Hydrogenics - Academy - Expert Water Electrolysis - vFINAL-compressed PDF

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Syllabus
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• No digital version will be shared
Program Time Topic
9h00 Registration
9h30 Opening
9h45 HySTAT® and HyLYZER® electrolysers: Part I
10h30 Coffee break
11h00 HySTAT® and HyLYZER® electrolysers: Part II
12h15 Questions & Answers
12h30 Lunch
13h00 Factory visit: electrolyser production @ Hydrogenics
14h30 Case study: HyBalance
14h45 A power-to-hydrogen project: step by step: Part I
15h30 Coffee break
16h00 A power-to-hydrogen project: step by step: Part II
17h00 DO & DON’T’s in Power-to-Hydrogen projects
17h30 Questions & Answers
18h00 Bus departure to NH Bloom Brussels
19h30 Arrival Bus at NH Bloom Brussels
Hydrogenics / Cummins
Introduction to
Cummins /
Hydrogenics
Q1 2020
Public
Powering a more prosperous world
190 62,610 1.5M+

Countries & territories Global employees Engines built in 2018
8,000 $894M 100

Wholly-owned &
Invested in research
independent Years of industry
& development in
distributor & dealer leadership
2018
locations
8
Our growth strategy
CORE CAPABILITIES GROWTH PLATFORMS
Technology Leadership Leverage our

Build on our Global
Engine Power strength in
Systems Distribution
Scale Advantage Powertrain Channel
Distribution Network Increase

Data-Enabled
Components Distribution Participation
Services
in Attractive
Partnerships & Customers
Markets
NEW TECHNOLOGIES
9
New technologies
Energy storage New prime mover
Distributed power Alternative fuels
Advanced manufacturing & materials Powertrain integration & electrification
Autonomous & advanced controls Connectivity, big data & artificial intelligence
10
The markets we serve
Heavy-duty Truck Medium-duty Agriculture Construction Oil & Gas Fire & Emergency
Truck & Bus
Marine Mining Light-duty Automotive Defense Power Generation Rail

& Recreational Vehicle
This is not an exhaustive display of Cummins-powered markets. Please refer to cummins.com for the most updated product information. 11
Public
Cummins: 100 years of power innovation
10,000
Global leader in
powertrain technologies,
providing diversified,
dependable power of the world’s brightest engineering
solutions minds working together
The power of choice
CLEAN DIESEL NATURAL GAS HYBRID ELECTRIC BATTERY ELECTRIC FUEL CELL
12
Our history with hydrogen
Cummins leadership in fuel cell and hydrogen production technologies is rooted in 20 years of research,
development, and strategic partnerships
2014 2018
Cummins joins a pilot project to Cummins joins the Hydrogen
explore the development of Council, a global coalition exploring
what would become the first and promoting hydrogen as a clean
hydrogen-fuelled transportation energy source in the face of climate
system in Costa Rica. challenges.
2003 2017 2019

Cummins develops an SOFC sy Cummins and Microsoft Cummins acquires Hydrogenics, a fuel
stem for the Department of announce the opening of the cell and hydrogen production technologies
Energy, demonstrating its ability Advanced Energy Lab, which provider, makes a minority investment in
to meet truck auxiliary power evaluates SOFC as a power Loop Energy, a fuel cell electric range
unit requirements source for future data centers. extender provider, and signs a
memorandum of understanding with
Hyundai Motor Company to collaborate
on hydrogen fuel cell technology.
13
Hydrogenics
ON-SITE HYDROGEN GENERATION

Electrolyzers
Industrial Hydrogen supply
H2O + electricity → H2 + ½ O2 “The addition of Hydrogenics to the

Electrified Power segment builds on
POWER SYSTEMS our strategy of using technological
Fuel cells innovation to bring the right
Stand-by Power
Mobile Power Modules powertrain solutions to our
MW Power Plants customers.”
-Chairman & CEO Tom Linebarger
H2 + ½ O2 → H2O + electricity
RENEWABLE HYDROGEN
Energy Storage
Hydrogen for Refueling Station
Power-to-X
Grid balancing services
14
Hydrogenics’ locations
Hydrogenics Europe
Hydrogenics Corporation
▪ Oevel, Belgium
▪ Mississauga, Ontario
▪ Since 1987
▪ Since 1995
▪ Power-to-X, industrial onsite hydrogen
▪ Fuel Cells, PEM electrolyser stacks,
production, and H2 refueling station projects
Power-to-Gas, H2 refueling and and
mobility products / projects
Hydrogenics GmbH
▪ Gladbeck, Germany
▪ Since 2002
▪ Fuel Cell power module integration
Hydrogenics USA
▪ Carlsbad, California Production Facility
▪ Since 2018 Sales Office
▪ Fuel Cell power module integration
15
Water electrolysis
Water Electrolysis
Water Electrolysis
Remark 1
Pure water is not an
electrical conductor
Alkaline electrolysis : we add a source
of electrical conductive ions to the
water : ‘KOH’
PEM electrolysis : we add a catalyst to

the membrane to split water directly
Water Electrolysis
2
Remark 2
Direct Current is needed
Alternating (grid) current would cause
fast oscillating O2 and H2 generation
at the same electrode
Water Electrolysis
Remark 3
A membrane is needed
H2 and O2 should be kept separated
once produced
An alkaline membrane need to be

