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KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 11

STANDARD OPERATING PROCEDURE

FOR

HYDROGEN GENERATION
SYSTEM

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 11

STANDARD OPERATING PROCEDURE FOR HYDROGEN GENERATION

STATION
OBJECTIVE : For Smooth and safe Operation of Hydrogen generation System.
SCOPE : This SOP is applicable for 2 nos. of Hydrogen generation station

WORKING PRINCIPAL :

The basic working principle of water electrolysis hydrogen generation unit is to use
electricity to decompose the particular electrolyte solution to get the hydrogen.
Specifically speaking, it immerses into the electrolyte with a pair of electrodes which
are spaced out to prevent the membrane permeated by the gas constituting the water
electrolysis pool, and when the direct current with a certain voltage passes through
the electrode, the water starts to decompose, namely, precipitation of hydrogen in the
cathode and oxygen in the anode. The reaction is shown as follows:
Cathode : 2H2O +2 e → H2 ↑ +2 OH-
Anode : 2OH-－2e → H2O +1 / 2O2 ↑
The overall reaction : 2H2O → 2H2 ↑ + O2 ↑
The electrolyte used in the water electrolysis Hydrogen generation device is the KOH
(or NaOH) solution. The KOH (or NaOH) serves as the catalyst in the solution instead
of involving in the electrolysis reaction,

GENERATOR DATA:-
Make : M/S DONGFANG ELECTRICAL MACHINERY CO. LTD , CHINA
Model : QFSN 600 Z – 22F
Cooling : Water – Hydrogen – Hydrogen
Out Put : 600 MW
Generator Quantity : 6 Sets
Generator hydrogen charging volume : 86 m3/set;

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 11

Rated operating hydrogen pressure of generator : 0.45MPa (g);

Maximum operating hydrogen pressure : 0.5MPa (g);
Guaranteed hydrogen leakage at day and night : ≤10 Nm3/day and night;
Hydrogen use level for one unit start-up : 725 Nm3;
Hydrogen purity (volume ratio %) in normal operation : 99.9%;
Hydrogen humidity : dew point-500C;

HYROGEN GENERTION TECHNICAL DATA :

 Hydrogen generation capacity : 10Nm3/h ( each )

 Hydrogen generation sets : 02
 Pressure : 1.5 ~ 3.2MPa
 Quality indexes
Hydrogen purity : 99.9% (with maximum, standard and 25% load respectively)
Temperature : 40℃
Dew point : -50℃
Oxygen purity : 99.2%

RAW WATER CONDITIONS :

Raw water quality : Demineralized water (without ammonia)
Electric conductivity : 8~10μS/cm,
Salinity : 5mg/l;
Raw water temperature : 25℃ ~ 35℃;
Raw water pressure : 0.35MPa;
Raw water flow : 6 T/h.

COOLING WATER CONDITIONS :

Cooling water quality : Demineralized water;
Return cooling water temperature : 42℃;
Cooling water pressure : 0.4 ~ 0.6MPa;

ELECTROLYTE TYPE : KOH solution, at concentration 30%

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
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KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 11

COMPRESSED AIR :

Type : Oil Free Air Compressor

Design pressure : 0.8MPa
Temperature : <50℃

RESPONSIBILITY: Unit Control Engineer, Field Engineer, Desk Engineer and shift chemist.

OHS RISK: NIL.

SAFTEY PPE’s: NIL

SPECIAL TOOLS/ EQUIPMENTS : NIL

ENVIRONMENT ASPECT: NIL

SAFTEY PRECAUTIONS:

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Signature: Signature: Signature:
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KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 11

SR No. DESCRIPTION
SAFETY PRECAUTION

Hydrogen generation electrolyser and relevant device instruments must be inspected and maintained
1
regularly to guarantee normal operation, so that the hydrogen purity accords with the specification.

In the hydrogen generation room or near other equipment containing hydrogen, firework must be
prohibited, placing inflammable and explosive material must be prohibited and the sign board “No Fire”
2
must be set up. There must be necessary fire fighting equipment provided in the hydrogen generation
room

Firework or operation that can generate sparks in hydrogen generation room or near hydrogen storage
tank is prohibited; working personnel must not wear shoes with nails, if they have to weld or kindle near
hydrogen pipelines, they must measure the hydrogen content in advance as well as confirm hydrogen
content in the air of working area is less than 3%, and start to work after getting the approval of leader
3
who is in charge of the plant production. If pipe valves or other equipment in hydrogen generation room
are frozen up, they must be thawed by steam or hot water instead of roasted by fire. For checking
whether the connections of pipes have hydrogen leakage, it can use instruments or suds, check with fire is
prohibited

4 No person than the staff is allowed to access the hydrogen generation station
There must be rubber gloves and protective glasses available in hydrogen generation room for application
5
related with alkali solution.

