HySTAT Basic principles of operation

Revision: 09

Revision date: 09/05/2011

WARNING AND DISCLAIMER
This manual is designed to provide tutorial information about the HySTAT electrolyzer. It should be made
clear that this manual only provides the strictly necessary information to enable an operator to (re)start the
HyStat installation once the power is turned on and the microprocessor is activated.

Hydrogenics Europe NV emphasizes that each operator should be adequately trained prior to operate the
installation and have a good understanding that proper maintenance is essential for a safe and reliable
operation. It's also important to note that the person who is responsible for the HySTAT installation should
have a more comprehensive knowledge. Hydrogenics Europe NV recommends at least a thorough knowl-
edge of the HySTAT Manual.

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 cop-
ied 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.
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Table of Contents Page 1
HySTAT Basic principles of operation

TABLE OF CONTENTS

Section 1: Safety ..............................................................................................................6

1.1. Conventions used in this publication ............................................................. 6
1.2. Registered trademarks .................................................................................. 6
1.3. The Hydrogenics Safety Philosophy .............................................................. 7
1.4. Hydrogenics general safety guidelines .......................................................... 8
1.5. First aid equipment ........................................................................................ 9
1.5.1. First aid kit ............................................................................................... 9
1.5.2. Eye wash station ..................................................................................... 9
1.5.3. Emergency shower.................................................................................. 9
1.6. Hydrogen properties .................................................................................... 10
1.7. Oxygen properties ....................................................................................... 11
1.8. Explosion hazard ......................................................................................... 12
1.8.1. Hydrogen risks ...................................................................................... 12
1.8.2. HySTAT hazardous area classification ................................................. 12
1.8.3. Safety guidelines ................................................................................... 12
1.9. Fire hazard .................................................................................................. 14
1.9.1. Hydrogen risks ...................................................................................... 14
1.9.2. Oxygen risks.......................................................................................... 14
1.9.3. Safety guidelines – prevention .............................................................. 14
1.9.4. Safety guidelines – effect mitigation...................................................... 15
1.10. Chemical corrosion hazard ........................................................................ 16
1.10.1. KOH risks ............................................................................................ 16
1.10.2. Safety guidelines – prevention ............................................................ 16
1.10.3. Safety guidelines – effect mitigation.................................................... 17
1.11. Asphyxia hazard ........................................................................................ 18
1.11.1. Inert gases risks .................................................................................. 18
1.11.2. Oxygen risks........................................................................................ 18
1.11.3. Safety guidelines ................................................................................. 18
1.12. Skin burn hazard ....................................................................................... 19
1.12.1. Hot surfaces risks................................................................................ 19
1.12.2. Safety guidelines ................................................................................. 19
1.13. Electrocution hazard.................................................................................. 19
1.13.1. General................................................................................................ 19
1.13.2. Residual voltage risk ........................................................................... 19
1.13.3. Safety guidelines ................................................................................. 20
1.14. Power outage ............................................................................................ 21

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HySTAT Basic principles of operation

Section 2: Operation ......................................................................................................24

2.1. Operating the unit ........................................................................................ 24
2.2. Operating the HySTAT ................................................................................ 26
2.2.1. Introduction ........................................................................................... 26
2.2.2. Operational phases............................................................................... 26
2.2.3. Checking the status of the HySTAT...................................................... 28
2.2.4. Checking the Water Locks .................................................................... 29
2.2.5. Nitrogen purge of the HySTAT.............................................................. 30
2.2.6. Hydrogen purge of the HySTAT............................................................ 32
2.2.7. Hydrogen production of the HySTAT .................................................... 35
2.2.8. Stopping the HySTAT ........................................................................... 37
2.2.9. Depressurization of the HySTAT .......................................................... 38
2.3. Operating the deoxo dryer .......................................................................... 39
2.3.1. Introduction ........................................................................................... 39
2.3.2. Operational phases............................................................................... 39
2.3.3. Checking the status of the deoxo dryer ................................................ 40
2.3.4. Nitrogen purge of the deoxo dryer ........................................................ 42
2.3.5. Depressurization of the deoxo dryer ..................................................... 45
2.4. Explanation of the utilities ........................................................................... 46
2.4.1. Introduction ........................................................................................... 46
2.4.2. Dehydro dryer ....................................................................................... 46
2.4.3. Frit sparger............................................................................................ 46
2.4.4. Reverse osmosis system ...................................................................... 46
2.4.5. Closed loop cooling............................................................................... 47
2.4.6. Chiller.................................................................................................... 48
2.4.7. Ventilation and Heating (Containerized) ............................................... 49
2.4.8. Coalescing filters................................................................................... 50
2.4.9. Mass flow meter.................................................................................... 50
2.4.10. Remote access viewer and data collector Software ........................... 50

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HYSTAT BASIC PRINCIPLES OF OPERATION

SECTION 1: SAFETY
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Section 1: SAFETY

1.1 Conventions used in this publication

For simplicity and consistency, this manual uses the following conventions.

Note sign. Notes call attention to information that is especially significant to

understanding and operating the equipment.

Caution sign. Caution notices are used where equipment might be damaged if
care is not taken.

Warning sign. Warning notices are used to emphasize hazardous conditions that
may cause serious personal injury if care is not taken.

