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HYDROGEN GENERATOR SYSTEM AND FUNCTIONS

Pressurized water Electrolysis Hydrogen Plant
Description of control and operation logic as per
P & I D- ANE/P&I/01
Sheet No - 1
1
Electric AC Power from the Power distribution panel is Sent to
MCC panel ( refer Electrical and Control circuit Drawing also )
2
From MCC panel the power is sent to the Transformer where the
transformer reduces the voltage and increase the current
3
From Transformer the power goes to rectifier for Changing it to DC
Power
4
Rectifier is provided with Temperature alarm and control
5
Supply to Electrolyser is given from + ve of rectifier & - ve of
transformer.
6
Suitable electrolyte is used to generate sufficient quantity of
hydrogen & oxygen through electrolysis.
7
Temperature of oxygen thus generated is controlled.
Sheet No - 2
1 Hydrogen with KOH is fed to R 101 hydrogen separator & where
hydrogen is cooled in cooler E 103.
2 This hydrogen is routed through Moisture Separator R 103 to water
gas separator, R105, where water is separated from Hydrogen. This
hydrogen is taken further for processing.
3 Similarly oxygen with KOH from electrolyzer is fed to R102 oxygen
separator. Again oxygen is cooled in cooler E104 & routed through

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Moisture Separator R104 to gas separator R106.

4 Pressure in oxygen separator R102 is controlled.
5 P101, Hydrogen lye pump is used to feed Electrolyte
to electrolyzer through filter F102 & lye cooler E102.
6 Also oxygen lye is pumped to electrolyzer by pump P102 & routed
through filter
F102 & then cooled in oxygen lye cooler E102.
Cooling water is used to cool the lye in both cases.
Sheet No - 3
1 Oxygen thus separated from water is vented through pressure control
valve PCV102 located in H2 Transmitter in O2 (HTO).
2 Hydrogen from separator R105 is taken to oxygen analyzer for
measuring oxygen content & further processing in catalyst column,
R301 on Sheet # 6. Impure hydrogen is vented through flame arrester
R601 through PV101.
Sheet No - 4
1 This is Electrolyte preparation system where lye is prepared & fed to
electrolyzer. And feed water pump system.
Sheet No - 5
1 This covers various utilities like cooling water (filtered water) supply
& return system. Filtered water is used for various equipments, like
H2 lye cooler (E101), H2 compressor (C101), chilling plant and water
seal (R501). A pressure switch (PIS 501) is considered to generate an
alarm on low pressure of filter water.
2

Nitrogen gas is used in R101 hydrogen separator, R102 oxygen

separator & R301 catalyst column. Battery of Nitrogen cylinders is
used for this purpose. A pressure regulating valve (PRV) is set at 5
barg to regulate nitrogen pressure.

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3 Air is used for various instrument, valve actuators and solenoid

valves. A pressure switch (PIS 801) is considered to generate an alarm
on low pressure and to trip the plant on low low pressure. An air
pressure between 3 to 8 kg/cm2 is required to operate the valves. Air
is also used in Hydrogen purifying system.
4 DM water at a pressure of is required for lye making. This is fed to lye
making tank R202. DM water is also fed to hydrogen separator R101
from DM water storage tank (R201).
5

Chilled water unit E401 is considered for hydrogen purifier. Filtered

water is used in chilling plant.

Sheet No - 6
1 This sheet covers hydrogen purification and drying system
2 Hydrogen is fed to R 301 palladium catalyst column for purification
under certain temperature conditions.
3 This deoxidized hydrogen but wet is now fed to gas condenser E301
& cooled using cooling water is condenser.
4 Water content is separated from hydrogen in R303, water-gas
separator. After removal of water, hydrogen is fed to gas cooler &
dryer system R302 A / B.
5 There are 2 no. of dryers & gas coolers. This is a typical dryer plant
having 2 drying beds with change over valves. One set of dryer is
regenerated & kept ready for next switch over cycle while the other
one is in use. Waste water collected from gas separator is fed to water

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Seal R 501.Gases if any are vented through fire arrester R 601.Surface

heaters are used on catalyst column & dryer towers for adsorption &
regeneration.
Sheet No - 7
1 Dried hydrogen is analyzed for moisture and for traces of oxygen in
different analyzers.
Sheet No 8
1
Pure hydrogen is now collected in hydrogen buffer tank R401.
2
Pressure is monitored locally & also remotely by using PT403
transmitter.
3
Over pressure in tank is vented through safety valve PZV 401 &
fire arrester R602.
4
Hydrogen from buffer tank is taken to hydrogen compressor.
Compressed hydrogen is sent to hydrogen filling equipment
GF101. 8 high pressure cylinders are considered for simultaneous
filling of hydrogen per stream that means there will be 16 cylinders
for both the streams together.
5
A common vacuum pump has been considered to evacuate the
system before filling.

Note- Please refer P&ID (ANE/P&I/01, sheet 1 to 8)