. Process skid

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 5 of 15
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The core component of the electrolysis skid is the HySTAT bipolar pressurized water-electrolysis cell
stack. The cell stack consists of circular electrolysis cells, each containing two electrodes and an
alkaline inorganic ion-exchange membrane.

The H2 and O2 are generated when current is


supplied to the cell stack. The gases are then
directed to the gas separator, which is a dual
stainless steel pressure vessel, after which they are
rinsed in a specially designed pressure vessel
located above the gas separator.

The process part equipment is made out of high


quality materials and is compliant with ATEX
directives (refer to explosion production document
for more info).

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)

6.1.2. Control Panel

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:

Approved electrical enclosure with 2 lockable doors


Cooling fans + air filtration system
PLC (Siemens S-7 software)
Exter: display terminal for visualization and HMI
Emergency stop on the enclosure door
UPS for safe shutdown
24 VDC power supply
Circuit breakers & Transformers
Printed Circuit Boards & Audible alarm

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6.1.3. Power Racks

The power rack converts the incoming three phase AC power into regulated DC current required for
the electrolysis process. It includes:

Enclosure with lockable door


Cooling fans + air filtration system
Door switch safety interrupt.
Transformer
Rectifier
Circuit breakers, contactors, thyristors & rectifier bridges
Ammeter & Voltmeter cell stack measurements on the door
Phase checker

6.2. OPTIONAL EQUIPMENT


6.2.1. ATEX Enclosure for HySTAT Process Part & Hydrogen Purifier

Hydrogenics can supply the process skid (and the optional hydrogen purifier) inside one single 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 switch

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 7 of 15
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6.2.2. HPS (Hydrogen Purification system)

The Hydrogen Purification System (HPS) is designed to further purify the hydrogen to a minimum 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.

HPS

The HPS is built in the same skid as the process part. The HPS is controlled by the central PLC in the
control panel and features:

Deoxo Vessel with catalyst to remove H2 in O2 (heated & insulated)


Heat exchanger
Coalescent Filter
Drain pot system for water removal
Instrumentation
Two drier towers filled with molecular sieve (heated & insulated) (time regenerated)
Connections to gas cooling loop
Connection to Process Part vent headers (H2 and O2)

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and models shown in this document. These are not necessarly showing the equipment that will be installed in your system. Page 8 of 15
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6.2.3. Chiller (gas cooling)

The chiller supplies low temperature cooling water in a closed-loop


circuit towards the HySTAT process hydrogen and oxygen gas
heat exchangers at a temperature of 15C, regardless of the
ambient temperature . The chilled water cools down the hydrogen
and oxygen gases, forcing the water vapour occurring in the
electrolysis process to condensate. This is then filtered and
removed from the gas stream. The chiller is installed inside an
enclosure for indoor use and includes a pump and expansion tank.

Ambient conditions Ambient temperature range +5C to +45C


Temperature cooling water +15C
Installation Dimensions (HXWXD) (m) 1,35 X 0,88 X 0,8
Empty weight 185 kg
Specifications Chiller

6.2.4. Electrolyte cooling system

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.

Ambient Ambient temperature range -20C to +40C


conditions Temperature cooling water out Ambient temperature + 3C
Max ambient temperature for 100 % output +40C
Noise level at 10m from the fan < 69 dBa
Installation Dimensions (LXWXH) (m) 2.7 X 0.8 X 1.05
Empty weight 113 kg

Specifications Dry cooler

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6.2.5. Feed water treatment system

The feed water treatment system (wall-mounted) will convert tap


water into pure demineralised water needed for the electrolysis
process. The water quality is continuously monitored before
allowing it to enter the process.

Height (m) 1.5


Width (m) 1,0
Depth (m) 0.5

Feed water treatment system


The system includes filtration purification stages such as:

Reverse Osmosis Membrane


Mixed Bed Ion Exchange Resin System (2 tanks filled with resin)
Water Softening System with digital dosing pump (anti-scalent)
Conductivity Meter
Active carbon and partuclate pre-filters
Pressure indicators and switches

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.