1.2 Registered trademarks

A IMET® www.hydrogenics.com (Inorganic Membrane Electrolysis Technology)

A HySTAT® www.hydrogenics.com (Hydrogen Station)

A Swagelok® www.swagelok.com

A Snoop® www.swagelok.com

A Ham-let® www.ham-let.com

A Siemens® www.siemens.com

A Simatic NET® www.siemens.com

A Microsoft® www.microsoft.com

A Windows® www.microsoft.com

A Exter® www.beijerelectronics.com
A Exter T70® www.beijerelectronics.com

A Exter T100® www.beijerelectronics.com

A Exter T150® www.beijerelectronics.com

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SAFETY HySTAT Basic principles of operation

1.3 The Hydrogenics Safety Philosophy

The standard “ISO 22734-1 – Hydrogen generators using water electrolysis process” is used as a
starting-point for the HySTAT systems. This International Standard defines the construction, safety and
performance requirements of packaged or factory matched hydrogen gas generation appliances.

Every HySTAT is designed from an “integrated safety” perspective:

1st priority: elimination of actions likely to create a hazardous situation;

2nd priority: prevention of hazardous situations by integrated safety features;
3rd priority: mitigation of the effects of an occurring incident.

Hydrogenics Europe NV has performed a risk assessment for all standard equipment, taking into
account the following standards:

A EN ISO 12100:2010 Safety of machinery. General principles for design. Risk assessment and
risk reduction.

A IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related

systems
A IEC 62061: Safety of Machinery - Functional safety of safety-related electrical, electronic and
programmable electronic control systems

A IEC 61511: Function safety: safety instrumented systems for the process industry sector

Alltough Hydrogenics Europe NV has chosen widely accepted design criteria,

it’s important to note that the customer should review wether the tolerable risk
that Hydrogenics Europe NV has used in the design of the generators is also
acceptable for this application. In case of doubt, please contact Hydrogenics
Europe NV.

A complete overview of all HySTAT hazards and safety guidelines can be found in the following
chapters. Read them carefully prior to operating the HySTAT installation.

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1.4 Hydrogenics general safety guidelines

Keep a copy of this manual, a set of electrical drawings, and a set of P&ID’s in a
designated place inside or near the HySTAT, so that this valuable information is
accessible to operators and engineers at all times.

Make sure that all personnel involved in the installation, operation, or maintenance of
the HySTAT is trained accordingly.
Do not allow unsupervised work on or around the HySTAT installation.

Always wear personal protective equipment: minimum recommendations are safety

shoes and safety goggles. When handling electrolyte or other chemicals, wear face
protection, suitable gloves, and protective clothing.

Make sure the area where the HySTAT is installed, all entrances to it, and all escape
routes from it, are properly labeled and kept free at all times.

Do not make any constructional changes to the unit without contacting Hydrogenics
Europe NV first.

Do not allow any spark generating equipment around the HySTAT during operation.
Prohibit smoking in and around the HySTAT.

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SAFETY HySTAT Basic principles of operation

1.5 First aid equipment

1.5.1 First aid kit

Make sure that a first aid kit is available and easily accessible in or near the HySTAT
unit. Check its contents on a regular basis.

Hydrogenics Europe NV recommends the following items to be present inside the kit:

A cambric bandage (5 cm x 5 m and 7 cm x 5 m)

A triangulated bandage (96 x 96 x 36 cm)

A wound plaster (6 cm x 1 m)

A adhesive plaster (1,25 cm x 5 m)

A adhesive plaster (2,50 cm x 5 m)

A easy-application bandage (8 x 10 cm and 12 x 12 cm)

A hybin, hygienic solution (30 ml)

A stainless safety pins - 10 pc

A medicated cotton-wool (25 gr)

A waterproof woundbandage (7 x 2 cm) - 12 pc

A compress (1/16)

A isothermal blanket (1,6 x 2,2 m)

A packet of latex gloves (powder free) - 4 pc

A elastic squeezing bandage

A pair of scissors

A Diphoterine® aerosol can (www.prevor.com)

1.5.2 Eye wash station

Install an eye wash station in or near the HySTAT unit, at a clearly marked and easily
accessible location.

Hydrogenics Europe NV recommends an eye wash station containing Diphoterine® as active

component. Refer to the customer checklist or contact Hydrogenics Europe NV for more information.

1.5.3 Emergency shower

Hydrogenics Europe NV recommends to install an emergency shower station if possible. This is a device
specifically designed and intended to deliver flushing fluid in sufficient volume to cause that fluid to
cascade over the entire body, to prevent or mitigate injuries caused by fire, abrasive substances, etc.
The shower needs to be easy to handle, view and access. The water should be of adequate quality and
temperature so that any danger for the health of the employees is avoided.

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1.6 Hydrogen properties

At standard temperature and pressure, hydrogen is a colorless, odorless, nonmetallic, tasteless, highly
flammable diatomic gas (H2). With an atomic mass of 1.00794 g/mol, hydrogen is the lightest element.

Hydrogen is non toxic, but does not support life.

Hydrogen gas is highly flammable and will burn violently at concentrations as low as
4% H2 in air. Its auto-ignition temperature is 844,3K (571,2°C).

Pure hydrogen-oxygen flames are invisible to the naked eye, thus it is difficult to detect if a hydrogen
leak is burning.

Hydrogen flames tend to ascend rapidly with the gas in air.

When mixed with oxygen across a wide range of concentrations, hydrogen explodes upon ignition.

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SAFETY HySTAT Basic principles of operation

1.7 Oxygen properties

At standard temperature and pressure, oxygen is a colorless, odorless, nonmetallic, tasteless diatomic
gas (O2). The atomic mass of oxygen is 15.9994 g/mol.

Concentrated sources of oxygen promote rapid combustion and therefore are fire and
explosion hazards in the presence of fuels.