capable to conduct the OH- ions
delivered from the dissolved KOH
3
A PEM membrane need to be capable
to conduct the H+ ions delivered from
the catalytic reaction at the anode side
Water Electrolysis
Remark 4
Reduce the distance
between the electrodes as
much as possible
A KOH solution and a membrane don’t
conduct electricity as well as copper.
Longer distance = more electrical
resistance = more ohmic loss =
production of waste heat
A PEM membrane (-electrode

assembly) is very thin
‘zero gap’ is the goal
4
Water Electrolysis
Remark 4
Reduce the distance
between the electrodes as
much as possible
Remark 4.1 A KOH solution and a membrane don’t
The anode and the cathode we conduct electricity as well as copper.
also call ‘electrodes’ Longer distance = more electrical
resistance = more ohmic loss =
production of waste heat
In a PEM system the membrane is

coated with electrode material.
Membrane Electrode Assembly ‘MEA’
4
Water Electrolysis
Remark 5
Choose the materials
wisely
A (KOH) alkaline solution will cause
corrosion to normal ferro metals 5
The PEM cell reaction means
migration of H+ ions. This is the
same as exposing the electrodes to a
very strong acid.
5 5
Water Electrolysis
6 Remark 6
Cells can be electrically
connected
In series = BIPOLAR
In parallel = UNIPOLAR
Water Electrolysis
BIPOLAR
Voltage X 2
Same Current
Water Electrolysis
UNIPOLAR
Current X 2
Same Voltage
Water Electrolysis
7
Remark 7
Water electrolysis is
possible under pressure
The gas evolving from the electrodes
will build up pressure. This doesn’t
hinder the electrolysis process.
The surrounding structure & sealings

should be capable to withstand
pressure.
Water electrolysis
2 commercial stacks developed by Hydrogenics
Alkaline HySTAT® PEM HyLYZER®

Pressurized design (10 or 27 barg) Pressurized design (30 barg)
Mature & established New & high performance
Low power density High power density
Limitations in operation Very flexible in operation
Alkaline electrolysers
IMET® cell stack
Bipolar stack ‘two sizes’

Filled with H2O + 30%KOH
Proprietary ion exchange membrane
Pressure design 10 bar or 27 bar
Up to 17 Nm³/h
Operating range 40 to 100%
Conversion efficiency 4,3 kWh/Nm³
HySTAT® alkaline electrolysers : basic process
Hydrogen output
Electrical connections
Water reservoir
Hydrogen gas separation
Water injection
Oxygen gas separation
IMET® cell stack
Electrolyte cooling
No moving parts !
HySTAT® alkaline electrolysers : process skid
A process skid will allow the cell stack(s) to

function:
• Feeding water will be injected to replenish the consumed
water
• H2 and O2 will be separated from the electrolyte
• The pressure will be kept constant controlled by regulating

valves
• The temperature will be kept constant, excess heat is

evacuated through heat exchangers
• The O2 gas quality will be monitored for safety
3 standard process skid sizes
Up to 2 cell stacks Up to 4 cell stacks Up to 6 cell stacks
30 Nm³/h 70 Nm³/h 100 Nm³/h
Control Panel & Power Supply
Per stack
200 V DC / 430 A
• CPU PLC (Siemens S-7 software) • Mains switch • Cell stack(s)

• PROFIsafe Communication • Circuit breaker(s) • Gas separators
• UPS with batteries 24 VDC for safe • Grid filter(s) • Heat
shutdown • Contactor(s) exchangers
• ‘Exter’ display terminal for visualization • SCR bridge(s) • Demistors
and HMI(2) • Air cooling • Water injection
• ‘eWON’ industrial VPN router(3) transformer(s) • Instruments
• Key switch, emergency stop, audible alarm • Rectifier(s) • Valves
on the enclosure door • Phase checker • Safety systems
3 standard process skid sizes
HySTAT® : peripheral equipment
Control Panel & Gas Generating O2 out 99 %
Power Rack Skid
Control &
monitoring H2 99,998 %
< 1 ppm H2O
H2 out 99 % < 2 ppm H2
AC power in DC power out

5 kWh per Nm³ H2 430 A per stack
Heat out Hydrogen

RO water Cooling water 60°C Purification
purifier 1 kWh per Nm³ H2 System
Tap water in Demineralized
2 liter for 1 liter water out
demineralized 1 liter per Nm³ H2
water
Cooling system
IMET® alkaline electrolysers : balance of plant
Dry cooler
RO feed water treatment system
Pump skid + thermostat control

Gas Generating Skid GGS
H2 ‘vent stack’
Pre integrated in ISO Chiller for gas cooling