6 When alkali burn occurred, wash with water immediately, and then use 3% boric acid solution to wash,
finally rinse with water.
In case when the hydrogen generation room catches fire, it shall immediately stop the electrical
equipment, cut off the power, release system pressure and use carbon dioxide to extinguish the fire, if the
7
fire is due to hydrogen leakage, seal off the leakage point with asbestos cloth to avoid hydrogen escaping,
or use cut off the hydrogen source by other means.
8 Tools which may generate sparks are prohibited for checking or operating the hydrogen system
Do not touch the electrolyser with water, and it is prohibited to touch two different electrodes
9 respectively with hands. There shall be an insulating rubber slab placed on the ground when operating
before the tank.

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
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KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 11

If the outage of hydrogen generation equipment needs to be over 6 months, the electrolyser shall have
10
alkali solution discharged and be filled with condensate.
11 Hydrogen generation room shall be configured with explosion-proof electrical devices
Hydrogen and oxygen mixture has an explosion risk, so the upper limit is 96% hydrogen and 4% oxygen,
12
the lower limit is 5% hydrogen and 95% oxygen

There shall not be any maintenance when hydrogen generation equipment is operating, if necessary, it
13
needs to shut down equipment operation, and then repair according to the relevant provisions

In case of accident or equipment piping leaking a great deal of alkali or gas, it shall immediately cut off
14 main circuit power and synchronization power of rectifier cabinet, release pressure in system gradually,
analyze the causes and take measures to remove the fault.
15 Operators shall not wear work clothes made from synthetic fibers or wool
16 Hydrogen tank shall not be operated when it is charged with hydrogen

PRE- START CHECKS:

RESPONSIBILITY
SR No. DESCRIPTION
SIC/UCE DE FE SC
PRE- START CHECKS:

1 All permits and cross permits have been returned. √ √ √ √

2 Power supply and control power supply available √ √

3 Check that all valves are in close state √ √

Open condensate inlet valve of water tank and close it until the water tank
4 √ √
is filled with water

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
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KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 7 of 11

Open cooling water inlet valve of alkali solution circulating pump. Open the
outlet valve of water tank to circulating pump, circulating pump by-pass
5 inlet valve, circulating pump outlet valve, straightway exhaust valve of √ √
hydrogen outlet and straightway exhaust valve of oxygen outlet, and start
circulating pump to fill water

As the water level rises to the middle of hydrogen and oxygen separator
level gauge, open inlet and outlet valves of filter and inlet valve of
6 circulating pump, close by-pass inlet valve of circulating pump and outlet √ √
valve of water tank to circulating pump, so that the water flushes circularly
in the system for 1 hour

Close outlet valve of circulating pump, open by-pass outlet valve of

circulating pump and inlet valve of circulating pump to water tank; the
flushing water is returned to the water tank and discharged through blow
7 √ √
down valve of water tank. Stop the pump after closing the circulating pump
by-pass outlet valve and the circulating pump inlet valve to condensate
tank

Open the left and right blow down valves of electrolyser to discharge the
residual clean water in it, and then close the left and right blow down
8 valves of electrolyser, inlet valve and outlet valve of filter, inlet valve and √ √
outlet valve of circulating pump, straightway exhaust valve of hydrogen
outlet and straightway exhaust valve of oxygen outlet.

PREPARATION OF ELECTROLYTE :
Prepare 24% 150L (specific gravity is 1.2571 in 30℃) of NaOH solution, add
a small amount of condensate to the clean alkali solution tank, and then
1 add 45Kg chemical pure sodium hydroxide (NaOH) solution till 150L. Plastic √
stick can be used to stir in dissolution process, in order to accelerate the
dissolution and heat elimination.

After safe dissolution and cooling, the specific gravity of sample measured
2 by hydrometer is about 1.26, and then adds 380g vanadium pentoxide and √
160g cobaltic oxide and stir to dissolve