Oxygen is no actual fuel, but as a reactant, concentrated oxygen allows combustion to proceed rapidly.
Some materials may auto-combust in a concentrated oxygen environment.

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1.8 Explosion hazard

1.8.1 Hydrogen risks

When mixed with oxygen, hydrogen combusts or explodes when ignited.

The concentration limits between which a hydrogen-air mixture combustion (or explosion) is supported
are defined in ISO 22734-1 as follows:

LFL*: 4.0% *Lower Flammability Limit, considered as LEL

UFL*: 75.0% *Upper Flammability Limit, considered as UEL

Upon ignition, a hydrogen-air mixture concentrated within these limits combusts or explodes. The
minimum ignition energy is 0.02mJ.

The range of volume for a ratio of hydrogen in air that will form a flammable atmosphere is more
extensive than the range that will form an explosive atmosphere. The LFL and UFL are used to
provide the maximum protective measures.

1.8.2 HySTAT hazardous area classification

EU US/CA
ATEX Zone 2 Class I Div II
Gas Group IIC Gas Group B
Temperature class T1 Temperature class T1

Information related to the Ex-zone boundaries can be found in the HySTAT Explosion Protection
Document.

Each HySTAT complies with the applicable codes & standards for the region in which it is installed. In
principle, the differences these may imply (i.e. CE vs. NRTL), affect nor the safety nor the reliability of the
installation.

It is of utmost importance that a full risk assessment is carried out for the
HySTAT and its surroundings. Please review project documentation (P&ID’s,
electrical drawings, zoning drawings, etc.). If something is not clear, please
contact Hydrogenics Europe NV.

1.8.3 Safety guidelines

A Provide clear identification of all hazards and hazardous areas

Keep activities not related to the HySTAT remote from it. Refer to the explosion
protection document. No exceptions can be allowed within the Ex-zone.

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SAFETY HySTAT Basic principles of operation

Ventilate hazardous areas sufficiently, so that, in case of a gas leak, the escaped gas is
vented to the outside of the building immediately.

Install continuous atmosphere monitoring equipment so that hydrogen and if

applicable oxygen leaks can be detected.

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1.9 Fire hazard

1.9.1 Hydrogen risks
Hydrogen burns violently in air. Pure hydrogen-oxygen flames are invisible to the naked eye, thus it is
difficult to visually detect a burning hydrogen leak. A cloth on a rod can be used to detect a hydrogen
flame boundary.

Extinguishing a hydrogen fire while the leak is not stopped may cause an explosion
worse than the fire itself.

1.9.2 Oxygen risks

Oxygen vigorously accelerates combustion. Some materials that will not burn in air will
burn in an oxygen rich atmosphere (>23 %). Fire resistant clothing may burn and offer
no protection.

Oxygen may also form explosive mixtures when exposed to combustible materials such as oil, grease
and other hydrocarbons.

During maintenance, no grease or oil can be applied to parts that are in contact with
oxygen during normal operation.

A standard HySTAT does not include a transmitter to detect an in- or decreased

concentration of oxygen in the atmosphere. Depending on site conditions, it may be
recommended to include one. Another approach is for operators to verify the oxygen
concentration with a portable oxygen analyzer before entering the process part.

1.9.3 Safety guidelines – prevention

A Minimize potential leaks of hydrogen and oxygen

A Eliminate ignition sources

A Prohibit smoking and open flames near the HySTAT

A Keep the HySTAT area free of dry vegetation and combustible matter

A Provide hydrogen and oxygen isolation procedures

A Provide a fire detection- and alarm installation

A Provide warning signs and escape routes

A Consult local fire authorities for appropriate fire-fighting equipment

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SAFETY HySTAT Basic principles of operation

1.9.4 Safety guidelines – effect mitigation

Always consult local authorities for correct fire fighting instructions.

If you hear a hissing sound from a pressurized vessel at or about the HySTAT, assume the possibility of
a hydrogen fire.

Never attempt to put out a hydrogen fire.

What you should do:

A Press an emergency shutdown button unless it appears unsafe to approach one

A Evacuate the area and raise the alarm if possible

A Summon help and call the fire fighting services

A Attempt to cut off the flow of hydrogen and/or oxygen

1.9.5 Non-hydrogen fires

Standard, non-hydrogen fires have visible flames and will not be preceded by alarms from a hydrogen
leak detection. Note that a hydrogen fire may also produce a visible flame and/or smoke if there is a
combustible material near.

It is a mistake to assume that a fire in or around the HySTAT is not hydrogen-fed

based on the presence of a visible flame.

What you should do:

A Press an emergency shutdown button unless it appears unsafe to approach one

A Evacuate the area and raise the alarm if possible

A Summon help and call the fire fighting services

A Use a fire extinguisher to fight small fires only, and only after notifying the fire fighting services

A standard HySTAT does not include a fire alarm to detect a standard fire.

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1.10 Chemical corrosion hazard

1.10.1 KOH risks
The HySTAT uses a 30% w/v solution of KOH (Potassium Hydroxide) in water.

KOH is highly corrosive and causes severe burns. The risk is enlarged by the nominal
working temperatures of 70°C – 75°C and elevated pressure.

Hydrogenics Europe NV service engineers are not allowed to, and therefore will not,
prepare KOH solutions on site.

When an aqueous solution is being prepared, an exothermic reaction takes place.

KOH solution skin contact may go unnoticed at first, but will cause severe skin burns within 48 hours.

Even under normal operating conditions, due to KOH presence, the pH values of the gases and liquids
inside the user lines, water locks and drains can rise to pH14.