Feed Water Specs.


Tap water consumption 1.5-2 l/Nm3 of H2 Ba2+ 0.05 mg/l max.
Temperature 10C - 30C Ca2+ 20 - 50 mg/l max.
Pressure 2 - 4 barg Mg2+ 10 - 30 mg/l max.
No microbiological contamination - Cl- 150 mg/l max.
Langelier Index 2.5 max. SO42- 150 mg/l max.
pH 7,0 8,5 HCO3- 100 mg/l max.
Free Clorine 0.02 mg/l max. Fe (tot) 0.5 mg/l max.
Suspended Solids 0.05 mg/l max. Al (tot) 0.05 mg/l max.
CO32- 0. 5 mg/l max. Conductivity 1000 S/cm max.
Turbidity NTU < 0,5 SiO2 0.5 mg/l max.
Na+ 200 mg/l max. Manganese 0.05 mg/l max.
K+ 50 mg/l max.

Feed Water Treatment system intake water specifications

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6.3. ADITIONAL OPTIONS


6.3.1. Process options

Purity upgrade -75C, 2ppm O2


This option lowers the atmospheric dew point of the produced H2 from -60C to -75C and the O2
content in the produced H2 from 10ppm to 2 ppm.

Reduced N2 content - Frit Sparger


The frit sparger is a device implemented on the demineralised water intake of the HySTAT to lower
the N2 content to less than 2 ppm of the H2 produced. This will allow a hydrogen purity of 99,999%.

Online Purity Measurement (OLP)


The H2 produced is continuously monitored in real-time on both water content (dew point) and the
oxygen content. This option can only be selected in combination with the HPS.

Blow off valve (only in combination with OLP)


This feature will automatically vent the H2 to atmosphere in case its quality is out of spec. This option
can only be selected in combination with the H2 Online Purity Measurement.

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.

Air conditioning on control panel


It is modular air conditioning unit installed on the electrical panels. This feature is recommended for
systems frequently operating in ambient temperatures above +40C but lower than 45C.

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 -10/10
Flow range 4 to 10 Nm3/h
Purity (before HPS: Hydrogen 99,9%* (*H2O saturated)
HYSTAT OUTPUT

Purification System) O2 < 1.000 ppm


Purity (after HPS) 99,998 %; O2 < 2 ppm; N2 < 12 ppm
Atm. Dew point: - 60C (- 75C with purity upgrade)
CO+CO2+THC < 70 ppb
Operating pressure @ full flow 10 barg (after HPS)
Cell Stack(s) quantity 1
O2 production ** Nominal flow Vented
Power Estimated power consumption 5.0 kWh/Nm
Requirements @ full flow without utilities
Voltage 3 X 400 VAC 10 %
POWER

3 X 480 VAC 10 % (Standard in US option)


3 X 575 VAC 10 % (Standard in CA option)
Frequency 50 Hz 3 %
60 Hz 3 % (Standard in US and CA option)
Installed power 1 X 100 KVA
Nitrogen for Purge Pressure 4 to 10 barg
3
Quantity per purge Approx. 1 Nm
Cooling Water Electrolyte Cooling Loop *** Supplied by Closed Loop Cooling System
If not included: Max. water temp. 40C
Max. flow 2 m/hr
Gas Cooling Loop Supplied by Chiller
UTILITIES

If not included: Water at 15C


Max. flow 0.15 m/hr
Feed water Consumption of demin water to < 1 litre / Nm H2
process
Consumption of tap water to RO **** 1.52 litres/Nm H2 (depending on tap water quality)
Pressure 2 to 4 barg
Instrument Air Min. pressure 6 bar (Air compressor as an option)
Consumption (no control valves) +- 80l/min (no continuous consumption)
Electrolyte Type H2O + 30 % wt. KOH
FILL
1st

Quantity Approx. 300 L


Ambient Ambient Temperature Range +5C to +40C
INSTALLATION

conditions Max temperature for 100 % output +40C


Installation area***** Indoor, General Purpose Area
Relative humidity < 95 %
Altitude < 500 m
The above data are for reference only and subject to review without prior notice. Performance data are not to be used for guarantee purposes.