(outside container)
container
Hydrogen Purification Skid
All equipment included

to limit utilities on site
to tap water &
electricity
Control Panel
AC/DC
Power distribution
‘All-in’ outdoor
Electricity intake 500 kW
Tap water intake 150 l/h
Hydrogen out :
Flow 100 Nm³/h
Pressure 10 bar or 27 bar
Purity of 99,998%
Operating range 40 to 100%
Conversion efficiency 5.0-5.2 kWh/Nm³
HySTAT® budget complete system + services
15 Nm³/h
30 Nm³/h
70 Nm³/h
100 Nm³/h
Options
Following customer’s requirements..
• Low/high temperature pack : as low as -40°C to up to 50°C ambient
• Different voltages / frequency : 440V / 600V / 60 Hz..
• Different codes & standards : UL/ASME, EAC..
• Extra instruments, sensors.. : monitoring & detection
• Service and maintenance : basic to ‘we care’
• And many more
Coffee break
PEM electrolysers
PEM : Proton Exchange Membrane ‘only circulating water’
PEM cell
Membrane-Electrode-Assembly (MEA) Technology
DO NOT PRINT
All about pure demin water management!
2012: Let’s go for it !
1500E
450E
92E
2012
PEM, 2012 : LET’S GO FOR IT
First test large stack

1.500 cm² active surface
2013
First HyLYZER® PEMWE
Unit Delivered
2014
First commercial large stack
2015
FIRST “MW” PEM STACK MEASURED EFFICIENCY
First 1.5 MW project

delivered
2015
2015
FIRST “MW” PEM STACK MEASURED EFFICIENCY
First 1.5 MW project

delivered
Relationship between cost and efficiency
First “MW” PEM Stack Measured Efficiency
Increase efficiency

Reduction of
operational cost (€/kg)
Example: 1.5 MW PEM Electrolyser,

WindGas Reitbrook, Hamburg
Increase current density → Reduction of capital cost (€/MW)
2017 - We’re Ready
▪ 2 x 1500 E stacks
▪ Up to 500 Nm³/h
(~1000 kgpd)
▪ 5 – 120%
▪ 30 barg
▪ 99,998%
2017
HyLYZER® 230-30 – dual stack
5.0 kWh/Nm³
2017
HyLYZER® 230-30 – dual stack
5.0 kWh/Nm³
Air Liquide, HyBalance, Hobro, Denmark
2018
2.4 MW, dual PEM cell stack
P2G Brunsbüttel, Germany
2018
First HyLYZER® PEMWE
Indoor Installation
Markham Energy Storage Project (Markham), Canada (2018)
Secondary Frequency Control for the IESO
+/- 1.05 MW of regulation service for the IESO
MW La puissance à l’électroyseur varie et donc la
production d’hydrogène fluctue en temps réel
Temps
2019
HyLYZER-250-30 Expandable
to HyLYZER-500-30
Maximator, Wuppertal, Germany
2019 First MV Connection
1.25 MW
Halcyon, New Zealand
New Benchmark in PEM Water Electrolysis, 3MW Stack
2019 2014
2019 HyLYZER® -1000-30
5 MW PEM Electrolyser
• Containerized design & compact footprint

• Plug&Play modular design based on 2 x 2,5 MW cell stacks
• Tested & certified @ Hydrogenics’s factory
HyLYZER®-1000-30 product presentation
▪ 2 X 1500 E stacks
▪ Up to 1250 Nm³/h
(~2600 kgpd)
▪ 5 – 125%
▪ 30 barg
▪ 99,998%
HyLYZER® -1000-30 – Block diagram
20 ft power container
Layout for 4000 Nm3/h outdoor plant (20 MW)
Layout for 4000 Nm3/h indoor plant (20 MW)
DO NOT PRINT
HyLYZER®-1000-30 system efficiency
With our
newest stacks
we have the
most efficient
product on the
market
DO NOT PRINT
HyLYZER®-1000-30 system efficiency
Electrolysers : HyLYZER® product line
Alkaline PEM (Proton Exchange Membrane)
HySTAT®-15-10 HySTAT®-60-10 HySTAT®-100-10 HyLYZER® -500-30 HyLYZER® -1.000-30 HyLYZER® -5.000-30
Output pressure 10 barg (27 barg optional) 30 barg
Number of cell stacks 1 4 6 2 2 10
Nominal Hydrogen Flow 15 Nm³/h 60 Nm³/h 100 Nm³/h 500 Nm³/h 1.000 Nm³/h 5.000 Nm³/h
Nominal input power 80 kW 300 kW 500 kW 2.5 MW 5 MW 25 MW
AC power consumption
(utilities included, at nominal capacity) 5.0 to 5.4 kWh/Nm³ 4.4 to 4.8 kWh/Nm³
Hydrogen flow range 40-100% 10-100% 5-100% 1-100%