1.10.2 Safety guidelines – prevention

For additional information, refer to the KOH MSDS sheet.

A Provide a KOH handling kit that consists of safety shoes, fase protection, protective gloves and
a chemical overall

A Install an emergency shower and eye wash station, and provide Diphoterine® rinsing systems
(refer to chapter 1.5: ‘First aid equipment’ for more information)

A Label all containers containing KOH solution

NEVER perform work involving electrolyte without the presence of someone else.

Avoid skin contact or swallowing.

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SAFETY HySTAT Basic principles of operation

Avoid vapor inhaling.

Wash hands and face thoroughly after handling a KOH solution.

A Use a suitable container and well-ventilated room for mixture preparation

1.10.3 Safety guidelines – effect mitigation

In case of eye- or skin contact:

A Always summon for medical assistance.

A Apply Diphoterine® immediately, or rinse with plenty of water.

A Use the eye wash station in case of eye contact.

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1.11 Asphyxia hazard

1.11.1 Inert gases risks
Inert gases are non-toxic, but may act as an asphyxiate by replacing the oxygen content in a confined
space.

1.11.2 Oxygen risks

If the concentration of oxygen in air drops below 19.5% or rises above 23.5%, respectively there is a risk
of asphyxia or hypoxia.

A standard HySTAT does not include a transmitter to detect an in- or decreased

concentration of oxygen in the atmosphere. Depending on site conditions, it may be
recommended to include one. Another approach is for operators to verify the oxygen
concentration with a portable oxygen concentration analyzer before entering the process
part.

1.11.3 Safety guidelines

A Provide adequate ventilation

A Install continuous atmosphere monitoring equipment

A Provide observers outside the hazardous area during work

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SAFETY HySTAT Basic principles of operation

1.12 Skin burn hazard

1.12.1 Hot surfaces risks
The nominal operating temperature of the HySTAT is 70°C.

During operation, some of the process equipment reaches temperatures high enough
to cause skin burns if touched.

The dryer vessels' internal temperature can rise up to 250°C during their regeneration phase. Connected
piping and tubing may reach temperatures far over 100°C.

1.12.2 Safety guidelines

Wear protective equipment entering the process part during operation.

Always allow the unit to cool down sufficiently before servicing.

1.13 Electrocution hazard

1.13.1 General
In general, the nominal three-phase AC voltage that is applied to the HySTAT is 400Vac, 50Hz for
European installations, and 480Vac, 60Hz for North American installations.

The AC voltage is converted to a DC voltage of around 170Vdc to power the cell stack.

Both the AC and DC voltages are life-threatening if touched directly.

1.13.2 Residual voltage risk

The cell stack holds a considerable residual voltage after shutdown.

Great care must be taken approaching the cell stack for over one hour after shutdown
to avoid the risk of electric shock. ALWAYS check for residual voltage using a voltage
tester.

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HySTAT Basic principles of operation SAFETY

1.13.3 Safety guidelines

an

A All electrical equipment used must comply with local codes & standards

Isolate the power supply before servicing electrical parts of the unit. ALWAYS check
for voltage using a voltage tester before servicing any electrical part.

A Mind the residual cell stack voltage

A Provide earthing according local codes & regulations

A Organize periodical detailed inspections and keep their recordings

A Perform maintenance

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SAFETY HySTAT Basic principles of operation

1.14 Power outage

While the loss of utilities, especially electricity, may pose an inconvenience, it will not cause a safety
problem. If electricity service fails, the HySTAT will stop and depressurize in a safe way. The backup
battery makes sure the PLC is powered long enough to be able to control this process.

Although power outage does not cause an immediate safety problem, in case
environmental temperatures drop below 0°C, irrepairable damage may be
caused to the HySTAT if the unit is not powered within a certain time. If sub-zero
temperatures are likely to occur and if the power supply is not supervised locally
(on site), it is advised to install one or more separate heaters, connected to an
emergency power supply, inside the HySTAT. Contact Hydrogenics Europe NV
for more information.

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HYSTAT BASIC PRINCIPLES OF OPERATION

SECTION 2: OPERATION
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HySTAT Basic principles of operation OPERATION

Section 2: OPERATION

2.1 Operating the unit

The HySTAT works fully automatically and is controlled by the PLC. All that is required is user input to
start, stop, depressurize or emergency-stop the unit. The controlling equipment consists off the following:

2
4

Figure 1 – Controlling equipment

1 HMI 4 Alarm buzzer

2 Key switch 5 Reset button
3 Emergency pushbutton

A the HMI: The display terminal is a touch screen and as such the buttons change depending on
the screen.

A the key switch: The key switch has two possible positions: 0 and I. The switch is used to acti-
vate a phase by turning the key from position 0 (STOP) to position I (START). Turning the key
in the opposite direction (from I to 0) will interrupt the phase.

A the emergency pushbutton(s): This button offers the operator the possibility to shut down the
process part of the installation immediately in case of emergency. However the emergency stop
needs to be reset manually on the door of the EPS (see ‘the reset button’ below). The system
will return to standby and can then be restarted.

A the reset button: In the case of a failure of a major fault the safey system will need to be reset.
The reset button will be lit blue.

A the alarm buzzer: The buzzer calls the attention of the operator in case of alarm or a stop of the
system. The buzzer can be cancelled by pressing the 'Buzzer' button on the HMI (it will be
coloured green).