(**) Oxygen utilization requires optional oxygen use feature


(***) Only applicable if the option closed loop cooling is not selected.
(****) Assuming that the RO Feed Water Treatment System is included in the Scope of Supply.
(*****) The process part must be equipped with the optional ATEX enclosure (Atex zone II without enclosure).

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8. DIMENSIONS
Process Part

Empty weight: approx. 1.600kg (+200 kg for the Deoxo-dryer).


Operational wight: approx. 1.850kg (+ 200kg for the Deoxo-dryer).

Power Rack Control Panel

Overall weight: approx. 900kg Weight: approx. 450kg


Size: approx. 900 x 900 x 2300mm Size: approx. 1000 x 500 x 2000 mm

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9. CODES AND STANDARDS


As a default the HySTAT is built to CE (ATEX directive 94/9/EC) and ISO 22734-1 2008 standards.
Compliance with North American or Russian standards is optionally available.

10. 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

11. LIMITS OF SCOPE


Unless stated otherwise in the quote, The limit for the HySTAT electrolyser are the:

Process Skid (or ATEX enclosure, if included in Scope).


Deoxo-Dryer Skid (or ATEX enclosure, if included in Scope).
Power Rack enclosures.
Control Panel enclosure.
Electrical Interconnections:
- 15 meters between the process skid and the power racks.
- 15 meters between the power racks and control panels.

Mechanical Interconnections: not included.


Electric Power: circuit breaker on the power rack.
H2 and O2 Gases: connection on the HySTAT process skid (H2 and O2) and deoxo-dryer
skid/enclosure (H2).
O2 and H2 Vents: connections on the HySTAT process skid. Vent lines are not supplied.
Feed Water: when included, the feed water treatment system is shipped in a separate box. The
interconnection to the HySTAT is not included in the scope of supply.
Instrument Air: connection on the HySTAT process skid.
Condensate Drain: connection on the HySTAT process skid (waterlock included).
Cooling Water (2 cooling loops):

- Chiller (gas cooling):


o The chiller is shipped in a separate box. The interconnection to the HySTAT is not
included in the scope of supply.

- Dry Cooler (electrolyte cooling):


o The dry cooler is shipped in a separate box. The interconnection to the HySTAT is
not included in the scope of supply.

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12. EXCLUSIONS
Unless specified otherwise in the proposal, the following items are not included in the scope of this
proposal:

Any civil work


Any consumables and spares
All utilities needed for the start up and operation of the equipment. These utilities must be
available in the required quality, quantity and form at the time commissioning and start up
begins (mentioned in the customer check list).
Any material/equipment outside the battery limits
Materials for building, lighting, ventilation and heating outside of the container
Equipment foundation
Pipe and conduit supports outside of the container
Walkways and drains
Anchor bolts
On site testing or testing equipment beyond Hydrogenics standard tests
Drawings, data, calculations of a proprietary nature
Heat tracing and insulation if required
Hazop, FMEA or other design studies
Management of site preparation activities including design, permitting, inspections, and
approvals
Any inspection, certificate etc. others than the standard document provided by Hydrogenics
Tools necessary for the commissioning and start up of the equipment and training of the
people.
Service time exceeding 8 hours per day (overtime will be charged at 185/hour). Overtime is
limited to 2 hours/day. Weekends are not worked.
Travel expenses and hotel lodging of the engineers of Hydrogenics.
Transportation between hotel and site during commissioning, start up and training.
All figures, measurements, names, weights and/or other descriptions of the Products as
stated by the Supplier have been carefully prepared but the Supplier cannot guarantee that
no variations will occur. Models or drawings shown or supplied shall merely be indications of
the Products concerned.

13. 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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