Hydrogen purity 99.998% 99.998%
O2 < 2 ppm, N2 < 12 ppm (higher purities optional) O2 < 2 ppm, N2 < 12 ppm (higher purities optional)
Tap water consumption <1.4 liters / Nm³ H2 <1.4 liters / Nm³ H2
Footprint (in containers) 1 x 20 ft 1 x 40 ft 1 x 40 ft 2 x 40 ft 2 x 40 ft 10 x 40 ft
Footprint utilities (optional) Incl. Incl. Incl. Incl. 1 x 20 ft 5 x 20 ft
Competitive Advantages
PEM vs. Atmospheric Alkaline for large scale projects
Reduced CAPEX
▪ Competitive equipment CAPEX → prices will continue to decrease with volume
▪ Non-classified process room → can use normal equipment for auxiliary systems
▪ Compact equipment → less land costs, smaller buildings, lower EPC costs for customer
▪ Simple interfaces → reduced installation costs
▪ Overdrive feature → design with N-1 redundancy in guaranteed flow applications
▪ Stacks will be refurbished → Do not need to buy new stacks
Reduced OPEX
▪ Highest efficiency stacks → less electricity usage
▪ Highly efficient Balance of Stack → no compressors required for H2 liquefaction or NG injection
▪ No KOH → easier for onsite works and maintenance
▪ No compressors → No risk of oil contamination, no added maintenance
▪ Very few moving parts → low maintenance costs (~0.5 to 1% of CAPEX per annum)
▪ Very low degradation → Many years between stack overhauls
▪ Future improvements → Refurbished stacks will have even better efficiency than today
Our PEM technology provides the best TCO for water electrolysis on the market
Race to 100MW+ projects
STEP 1: validation of 20 MW plant (ongoing)
• Deliver the Becancour project in Canada: 20 MW PEM
• Validate in the field the performance of the 2.5 MW
stacks
• Validate the Balance-of-Stack
• Validate the Balance-of-Plant design and integration with Future
EPC
STEP 2: replications 20 MW modular plants to build 40, 60,

80 and 100 MW
STEP3: cell stack upscaling
Drivers for cost reduction
• Product standardization and specialization

• Project upscaling
• Market uptake → higher volumes → cost reduction
• Improvement of the supply chain: more suppliers
• Higher competition → lower margins → lower prices
• Better products : quality, efficiency, higher pressure, lifetime…
• Decrease the use of expensive raw material (catalysts)
• Products will be more compact → less BOP, logistics, civil works
• Synergies with PEM fuel cells (volumes are increasing rapidly there already). The
cost of PEM electrolyzers will benefit from this synergy (+/- same suppliers).
HyLYZER: product configurations
- Low Voltage vs Medium Voltage power supply

- By-products valorization (O2/heat)
- DC/DC coupling
- Noise management
- Scope configurations
LV vs. MV power supply
LV Input MV Input
Inhouse Design SMA partnership
3x 400/690V 6-36 kV
Single/Dual Stack Single Stack
0- 500 Nm3/h 0- 500 Nm3/h
40ft Container 20ft Container
Dual Stack
0- 500 Nm3/h
40ft Container
By-products valorization (O2/heat)
Oxygen output:
Heat output: 200...300kW heat loss per installed MW of electrolysis

Low temperature though (max. 55°C)
DC/DC coupling
Safety check on
voltage and current
Direct connect
via DC/DC convertor
DC/DC coupling - Situation today
Safety check on
voltage and current
Direct connect
via DC/DC convertor
Customer Scope Hydrogenics Scope
DC/DC coupling - Situation future
Safety check on
voltage and current
Direct connect
via DC/DC convertor
Customer Scope Hydrogenics Scope

Noise Management
• Standard Noise Emissions: 75 dB at 3m
Low speed fans on dry cooler
Vent stack silencer
Silencers on
ventilation exhaust
Utilities – who’s scope?
- Demin water
- Instrument air
- Chiller
- Dry cooler
- Ventilation
3 options:
- All pré integrated

- All provided by customer
- A mix
HyLYZER® 500-30
Containerized solution
Operation of Electrolysers
Standby N2 purge
An electrolysis system MUST proceed through a number
of steps before hydrogen can be produced SAFELY.
N2 purge Depressurize
1. Inert gas purge – to prevent explosion/fire. (Only
needs to be repeated if the pressure is lost because
air may enter the system)
Standby H2
2. Hydrogen purge – to remove inert gas and replace purge
with hydrogen
3. Hydrogen Production – production of hydrogen to
H2 purge
the user.
(With standby steps in between) Standby H2

production
H2 Production
Differences between PEM and Alkaline operating range
1. Alkaline stacks are limited in lower range of current (40-100%)

=> Gas purity (H2 diffusion in O2) is inversely related to current density. Low current means worse gas purity
– Safety limits.
0% 40% 100%
2. PEM stacks are less limited in lower range of current (5-100%)

=> Gas purity not impacted by low current density. Practically the lower limit is about 5-10% due to
limitations on AC/DC rectification.
0% 5% 100%
What does this mean for flexible operations?
 From COLD START both types electrolysers can take 20-30 minutes to be supplying gas safely.
 For power balancing operations electrolysers can react in 15-30 seconds to demand from STANDBY.
 Once in operation an electrolyser can react to load changes in 1 SECOND.
 Often the limiting factor is the end user of the hydrogen – storage size, compressor flexibility. How will the
hydrogen be used and how often?
DO NOT PRINT
2.5MW PEM electrolyser
(real operation data – during commissionning)
5 seconds
Regulation Range =
Careful balance between
investment and capacity
Safety
Safety
Safety begins with the identification of the Hazards

involved in any process and assessing the probability
they might occur
= RISK ANALYSIS
Risk Analysis
1. Identify the Hazard and its consequence.