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OPERATION HySTAT Basic principles of operation

The display terminal enables the user to consult process parameters, and can be used to change
setpoints, and read events and alarms. Once the HySTAT is powered on, the Main screen pops up:

Figure 2 – Main screen

Pressing the ‘Go to Process’ key will open the Electrolyzer screen.

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HySTAT Basic principles of operation OPERATION

2.2 Operating the HySTAT

2.2.1 Introduction

Figure 3 – Process part of a HySTAT-Q (Backside View)

The hydrogen and oxygen bubbles formed inside the cell stack’s individual cells, are carried along with
the electrolyte to the tops of the cells, and collected in two separate channels in the cell stack. The gases
flow through the cell stack outlets into the gas-liquid separators, where the gas is separated from the
liquid electrolyte.

From the gas-liquid separator, the hydrogen passes the rinser in which the gas is rinsed with clean
incoming demineralized water, to reduce the amount of residual electrolyte in the gas stream.

Next the hydrogen flows through the coalescent filter, where it is cooled and the present water droplets
are removed. From this filter the gas flows either to atmosphere, to the deoxo dryer system or to the user
line.

The entire system is regulated by means of actuated valves. Closing of certain valves in the H2 or the O2
lines allows the system to build up pressure. The nominal pressure at which the hydrogen is produced is
between 4 and 10 barg. The final pressure in the user line depends on the configuration of the HySTAT.

2.2.2 Operational phases

The HySTAT system progresses through a series of phases. The three HySTAT operational phases are
nitrogen purge, hydrogen purge and hydrogen production. Both the nitrogen and hydrogen purge phases
are preparation phases, hydrogen production is the HySTAT standard production mode. Nitrogen and

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OPERATION HySTAT Basic principles of operation

hydrogen purge are necessary to be able to start hydrogen production in a safe way, and with the right
quality of gas to the user line.

The flow diagram below is a graphical representation of the HySTAT operational phases, and the
sequence in which they can occur. Each of the phases can be activated only when its start conditions
(see further) are fulfilled. After a production session, the HySTAT enters the 'standby'-position, from
which either a production session can be started via a start signal, or the depressurization phase can be
initiated.

A production session is ended by a stop signal, which comes either from the user, local or remote, or
automatically: pressure in the user line, a fault or failing start conditions.

Figure 4 – HySTAT operational phases flow diagram

A production session is ended by a stop signal, which comes either from the user, local or remote, or
automatically: pressure in the user line, a fault or failing start condition.

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HySTAT Basic principles of operation OPERATION

2.2.3 Checking the status of the HySTAT

Figure 5 – GGS1 screen

The header is visible at the top. Next to a number of command buttons, it contains the following informa-
tion labels:

A day, date and time

A HySTAT status (N2 purge, H2 production, etc.)

A actual password level (PW 0 to PW 7)

A keyswitch position (green/red, i.e. on/off)

A additional status information (during production: actual production rate

and produced volume of hydrogen; during purge phases: time left in sec-
onds; etc.)

A buzzer status (green/red, i.e. off/on)

This screen displays the access to the various parts of the electrolyser system. It is possible to access
the different subsystems using the function keys. An entire overview of the menu can be found in the
HMI appendix of the HySTAT Manual.

Listed below are the various messages that can be displayed in the Electrolyser screen with a short
explanation.

Phase Explanation
Standby for N2 Purge Ready for Nitrogen Purge
N2-Purge Depressurisation Depressurisation during Nitrogen purge
N2-Purge failed @ depressurisation Failed to depressurize before purge
N2-Purge Active Nitrogen purge active

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OPERATION HySTAT Basic principles of operation

Phase Explanation
N2-Purge Failed @ Pressurisation Failed to reach purging pressure
N2-Purge Interrupted by Operator Nitrogen purge interrupted by operator
Standby for H2 purge Ready for Hydrogen purge
H2-Purge Active Hyrogen purge active
H2 Production to Atmosph. Hydrogen production to atmosphere
H2 Production Active Hydrogen production active
Standby for H2 production Ready for Hydrogen production

For example: ‘Standby for N2-Purge’. This means the system is ready for the next phase (Nitrogen
Purge) to be activated by turning the key switch from position 0 (STOP) to position I (START). Note that
turning this key to position I will activate the next phase of the active unit in standby.

2.2.4 Checking the Water Locks

Before the operator can start the different purge processes, he or she has first to check the status of the
Water Locks at the end of both vent lines. The dead ends have to be filled with water up to half the height
of the pipe. If necessary, the operator can add some tap water. We recommend that this check be
performed on a regular basis.

5
1

4
3

Figure 6 – Water lock

1 Incoming connection from vent line 4 Connection to drain

2 U-curve (actual water lock) 5 Free opening
3 Plug (optional level switch)

The condensate that collects in the vent lines, flows into the water locks (1) by gravity. Once the water
lock is full, the collected condensate flows out through the drain connection (4). This way condensate
can be drained to the sewer, while the gas flowing through the vent line is prevented from passing the
water lock and entering the process part or the drain system. In standard units, no automatic refill instal-
lation is present. Hence instead of a level switch, a plug is fitted on the middle connection of the water
lock (3). Always make sure the plug is fitted and tightened, otherwise the condensate will flow out the
opening instead of to the drain.

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2.2.5 Nitrogen purge of the HySTAT

The first phase in the start of the HySTAT is the ‘Nitrogen Purge’.

Figure 7 – Nitrogen panel: manual (left side) and automatic (right side)

1 PI N 5 MV N2 (Nitrogen to HySTAT)
2 HV N 6 MV N3 (Nitrogen to vent)
3 BV N1 (Nitrogen supply) 7 MV N1 (Nitrogen supply)
4 BV N3 (Nitrogen to vent)

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1. Make sure the HySTAT is in the ‘Standby for N2 purge’ status.