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 8 of 11

After electrolyte preparation competed, use circulating pump to inject it

3 into electrolyser √

First check Circulating Pump each valve is closed, open by-pass inlet valve
of circulating pump, alkali solution tank to circulating pump outlet valve,
outlet valve of circulating pump, straightway exhaust valve of hydrogen
outlet and straightway exhaust valve of oxygen outlet; check the opening
4 of circulating pump by-pass inlet valve, start circulating pump and until √
alkali solution reaches the lowest level of separator level gauge, close by-
pass valve of circulating pump, alkali solution tank to circulating pump
outlet valve, straightway exhaust valve of hydrogen outlet, straightway
exhaust valve of oxygen outlet and cooling water inlet valve of circulating
pump.
EXHAUST OF AIR IN HYDROGEN STORAGE TANK :
1 Exhaust air in hydrogen storage tank with water
(a) Connect water with blow down valve at the bottom of hydrogen storage
tank by tube. Feed water and open vent sampling valve, when vent
√
sampling valve overflows water, keep overflowing for 15 minutes, and then
close blow down valve at the bottom and vent sampling valve.
2 Exhaust air in hydrogen storage tank with carbon dioxide
( a ) In order to antifreeze in winter, it can use carbon dioxide to exclude air
in hydrogen storage tank and use rubber hose to connect carbon dioxide
cylinder with blow down valves at the bottom of hydrogen storage √
respectively through reducing valve, intake carbon dioxide and exclude air
through the vent sampling valves of hydrogen storage tank

( b ) Analyze samples from each vent sampling valve of hydrogen storage

tank, when the carbon dioxide content ≥95%, stop carbon dioxide intake √
and close blow down valve at the bottom and vent sampling valve.

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 9 of 11

OPERATING PROCEDURE –

RESPONSIBILITY
SR No. DESCRIPTION
SIC/UCE DE FE SC
START UP :
1 After checking that all valves are closed √
2 Put the water-supply switch at “manual” position √
Turn on power switch of hydrogen and oxygen analyzer, warm up
3 √
instruments and put the option switch at “calibration” position
Open cooling water inlet valve of air compressor and adjust the flow;
open inlet and outlet valves of dryer, inlet valve of compressed air
4 storage tank and start air compressor, when the pressure of air √
storage tank is more than 0.4Mpa, open primary and secondary
outlet valves of air storage tank

Open water tank to water-supply pump outlet valve, water-supply to

oxygen separator inlet valve and cooling water inlet valve of
circulating pump, filter inlet and outlet valves, circulating pump inlet
5 valve, hydrogen outlet valve, vent valve of hydrogen control valve, √
oxygen outlet valve and vent valve of oxygen regulator valve. Start
circulating pump, open outlet valve of circulating pump and adjust
the flow to stabilize at 500L/hour.
After oxygen tank temperature reaches 50℃, operate the set value of
6 bath pressure recording regulator is 3.2 Mpa when alkali solution √
circulation volume is adjusted to 800L/hour.
According to the indication of tank temperature (mainly oxygen tank
temperature), adjust the set value of tank record regulator to
6 √
maintain the tank temperature between 85-90℃ (usually set at 65-
70℃).
7 Adjust the rectifier cabinet electrolysis current to 720A √

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 10 of 11

Open inlet valves of oxygen regulator and hydrogen regulator respectively,

adjust regulator to ensure outlet pressure is about 0.01 Mpa. Conduct
hydrogen and oxygen purity analysis based on the application methods of
8 hydrogen and oxygen analyzers, as well as analyze the samples. When √
hydrogen purity >99.8%, humidity<5g/m3, input hydrogen dryer, slowly
open inlet valve of hydrogen storage tank to be filled and close hydrogen
vent valve.

SHUTDOWN :
Press the stop button to shut down water-supply pump and stop
1 √
operating
Switch off the power of hydrogen in oxygen and oxygen in
hydrogen analyzers, close the inlet valve of hydrogen and oxygen
2 reducing valve, open vent valve of hydrogen control valve, close all √
inlet valves of hydrogen storage tanks which are filling with
hydrogen, close hydrogen dryer

Switch bath temperature regulating system to “manual” state, to

maximize the opening of control valve, by this time, the cooling
3 water volume is maximum, so that the temperature reduces √
quickly, also open the cooling water straightway valve of bath
temperature control valve to increase the flow rate.
4 Reduce the electrolytic current to “0”, stop operating √
Close hydrogen and oxygen outlet valves to maintain bath
5 √
pressure and normal differential pressure
After bath temperature has reduced to 50℃, the devices can start
6 √
pressure relief

Press the stop button of alkali solution circulating pump to stop

7 circulating pump operating; close outlet valve of circulating pump, √
shut down air compressor and close all valves

8 Close all valves of hydrogen generation equipment √

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
Designation: Asst.Manager Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/OPR/HYDROGEN
GENERATION SYSTEM / 01
SOP FOR HYDROGEN GENERATION SYSTEM `

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 11 of 11

ABBREVIATIONS :

o SOP : Standard Operating Procedure

o SIC : Shift In Charge
o UCE : Unit Control Engineer
o DE : Desk Engineer
o FE : Field Engineer
o DCS : Distributed Control System
o SC : Shift Chemist

 References: Hydrogen Generation Station “O & M “ Manual.

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Signature: Signature: Signature:
Name: Triveni kumar Name: Name:
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