2. Assess the likelihood of this happening.
3. Where required, reduce the consequence or the likelihood by the use of
additional measures.
IMPORTANT
Though risk analysis has been performed on separate systems, an overall site assessment will
need to be performed. This is often dependant on local conditions and regulations.
Risk assessment matrix
SIL - Safety Integrity Levels
Identified Hazards
1. High temperatures (70 to 240°C)
2. Fire (Hydrogen/Oxygen)
3. Explosion (Hydrogen/Oxygen)
4. Asphyxiation (Nitrogen/calibration gases)
5. Chemicals burns (Pottasium Hydroxide – KOH)
6. High Pressure (up to 1000 bar)
7. Electricity (230-15000v / AC and DC)
Hazard mitigation methods
• High quality fittings and components - Stainless Steel 316L
• ATEX classified equipment in hazardous areas
• FAIL SAFE (valves, signals, transmitters)
• All vessels are protected with safety relief valves
• Oxygen cleaning of components
• Protection around the cell stacks and high temperatures
• Independent SIL rated safety loops
• Atmosphere monitoring – hydrogen/oxygen content
• Pressure monitoring linked to inert gas purging routines
• Active ventilation of hazardous areas
Potassium Hydroxide (KOH)
• Always wear appropriate Personal Protective
Equipment while handling KOH!
Safety boots
Face protection
Protective gloves
Chemical overall
Hazardous areas and zoning - Internal
Hazardous area
Safe area
Hazardous areas and zoning - External
Zone 2
Zone 1
Zone 0
General Safety Guidelines
• Documentation must be kept available to assist operators and engineers

• Electrolyser Manual and third party manuals
• Electrical Drawings
• P&IDs
• Operation & Maintenance personnel must be trained

• Make sure that all personnel involved in the installation, operation, or
maintenance of the Electrolyser are trained accordingly. Do not allow
unsupervised work on or around the Electrolyser installation.
• Use Permit to Work or similar control procedures.
Questions ?
Factory visit: electrolyser production at Hydrogenics
• 4 groups: A, B, C, D
• There will be 2 guides from Hydrogenics with each group
• Always follow the instructions of your group leader
• Pictures are not allowed during the factory visit
• Some units might be energized and pressurized !

• Turn off your mobile phone during the visit
• No smoking onsite is allowed
• Safety glasses will be distributed at the entrance of the production hall
• Safety shoes are not needed but you have to stay outside of the yellow zones
(unless you are authorized by your group leader)
• Do not touch the equipment
Factory visit: electrolyser production at Hydrogenics
• All visitors need to take the shuttle buses
• Visit duration : ± 1 h
Lunch time
• 13h00: departure Bus
Factory visit
Case study: HyBalance
Air Liquide: more than 60 years of experience with H2
Air Liquide Future
HyBalance
Why has Denmark been chosen for the project
● Denmark is one of the countries in the EU with the most ambitious energy policy
● Denmark has a lot of wind energy
● Denmark has know-how within FCH technologies
● Denmark is the first and only country in the world to have a national network of
hydrogen refueling stations
● Hydrogen cars are exempt from taxes until 2019
HyBalance
Specification
● 1,25 MW H2 production = 20 kg or 230 Nm3/hr @ 30 bar

● 75 kW Compressor = 25 kg compressed at 900 bar
● 420 bar storage with capacity of approx. 600 kg Hydrogen
● 900 bar storage with capacity of approx. 90 kg Hydrogen
● 24/7 pipeline operation at 10 bar
● Trailer capacity of 350 kg => 17.5 hr production at full speed.
● High reliability is key
HyBalance
HyBalance
Summing up: HyBalance will promote green transition
A power-to-hydrogen project: step by step
1. Project preparation
2. Contracting with Hydrogenics
3. Project Management at Hydrogenics
4. Project Management at Site
5. Operation and Maintenance
Project preparation
Step by step approach for commercial projects
1. General project definition : objectives, application, H2 offtaker (client), partners, suppliers, business case,
financing, sizing (global and each component)
2. Pre-feasability : inhouse or outsourced (consulting firms) → budget quotation (RFI)
3. Project lead: EPC or not ?
4. Tendering : involve the potential suppliers during the preparation phase
5. Feasability → detailed quotations (RFQ)
6. Start permitting process
7. Apply for funding (if required)
8. Tendering: final RFQ
9. Final Investment Decision (FID)
Project preparation: electrolyser selection
How to make a good comparison between various technology suppliers
• Compare apples with apples: certainly not only CAPEX (€/kW)
• Use rather ‘Nm³/h’ than ‘MW’
• What matters is the €/kg H2 production cost related to water electrolysis over the entire project
lifecycle (Total Cost of Ownership) which needs to consider at least:
• Total investment : electrolyser (+ compression) + grid connection + civil works + project costs
• Efficiency & lifetime (incl. degradation) & cell stack replacement (or refurbishment)
• Maintenance
• Warranties
Project preparation: HyBalance
• Coordinator: Air Liquide
• Co-funding : FCH-JU / National funding (DK)
• Transfer of ownership to Air Liquide in the project
• Several contracts:
• Grant Agreement
• Consortium Agreement
• Bilateral agreement
• Service contract
5. Operations and Maintenance
Contracting with Hydrogenics
Attention points:
• Payment conditions: 50% down payment – 40%
before delivery – 10% after commissioning
• Delivery time: typically 8 months (ALK), 12 months
(PEM)
• Warranty: one year, extended warranty possible with
maintenance contract
Others:
• Identifications of parties & type of agreement
• Definitions & Scope of supply
• Price & Liabilities
• Termination, Governing law & Arbitration
Project Planning: overview
Project Planning: milestones overview
Operational Commissioning
• Contract Readiness • Assembly Readiness • Startup and
implementaion • Inhouse Testing commissioning
• Engineering • Installation
• Factory • Site Acceptance
• Procurement Test
Acceptance test
• Packing • Training
Intermediate
Kick off Final closing
closing
Engineering
PROJECT ENGINEERING
PROCESS ELECTRICAL MECHANICAL AUTOMATION DOCUMENTATION
• Process Flow • Single Line • General Lay Out • Control System • Material Lists
Diagram Drawing Drawings Architecture
• Component
• Utility Specs • Electrical Load • Foundation • Functional Documentation
List Drawings Descriptions
• P&ID • O&M Manual
• Electrical • Interconnection • Logic
• Equipment Diagram Drawings programming • Certification
Design Documentation File
• 3D design of • HMI
• Instrumentation electrolyser programming
Selection
• 2D production • Communication
drawings with customer
SCADA
Documentation
Obligatory Common practice Project specific
• O&M manual • Process & instrumentation diagram • Inspection and test plan
• Certificate of conformity • Mechanical drawings (foundation, • Painting specifications
• ATEX 2014/34/EU interconnections,..) • Signal exchange lists
• Machine Directive 2006/42/EC • Electrical schemes • PLC-I/O exchange list
• EMC 2014/30/EU • Material lists mechanical & electrical • Instrument list
• LVD 2014/35/EU • Material Safety Data Sheets • Test reports and certificates for I&C
• PED 2014/68/EU • Explosion protection document • Calibration reports
• Overview of PED equipment • Drawings for ATEX zoning • Control logic diagram
• Components certificates and suppliers OEM • Instrument and junction box location drawing
documentation • Packing and shipping procedure
• Customer check lists • Name plates and tagplate drawing
• List of spare parts and consumable parts • Project quality plan
• Commissioning procedure
• Cable sizing calculation
• List of auxiliary motor equipment
• Earthing lay out with details
• Power & control cable schedule
Procurement, construction and assembly
1. Bill Of Material (BOM)

