ADHUNIK POWER & NATURAL RESOURCES LIMITED

2 X 270 MW, PADAMPUR

SOP
DOC REF NO APNRL/IMS/SOP/OP/001/17 REV 0 DATE OF ISSUE
RESPONSIBILITY MECHANICAL-OPERATION
PURPOSE OPERATION OF HYDROGEN GENERATION PLANT PAGE 0

Brief System Description

Hydrogen generation Plant is an intermediate type of operation in nature and objective are to
generate Hydrogen Gas, filling into the cylinders and stocks them. The main inputs to this plant
are DM Water, Nitrogen Gas and KHO (Potassium Hydroxide). Whole process takes place with
following systems
1. Lye preparation system
2. Purification system
3. Filling system

02 Nos. of skids are provided for the plant, usually one in running & one in standby. Plant check
points, Start-up, Shut Down, and Emergencies are covered up in this SOP.

(NOTE: Hydrogen gas is highly flammable and will burn in air at a very wide range of
concentrations)

Important points before starting the plant –

1. Power ON of PLC panel by its MCB.

2. ON PC.
3. Go to work bench → Screen → Main menu.
4. SCADA will be available on PC.
5. Start chiller.

Plant check points –

1. Oil level compressor should not reach to minimum level.

2. Open 30% water cooling valve of skid which is coming from main service water line.
3. Lye level 450 to 550 mmWC from field transmitter or PLC.
4. Check all vent valve.
5. Check all service air & Instrument airline.
6. Check service water line (Availability of Service water)
7. DM water tank (A+B) level.
8. In Separator skid DM service water valve must open.

Important points to be remember –

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 1. All electrical feeders must in ON condition.
2. Separator skid temperature should not increase more than 75°C.
3. Separator skid pressure should not increase more than 18 kg.
4. ON chiller before transferring gas to purification chamber.

In case of Emergency –

1. Press emergency button on rectifier panel.

2. Depressurising system by venting gas for H2-O2 vent.
3. Off H2 or O2 lye circulating pump. (It will also stop rectifier)

Plant Operation (PUMP, RRECTIFIER, DM PUMP) –

1. Open H2 & O2 vent valve from SCADA by clicking particular valve, Indicator will turn from
red to green.
2. Convert Auto mode from manual mode of H2 & O2 control valve.
3. Submit average value of both level separators in dialog box provided in H2 & O2 mimic.
4. Power ON the feeder of H2 & O2 lye pump from MCC panel.
5. Give start command to both H2 and O2 Lye pump from H2 & O2 separator mimic.
6. After checking all interlocks of rectifier at electrolyser mimic, start rectifier from SCADA.
7. Follow the following parameters at electrolyser screen and H2 & O2 separator screen.
O2 Pressure Rectifier Current

1 50

1 100

2 150

2 200

- -

- -

15 500

16 600
(Set value 19 ˂ Trip) (Set value 800 ˂ Trip)

Purification (CATALYST COLOUM, DRYER, CHILLER) Start-up –

1. Before starting any procedure open chiller water valve.

2. Put all valves of purification system in to auto mode from SCADA & Operate as per
purification cycle.

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 3. Close H2 vent valve of separator section and send it (H2 Gas) to purification system by
opening H2 Purification valve
4. Open H2 separator vent valve to maintain pressure & level of H2 & O2 level in separator.
5. Wait to achieve at least 10 kg pressure in purification system & Temp. at least 65°C in H2
separator only.
6. After achieving purity (i.e Trace O2: 30 ppm & Dew point: -63°C to -65°C) start filling
buffer tank upto 16 kg pressure (25 to 30 Min. required for filling of buffer tank).

Compressor Start-up –

1. Open cooling water valve.

2. Power ON compressor from SCADA.
3. Check buffer tank pressure in SCADA (between 16 to 17 kg/cm2).
4. Open compressor suction valve up to 50% for cylinder filling.
5. Once Pressure of the cylinder reached 150 kg (within 15 to 20 min.) then close
compressor suction valve.

Shut down procedure –

1. Turn OFF compressor from SCADA.

2. Closed H2 buffer tank storage valve & open H2 purification vent valve.
3. Let Temp. of the dryer decrease at least to 40 °C then Power OFF heater feeder.
4. Close H2 purification vent valve & open H2 vent valve & close H2 purification inlet valve of
separator.
5. Open 100% of cooling water control valve from SCADA by changing it from Auto to
manual mode to decrease temp. at least 35°C of H2 separator.
6. Start decreasing Pressure of separator & rectifier current as follows
O2 Pressure Rectifier Current

16 600

15 500

14 450

- -

- -

0 0
(Stop rectifier unit)

7. Maintain the level (Trip at mini. 150 & max. 900 mmWC) of H2 - O2 separator by placing
avg. value in the dialogue box.
8. Open H2 - O2 gas control valve to 100% by changing it from Auto to manual from SCADA.
9. Let the plant come to gravity (i.e H2 - O2 Level should be approx. same.)

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 10. Power off H2 - O2 lye circulating pump.
11. Again let the plant to achieve gravity level.
12. Close all vent valves.
13. Turn of PC.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

NAME
DESIGNATION ENGG OPERATION HEAD HEAD– O & M PRESIDENT
SIGNATURE

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