Figure 8 – HySTAT Standby for N2-Purge

2. Open the nitrogen supply. Check the nitrogen pressure on the nitrogen pressure gauge PI N
mounted on the nitrogen panel. This pressure has to be between 4 and 6 barg. If not, adjust the
nitrogen pressure until it reaches this value.

The nitrogen pressure should not be greater than the rating of the fitted safety
relief valves.

3. Close BV N3 and then open BV N1 - Unless automatic.

4. Open the hand valve HV N.

5. Turn the key switch from 0 to 1.

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6. The generator status changes to ‘N2 purging’; one counter indicates the remaining time for valve
MV H-A to be opened, and the other counter indicates the remaining time allowed. The counter
values are visualized on the HMI display terminal.

Figure 9 – HySTAT N2-Purge Active

7. When nitrogen purge is finished the generator status changes to ‘Standby for H2 purge’.

8. Close the hand valve HV N. Close BV N1 and then open BV N3 - Unless automatic.

9. Turn the key switch back to position 0. Nitrogen purge is completed.

If your HySTAT is equipped with ‘Automatic N2 purge’, N2 purge is started from the HMI
display terminal and no further operator action is required.

If your HySTAT is equipped with ‘Automatic N2 initialisation’, three phases are

completed: depressurisation, N2-Purge and again depressurisation. The HySTAT unit
will wait in this position.

2.2.6 Hydrogen purge of the HySTAT

The second phase in the start of the HySTAT is the ‘Hydrogen Purge’.

If your HySTAT is equipped with a ‘deoxo dryer’, the operator must first perform the
nitrogen purge of the hydrogen dryer before he or she can go on with the hydrogen
purge described in the next section.

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1. Make sure the HySTAT is in the ‘Standby for H2 purge’ status.

Figure 10 – HySTAT Standby for H2-Purge

2. The operator checks which of the cell stacks are enabled. Press the button ‘En/Dis CS’ at the
bottom of the electrolyzer screen to enter the screen for enabling the cell stacks for H2 Purge.

Figure 11 – Enable/disable cell stacks screen

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3. Enable two cell stacks for H2 Purge, for example cell stack 2 and 4. Change the buttons on cell
stack 2 and 4 from ‘Purge Disabled’ into ‘Purge Enabled’.

Figure 12 – Enable/disable cell stacks screen

4. Turn the key switch from 0 to 1.

5. The generator status changes to ‘H2 purging’; a counter indicates the remaining liters to be pro-
duced.

Figure 13 – HySTAT H2-Purge Active

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6. When hydrogen purge is finished the generator status changes to ‘Standby for H2 production’.

7. Turn the key switch back to position 0. Hydrogen purge is completed.

2.2.7 Hydrogen production of the HySTAT

The third phase in the start of the HySTAT is the ‘Hydrogen Production’.

1. Make sure the HySTAT is in the ‘Standby for H2 production’ status.

Figure 14 – HySTAT Standby for H2 production

2. Press the button ‘En/Dis CS’ at the bottom of the electrolyzer screen to enter the screen for
enabling the cell stacks.

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3. Enable one or more cell stacks (depending on the production required) on the HMI display termi-
nal.

Figure 15 – Enable/disable cell stacks screen for H2 production

In this screen the operator can enable or disable each cell stack. The button ‘Prod. Enabled’ for each cell
stack will enable and disable cell stacks 1, 2, 3 and 4. The buttons ‘En All’ and ‘Dis All’ will enable or
disable all cell stacks.

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4. Turn the key switch from 0 to 1. Hydrogen (and Oxygen) production starts.

Figure 16 – HySTAT H2 production Active

2.2.8 Stopping the HySTAT

Turn the key switch from 1 to 0. If in hydrogen production mode, the generator status changes back to
‘Standby for H2-production’.

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2.2.9 Depressurization of the HySTAT

Depressurization reduces the pressure inside the HySTAT (in the gas separator and the deoxo dryer) to
a safe level. This is done automatically.

There are two ways to depressurize the unit:

1. Standby depressurization: Pressure is decreased to approx. 0,15 barg. An inert gas purge is
required afterwards, before restarting the unit. This can be initiated:

1.1. by pressing the ‘Depress.’ button on the HMI display terminal (for the gas liquid sepera-
tor and for the deoxo drier). This screen can be reached by pushing on the ‘Actions’ but-
ton on the electrolyzer screen.

Figure 17 – Electrolyzer actions screen

1.2. when the 24V supply drops below a minimum level.

2. Emergency depressurization: Pressure is decreased to approx. 0,50 barg. This can be initiated by:

2.1. HTA: Hydrogen in Atmosphere detection

2.2. EMS: Emergency Stop Button pressed

2.3. LTH L, LTO L: Electrolyte level gas separator low

2.4. LS Drip Tray: Drip tray leak detection

2.5. UPS: UPS low voltage

After an emergency depressurization, the pressure inside the HySTAT is still

around 50kPa, and the HySTAT is in the ‘Standby for H2 production’ phase. If the
cause of the depressurization is found and solved, a manual reset is required.

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2.3 Operating the deoxo dryer

2.3.1 Introduction

Figure 18 – Deoxo dryer

The HySTAT deoxo dryer improves the standard H2 purity. The deoxo dryer is installed at the outlet of
the HySTAT installation, and will further remove impurities from the H2 gas stream. It is heat-activated,
and regenerated with H2.
The first stage removes the O2 from the H2 gas stream (deoxo stage); the second stage removes the
moisture from the H2 gas stream (dryer stage).