2. Orders
3. Production planning
4. Assembly
DO NOT PRINT
Inhouse Testing & Factory Acceptance Test
1. Inhouse testing of the unit

• I/O
• Alarms
• Pressure
• Thermal
• Safety tests
• Operational
• Gas qualities
2. Client is invited for a Factory

Acceptance Test (FAT)
Deassembly, packing & shipment
1. De-assembly by Hydrogenics (disconnect all power cables, release pressure, remove liquids)
2. Packing & shipment by external partner following SEI shipping standards
• Standard 20/40 ft containers
• Loose items (Dry Cooler, Chiller, transformer) – SEI class 3C
• Extra packing for sensitive (Cell stacks, cabinets) – SEI class 4C
Coffee break
Project management at Site
• Site preparation
• Civil works (foundations)
• Water & electricity
• Consumables
• Safety
• Electrolyzer installation
• Startup & Commissioning
• Training of the operators
Site preparation – civil works
• Foundation drawings:
• Loads & load distribution
• Maintenance areas
• Foundation layout recommendation
• Interconnection drawings:
• Position & specifications of interconnection points
• Mechanical
• Electrical
Site preparation – water & electricity
• Water
• Up front water analysis for our control & recommendations to the customer
• Maximum flow ≠ average flow: intermittent operations of RO system
• Waste water drain
• Reverse osmosis deminwater production
• Demin water depollution
• Electricity
• PEM needs a freeze protection => 2 different electrical sources
• PEM Standard power input:
1. LV/MV main power & back-up supply
2. LV auxiliaries supply
• Alkaline Standard power input :
1. LV main power
2. LV auxiliaries supply
Site preparation - Consumables
• Temporary electricity supply for installation
• Nitrogen for intertization
• Calibration gases
Site preparation - Safety
• Documentation for site safety evaluation will be provided:
• Explosion protection document
• Boundary HAZOP
• On request we can support the interconnection HAZOP exercice for our supply scope (optional service)
Electrolyzer installation
• Installation mostly executed by customer
• On request we can provide installation supervision service (optional)
• Electrolyzer manual provides installation guidelines
• Customer checklist gives further support to client before shipping electrolyzer
• Site preparation by client is key for fast, succesful & cost-efficient installation
Startup & Commissioning - SAT
• Completed customer checklist must be provided by the customer before commencing S&C
• Limited (functional) SAT part of standard S&C
• Duration (after completion of site works & electrolyzer installation), 1 unit:
• Alkaline: 2 weeks
• PEM: 4 weeks
Training of the operators
• Full training for normal operation is part of the S&C
• duration 2 days
• Additional training can be provided on request (optional)
Project management @HyBalance
Project management @HyBalance
• FAT- 24 hr test - Guarantees that the unit works before being shipped to site
• SAT- 3 weeks on site before
• Run through of confirmed specification during a 24 hour SAT test
• Full check of system
• Easy overview over CE marks of Skids which made process with Third Body Notice much easier.
• Working very closely and open dialog with project-manager, engineering as service-engineers
Operation requirements
Our HySTAT® & HyLYZER® can be remotely operated and require only
weekly visual inspections by operator
• Scope of control
• Customer can change production parameters (Capacity, Output Quality, Pressure finetuning...)
• Functional and Safety logic is locked and can only be accessed by Hydrogenics.
• Control & Monitoring channels

1. Direct on Human Machine Interface (Standard)
2. Indirect via SCADA to Customer PC (Optional)
Standard vs Full Warranty Package
Availability
warranty
% time
1-year Efficiency Extended

Product warranty Product
warranty [kWh/kg] warranty
Full
Standard
Warranty
warranty
Package
Advanced
Training local Spare parts
operators onsite/HYGS Training local
operators
Full scope
LTSA
Maintenance: Service packages
SA4000+ SA4000 SA3000+ SA3000 SA2000
Service (Full scope
LTSA)
packages
Remote Assistance ▀ ▀ ▀ ▀ ▀
Preventive Maintenance ▀ ▀ ▀ ▀
Wear Parts ▀ ▀ ▀
Spare Parts ▀ ▀
Corrective Maintenance onsite ▀
Maintenance: Remote support
• Customer to submit “Support Request”
• Hydrogenics will login to HMI and PLC to analyse
• eWON = VPN connection via 3G / 4G / Ethernet
• 7/7 – Belgian office hours
• Lead times contractual defined
• Reporting can also be automated (project dependant)
Preventive maintenance: HySTAT® vs HyLYZER®
Item HySTAT® HyLYZER®

Visual inspections
(site, equipment, process parameters) Weekly by operator
KOH handling YES NO
Preventive maintenance 2x/year 1-2 x/year

(Filters, Calibration, Media)
HyLYZER® Stack Refurbishment
▪ PEM Stacks that have reached End-of-Run (EOR) performance can
be sent by the Hydrogenics to be refurbished
▪ Refurbished stacks will meet Start-of-Run (SOR) performance
▪ Swapping out a stack will take approximately one (1) day provided
that there is a spare stack on-hand
▪ A stack is the repetition of
BPP:GDL:MEA:GDL:BPP:GDL:MEA:GDL:BPP… held together with
two end-plates, tie rods, washers and nuts.
➢ BPP = Bi-Polar Plate
➢ GDL = Gas Diffusion Layer
➢ MEA = Membrane Electrode Assembly
▪ In a stack refurbishment, Hydrogenics replaces the soft goods in the

stack (MEA and GDL).
▪ The hard goods (endplates, tie rods, BPP, etc.) will be reused.
▪ A refurbished stack costs much less than a new stack, reducing
CAPEX requirements over plant life
O&M: HyBalance
● Easy overview
• Cooling system incl chiller
• Gas balancing
• Water CT
• Flow measurement
• Outlet pressure
• Dew point
• Oxygen level
• Easy troubleshoot
● Maintenance
• Designed for easy access to most
common maintenance jobs
• Working well both in cold and hot
Ambient temperature
• Not many moving mechanical parts
Part II: DO and DON'T's in
power-to-hydrogen projects
Project development DO’s & DON’T’S
• Focus first on the hydrogen offtake and then on the rest
• Incorporate the legal framework in the economics
• Be creative (multi purpose projects, extended value proposition)
• Engage with policy makers, regulators for a favorable regulatory framework
• Don’t do it alone !
• Build alliances / consortium with major commercial stakeholders in the project
• Hire specialized consultants on hydrogen projects
• Projects are usually complex because the value of hydrogen is in the connection of
several applications sectors
• Define clearly the project and the role of each partner
• Build the project steps by steps and validate each steps before jumping to the next one.
• Be patient , don’t give up !
Project management : DO’s
• Consider pre-engineering phase (permitting – HAZOP – inspections - onsite

conditions & requirements – layout)
• Strive towards a transparent & full “Scope” from the start of the project:
• Define a clear “Scope of Work Matrix” (Responsible / Collaborator / Coordinator)
• Define a “Master Document List” keep the #documents limited & align from the start
• Define Scada & DCS requirements & integration (details!)
• Check Site Conditions versus product (power & frequency / water quality / env.
temperatures / seismic loads / regulations & standards ...)
• Create a “Communication Matrix” from the start of the project
• Make a day by day “Installation scenario”
• Prepare yourselves for Operation & Maintenance after SAT (Site Acceptance Test)
Project management : DON’T’s
• Unclear & incomplete scope / H2 applications will lead towards delay & extra cost.
• we will just work out the details later ;-(
• Don’t treat 1-2 M€ projects in the same way as 1B€ projects.
• B2B is not always the best solution
• do we want project managers to become contract managers?
• Contract implementation delays may not eat into the project timeline.
• everybody needs his time into the project !
KEEP IN MIND:
• Scope changes (due to unknown requirements from the start) will mostly delay the project !
• Permitting & certification is essential but many times unclear & too late!
• We can’t always mitigate the planning (delay) by adding extra resources / budget !
• specialized equipment + limited #suppliers, drives us into long delivery times.
Safety & permitting DO’s & DON’T’S
• Include safety at the very beginning of your project definition