The first stage (deoxo) involves a chemical reaction in a catalytic conversion reactor column. In this
noble metal catalyst column, the O2 in the gas stream reacts with H2 to form H2O (+ heat). The H2O
formed in this reaction is added to the H2O that is already present in the gas stream.
The normal operating temperature of the catalyst column is 60 to 80°C; this prevents condensation in the
bed.

In the second stage of the deoxo dryer process, H2O is removed through molecular sieve adsorption.
The porous crystalline nature of the molecular sieves allows it to selectively adsorb H2O impurities.

2.3.2 Operational phases

The dryer stage of the deoxo dryer operates in different phases. An overview of these dryer phases is
shown below.

Dryer B Dryer A
Phase A HEAT DRY
Phase B COOL DRY
Phase C PRESSURIZE DRY
Phase D DRY HEAT
Phase E DRY COOL

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Dryer B Dryer A
Phase F DRY PRESSURIZE

While one dryer bed is in operation (drying stage), the other is regenerating. During regeneration, the
bed is first depressurized to around 50kPa. Then the bed is heated (heating phase), afterwards it is
allowed to cool down (cooling phase), and finally it is pressurized. During the heating and cooling
phases, a flow of regeneration gas, which is dry gas that comes from the active bed, flows through the
bed that is regenerating. The dry gas transports the moist that is freed from the molecular sieve during
the heating phase, to the vent line, thus ‘drying’ the bed. After pressurization, the bed is standby to take
over (standby).

Both the ‘heat’ and the ‘cool’ phases of the dryers are performed at atmospheric
pressure.

2.3.3 Checking the status of the deoxo dryer

By pushing the ‘HPS’ button in the header of the electrolyzer screen the following screen will appear:

Figure 19 – HPS screen

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The header is visible at the top. Next to a number of command buttons, it contains the following informa-
tion labels:

A day, date and time

A actual password level (PW 0 to PW 7)

A keyswitch position (green/red, i.e. on/off)

A additional status information about the HPS

A buzzer status (green/red, i.e. off/on)

A heating of the HPS enabled or disabled

The actual deoxo dryer screen contains the following information:

A Indication of actual HPS status

A Indication of remaining H2 production capacity until dryer bed swap

A Pressure transmitter values

A Temperature switch states (dryer Da, dryer Db, deoxo vessel Dxo)

A Flow switch status

A Analyzer panel transmitter values (if applicable)

A Booster pump (if applicable)

Listed below are the various messages that can be displayed in the HPS screen with a short explanation.

Phase Explanation
HPS Standby Deoxo dryer ready
HPS Phase A Deoxo dryer phase A
HPS Phase B Deoxo dryer phase B
HPS Phase C Deoxo dryer phase C
HPS Phase D Deoxo dryer phase D
HPS Phase E Deoxo dryer phase E
HPS Phase F Deoxo dryer phase F

For example: ‘HPS Standby’. This means the system is ready for Nitrogen Purge.

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2.3.4 Nitrogen purge of the deoxo dryer

Nitrogen purge of the deoxo dryer is required:

A before initial startup;

A before maintenance;
A after maintenance;
A whenever the system pressure has dropped below 0,20 barg.
The HMI does not inform the operator of the need for nitrogen purge. It is the
operator’s own responsibility to perform a nitrogen purge of the deoxo dryer
when needed, based on the indications on the dryer pressure gauges (PI_Deo;
PI_Da; PI_Db)

The first phase in the start of the HySTAT is the ‘Nitrogen Purge’.

2 4
3

Figure 20 – Nitrogen panel: manual (left side) and automatic (right side)

1 BV N_Deo-A 5 PCV N-Deo

2 HV N_Deo 6 MV N-D2
3 BV N_Deo 7 MV N-D3
4 MV N_D1

1. Make sure the nitrogen purge of the dryer is performed after the nitrogen purge of the electrolyzer.

2. Turn the key switch to position 0.

3. Isolate the deoxo dryer from the electrolyzer and the user line by closing valves BV H and BV H-U.

4. Open the nitrogen supply. Check the nitrogen pressure on the nitrogen pressure gauge PI N. The
pressure should be controlled between 1 barg and 2 barg.

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5. Close BV N_Deo-A and then open BV N_Deo - Unless automatic

6. Open the hand valve HV N_Deo fully - Unless automatic.

7. Open hand valve RHV RG_H on the regeneration flow meter of the dryer.

8. Open the hand valve HV H-D fully.

9. Start the nitrogen purge from the HMI display terminal.

The purge time counter will only count down if the flow switch on the regeneration flow
meter is activated (i.e. if the flow is equal to or greater than required).

Push the button ‘N2 Purge’ on the HPS screen. The following screen will appear:

Figure 21 – HPS N2 purge screen

Push the button ‘Yes’ to perform a nitrogen purge of the HPS. The HPS screen will open. In the upper
right corner of the header a ‘Purge timer’ will start counting down.

10. Regulate the nitrogen flow with the hand valve RHV RG-H to 100% of full scale of the regeneration
gas flow indicator.

11. Dryer beds A and B are purged in series.

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12. A counter on the HMI indicates the remaining purging time.