• Engage with local authorities, local fire brigade and neighbors
• Do not underestimate the time / work if this is a first of its kind project I your
region
Service & Maintenance: DO’s & DON’T’s
• Perform strict preventive maintenance as specified in the manual
→ It can significantly increase the lifetime.
• Make sure to maintain knowledge about electrolyser systems within your
company.
→ It reduces the O&M cost as less outsourcing is needed.
• Contact Hydrogenics Service department who is available to support you
→ We have the right structure in place for this and experienced service engineers
• Don’t be negligent on the visual inspections and parameter follow up.
→ Handling issues in an early stage mostly avoids impact on the operations.
• Don’t open the Hydrogen process without depressurization and nitrogen purge.
→ Work Safely!
HyBalance: recommendation from the client
● Container based solutions => surroundings design,

working space around the container during winter and rain
● Every person who will be part of the operations should
participate from the start of the training and start-up
● PPE
● Man-down safety function
● Gas detector which can measure PPM
Questions ?
Conclusions and wrap-up
• Thanks for attending this Expert Training on Water Electrolysis

• Please give us your feedback in order to improve it !
• Hydrogen technologies are ready
• New business opportunities in hydrogen are emerging every day and everywhere
• This is the right time to prepare your projects
• We hope to work with you in the near future !
THANK YOU & see you tomorrow (6 Feb)
8h45: Departure Bus shuttle from NH Brussels Bloom Hotel.

BE ON TIME. The bus will not wait !
9h30: Arrival at Colruyt (Zinkstraat 7, Hal, Belgium)
9h45: Start of site visit
11h45: Shuttle pick-up
12h30: Arrival at Brussels airport
Hydrogen | Basic math
Hydrogen physics
• 1 kg ↔ 11,1 Nm³ ↔ 33,3 kWh (LHV) and 39,4 kWh (HHV)
• High mass energy density (1 kg H2 = 3,77 l gasoline)
• Low volumetric density (1 Nm³ H2 = 0,34 l gasoline)
Hydrogen production from water electrolysis (~5 kWh/Nm³ H2)

• Power: 1 MW electrolyser ↔ 200 Nm³/h H2 ↔ ± 18 kg/h H2
• Energy: +/- 55 kWh of electricity → 1 kg H2 ↔ 11.1 Nm³ ↔ ± 10 liters demineralized water
Power production from a hydrogen PEM fuel cell from hydrogen (+/- 50% efficiency)
• Energy: 1 kg H2 → 16 kWh
Cars and buses

FCEV H2 tank H2 Driving Annual driving Annual H2
consumption range distance consumption
Car (passenger) 5 kg 1 kg/100 km 500 km 15.000 km 150 kg
Bus (12 m) 35 kg 8 kg/100 km 350 km 60.000 km 5 tons

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Introduction

• Your feedback will be highly appreciated !

• Only a printed version

190 62,610 1.5M+

8,000 $894M 100

Technology Leadership Leverage our

Distribution Network Increase

Energy storage New prime mover

Distributed power Alternative fuels

Advanced manufacturing & materials Powertrain integration & electrification

Marine Mining Light-duty Automotive Defense Power Generation Rail

The power of choice

2003 2017 2019

ON-SITE HYDROGEN GENERATION

H2O + electricity → H2 + ½ O2 “The addition of Hydrogenics to the

PEM electrolysis : we add a catalyst to

An alkaline membrane need to be

A PEM membrane (-electrode

‘zero gap’ is the goal

In a PEM system the membrane is

The surrounding structure & sealings

Alkaline HySTAT® PEM HyLYZER®

Bipolar stack ‘two sizes’

Hydrogen gas separation

Oxygen gas separation

IMET® cell stack

A process skid will allow the cell stack(s) to

• H2 and O2 will be separated from the electrolyte

• The pressure will be kept constant controlled by regulating

• The temperature will be kept constant, excess heat is

• The O2 gas quality will be monitored for safety

Up to 2 cell stacks Up to 4 cell stacks Up to 6 cell stacks

30 Nm³/h 70 Nm³/h 100 Nm³/h

• CPU PLC (Siemens S-7 software) • Mains switch • Cell stack(s)

AC power in DC power out

Heat out Hydrogen

RO feed water treatment system

Pump skid + thermostat control

Pre integrated in ISO Chiller for gas cooling

All equipment included

All about pure demin water management!

First test large stack

First 1.5 MW project

First 1.5 MW project

Example: 1.5 MW PEM Electrolyser,

Increase current density → Reduction of capital cost (€/MW)

Air Liquide, HyBalance, Hobro, Denmark

+/- 1.05 MW of regulation service for the IESO

Maximator, Wuppertal, Germany

Halcyon, New Zealand

• Containerized design & compact footprint

HyLYZER®-1000-30 system efficiency

HyLYZER®-1000-30 system efficiency

HySTAT®-15-10 HySTAT®-60-10 HySTAT®-100-10 HyLYZER® -500-30 HyLYZER® -1.000-30 HyLYZER® -5.000-30

Output pressure 10 barg (27 barg optional) 30 barg

Number of cell stacks 1 4 6 2 2 10

Hydrogen flow range 40-100% 10-100% 5-100% 1-100%

Tap water consumption <1.4 liters / Nm³ H2 <1.4 liters / Nm³ H2

Footprint (in containers) 1 x 20 ft 1 x 40 ft 1 x 40 ft 2 x 40 ft 2 x 40 ft 10 x 40 ft

Footprint utilities (optional) Incl. Incl. Incl. Incl. 1 x 20 ft 5 x 20 ft

STEP 2: replications 20 MW modular plants to build 40, 60,

STEP3: cell stack upscaling

• Product standardization and specialization