Figure 22 – HPS N2 purge active

13. When the ‘Purge Timer’ on the HMI display terminal dissappears, the dryer purge is finished.

14. Close the hand valve HV N_Deo - Unless automatic.

15. Close the hand valve RHV RG_H on the regeneration flow meter of the dryer, and then open one
turn (360°).

16. Close the hand valve HV H-D and then open it 3 to 4 full turns.

The regeneration flow and pressure will have to be re-adjusted using the valve RHV
RG_H once the dryer is in production (regeneration phase) again. The correct flow rate
should be indicated on the flow indicator during first startup of the unit.

17. Close BV N_Deo and then open BV N_Deo-A - Unless automatic.

18. Nitrogen purge of the deoxo dryer is finished. The HySTAT is ready for hydrogen production.

If your deoxo dryer is equiped with ‘Automatic N2 purge’, the following valves are
replaced:

A BV N_Deo is replaced by MV N_D1

A HV N_Deo is replaced by MV N_D2
A BV N_Deo-A is replaced by MV N_D3

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After nitrogen purge of the deoxo dryer, the system pressure is between 1 barg
and 2 barg. If the deoxo dryer is purged for maintenance reasons, it needs to be
depressurized afterwards. Follow the procedure ‘2.3.5 Depressurization of the
deoxo dryer’ below.

2.3.5 Depressurization of the deoxo dryer

1. Turn the key switch to position 0.

2. Isolate the deoxo dryer from the electrolyzer and the user line by closing valves BV H and BV H-U.

3. Ensure the nitrogen supply to the dryer is closed by closing BV N_Deo and HV N_Deo, and
opening BV N_Deo-A. (In case of automatic block & bleed, isolate the nitrogen supply from the
source).

4. Open hand valve RHV RG_H on the regeneration flow meter of the dryer.

5. Open hand valve HV H-D fully.

6. Start depressurization on the HMI display terminal by pushing the ‘Start Depres’ button.

Figure 23 – HPS N2 purge screen

7. Dryer beds A and B are depressurized in series.

8. If the pressure is not atmospheric at the end of this sequence, repeat it.

After a dryer purge cycle the regeneration flow and pressure will have to be reset
once the system is put back into normal operation.

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2.4 Explanation of the utilities

2.4.1 Introduction
All utilities - like chiller, reversed osmosis system, heating and ventilation, closed loop cooling, ... - are
controlled automaticly by the PLC. No input of the user is required.

The following components may or may not be included in your HySTAT system.

2.4.2 Dehydro dryer

The dehydro oxygen dryer is identical in operation to the deoxo hydrogen dryer; except that the main gas
is oxygen instead of hydrogen.

2.4.3 Frit sparger

The frit sparger reduces the nitrogen content in the hydrogen stream. This nitrogen mostly comes from
the feed water: the lower its temperature, the higher the nitrogen concentration.
The frit sparger is located inside the break tank, and purges the feed water with hydrogen from the
generator. The total flow through the frit sparger is less than 1% of the total capacity of the HySTAT.

2.4.4 Reverse osmosis system

Figure 24 – Reverse osmosis system

The reverse osmosis system purifies the incoming water supply if the specifications are not met.

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2.4.5 Closed loop cooling

Figure 25 – Closed loop cooling pump unit

The closed loop cooling system consists of a pump unit, the electrolyte heat exchangers and a water-to-
air heat exchanger (dry cooler). The pump unit circulates the coolant, a mixture of water and glycol,
through the system. The dry cooler transfers the cooling water heat to the environmental air.
The closed loop cooling is controlled by the PLC.

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2.4.6 Chiller

Figure 26 – Chiller

The chiller cools the coolant in the gas cooling circuit. The chiller itself is cooled with water from the
closed loop cooling system.

The first purpose of cooling the gas is to minimize the water content in the H2 stream after the deoxo
vessel. Thus the stay-on time of the dryer bed can be maximized, and the total H2 losses during
regeneration of the dryer vessels minimized. The second purpose is to minimize the KOH content in the
H2 stream. This increases the lifetime of valves and deoxo catalyst.

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2.4.7 Ventilation and Heating (Containerized)

1 2 3 4 5 6 7 8 9

8
10
11
1

Figure 27 – Ventilation and heating equipment

1 Air inlet grid 7 Ex heaters

2 Inlet filters (optional) 8 Ex Fan 1
3 Recuperation heater (optional) 9 Ex Fan 2
4 Heater 1 10 Power rack fans
5 Heater 2 11 Power rack inlet grids + optional inlet filters
6 Transfer grid

Electrical fan heaters (4 and 5) are installed in the general purpose room. For standard -20°C installa-
tions, these heaters also heat the process room via the ventilation system. For -40°C installations, extra
Ex-heaters (7) are installed in the process room to compensate the higher heat losses.

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Figure 28 – Ventilation flow overview

The flow is as indicated in the figure above.

The ventilation interlocks are:

A air flow switch that is located near the transfer grid (6)

A current switches to verify the status of Ex fan 1 and 2 (8 and 9)

The differential pressure switch that is located near inlet filters (2) is an indicator for replacing the Inlet fil-
ters.

The power rack and container ventilation are seperated systems.

Keep container doors and power rack doors closed under normal operation.

2.4.8 Coalescing filters

The additional coalescing filters further reduce the residual moisture and KOH in the gas stream, and
can be applied when no deoxo dryer is installed.

2.4.9 Mass flow meter

The mass flow meter measures the exact mass of hydrogen that flows into the user line, and can be
used for exact quantification of the hydrogen produced to the user line.

2.4.10 Remote access viewer and data collector Software

With the remote access viewer and data collector software, the unit can be supervised on a remote
Microsoft® Windows® pc. Basic remote control actions such as start, stop and depressurize can be
performed.

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