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Titan HMXT 062007
Titan HMXT 062007
Titan HMXT 062007
FOR THE
ES-M008 (1/03)
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
FOREWORD
The purpose of this manual is to provide the operator with a basic description of
the system and sufficient information to install, operate, and maintain the
equipment. This information is intended for use by qualified personnel. Use of
the information by other than qualified personnel may negate the warranty
extended by Teledyne Brown Engineering to the equipment Purchaser.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
NOTICE
LIMITED WARRANTY
To avoid unnecessary charges and delays in U. S. Customs, any and all returned
components of the Teledyne Energy Systems equipment should be handled as
follows:
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
Table of Contents
List of Figures
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List of Tables
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
1.1 Introduction
The inputs required to operate the system include high purity water and electrical
power for electrolysis, nitrogen for initial purging and cooling water for waste heat
removal. Using these inputs the system will supply hydrogen at 100 PSIG (7.0
kg/cm2). Oxygen, which is vented to the atmosphere, is produced at one-half of
the rate of hydrogen. The complete generator installation must include
provisions for supplying the feedwater, nitrogen, cooling water and electrical
power inputs, and plumbing for delivering the hydrogen product gas and separate
hydrogen and oxygen vents.
The system has been designed for safe and reliable operation. However, it is
important that preventive maintenance be scheduled and performed to maintain
system reliability. Routine maintenance includes component inspection and
adjustment, electrolyte checks and changes, and controller and instrumentation
calibration. In the event of component failure, the system instrumentation and
display provides information useful in determining the cause of system shutdown
and in locating the problem area.
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The system description that follows uses letter coded references to system
components. These references can be found as component labels on the piping
diagram and wiring diagram in appendix b of this manual. It is recommended
that the reader refer to these diagrams as an aid in understanding the HM
system. The physical location of each of the components is illustrated in the
exploded views in Section 6.
1.2 Electrolyte
2H2O 2H2 + O2
The rate of the reaction is directly proportional to the amount of current that flows
between electrodes.
The heart of the HM system is the electrolysis module. This is where the basic
process of separating H2O into its elemental components occurs. The HM
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electrolysis module seems deceivingly simple from the outside but the process
occurring inside is complex. The configuration requires close tolerances and
special equipment and tooling for disassembly and assembly.
The module arrangement requires electrolyte circulation through each cell. The
HM module is unique in that it only requires electrolyte circulation through the
anode (oxygen) half-cell side of each cell. This single irriguous design greatly
simplifies the electrolyte subsystem that supplies the module. The single
irriguous process is achieved by maintaining the production of hydrogen at a
slightly higher pressure than the oxygen production. The pressure difference
allows the matrix material to stay saturated with electrolyte while preventing the
cathode (hydrogen) half-cell side of each cell from flooding with electrolyte.
The electrolyte is continually circulated within a closed plumbing loop. The loop
includes a reservoir, filter, circulating pump, heat exchanger, flow switch,
temperature sensors, and the module itself. Circulation of the electrolyte through
the loop allows for a continuous supply of water for each cell of the module while
removing the waste heat of the process.
The oxygen produced in each cell is carried away with the electrolyte and
separated in the reservoir. The electrolyte is cooled in the heat exchanger and
solids are removed in the filter. The flow switch and temperature sensors provide
for electrolyte flow and temperature monitoring. The system will shut down as a
result of either low electrolyte flow or high electrolyte temperature.
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pump. The centrifugal design allows for continuous and long-life operation. The
use of a magnetic coupling between the pump motor and pump impeller provides
for leak-free operation by eliminating rotating seals at the pump shaft. Except for
bearing surfaces, all wetted parts of the pump are stainless steel. The impeller
bearing is a carbon and thermoplastic compound that rotates on a ceramic shaft.
Periodic inspection of these bearing surfaces is recommended as part of the
preventive maintenance schedule. Nominal KOH flow rate is between 8 and 11
GPM (30 and 42 LPM) depending on electrolysis module size and electrolyte
filter condition.
The reservoir is a stainless steel pressure vessel providing a storage volume for
KOH within the electrolyte plumbing loop. Tri-Clamp fittings at both the top and
bottom of the reservoir provide access to the level sensors and electrolyte filter in
the reservoir. The system is also filled with electrolyte through the top Tri-Clamp
fitting on the reservoir. The reservoir is located upstream of the KOH pump
supplying the necessary suction conditions for proper pump start-up and
operation. Oxygen and electrolyte returning from the electrolysis module are
separated within this volume. The make-up feedwater necessary to replenish the
water consumed by electrolysis is added to the reservoir.
The heat exchanger is a standard shell and tube configuration of stainless steel
construction. The electrolyte passes on the shell side and is cooled by water on
the tube side. The heat rejection rate is controlled to maintain a stable electrolyte
temperature into the electrolysis module by varying the cooling water flow rate.
The water flow rate is varied by the temperature-regulating valve (BV1).
The electrolyte filter is located in the bottom of the KOH reservoir. The filter
element is a stainless steel cartridge. The cartridge is capable of removing all
particles down to 100 microns in size. Keeping the electrolyte subsystem free of
particulate matter is especially important for the electrolysis module where solids
can deposit on charged surfaces and clog intricate flow passages. Cleaning or
replacing the cartridge at regular intervals is part of the routine maintenance
schedule.
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Two iron-Constantine thermocouples (TC1 and TC2) are used to sense the
electrolyte temperature within the flow loop. Thermocouple TC1 monitors the
KOH temperature leaving the electrolyte heat exchanger before entering the
module. This temperature is used in controlling the heat rejection rate by varying
the cooling water flow to the heat exchanger. The TC2 thermocouple monitors
the KOH temperature leaving the electrolysis module to prevent overheating. If
this temperature exceeds a preset maximum, the system is shut down.
The feedwater subsystem delivers the high purity water required for electrolysis
to the electrolyte in the KOH reservoir. The system includes a feedwater quality
monitor, a high-pressure pump, and switches and valves for control.
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1.5.1 Feedwater
The HM system consumes approximately three GPH (11 LPH) of water at the a
hydrogen production rate of 200 SLM. At other gas production rates, the
feedwater consumption rate is directly proportional.
Feedwater should conform to the American Society for Testing and Materials
(ASTM) specification D1193-72 for Type IV water. This water may be prepared
by distillation, ion exchange, reverse osmosis, or electrodialysis. The minimum
allowable electrical resistivity is 200k ohm-cm at 25 C (77 F). Using feedwater of
inferior quality may lead to the formation of deposits in the electrolysis module
which, if extreme, can cause module failure.
A water resistivity monitor is used to monitor feedwater quality. The flow probe
with an indicator light is located in a plastic tee just inside of the feedwater inlet
port. The probe has a fixed set point of 200K ohms-cm. When the resistivity is
above the set point the water purity is acceptable and the indicator light is green.
If the resistivity drops below the set point the light will turn red and the HM will
shutdown.
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Hydrogen from the electrolysis module and oxygen from the KOH reservoir,
leave as gases saturated with water vapor. Both gases flow through separate
water cooled condensers and moisture traps to remove much of the moisture.
The condensate from the oxygen condenser collects in a trap and returns directly
to the KOH reservoir. Condensate from the hydrogen condenser collects in the
hydrogen trap, but must flow through a matrix barrier in the bottom of the trap to
reach the KOH reservoir. The matrix barrier prevents hydrogen from entering the
electrolyte plumbing.
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1.6.3 Prepressurization
When the HM system initially starts without any residual hydrogen pressure, a
15-minute prepressurization period is required. The system is pressurized with
nitrogen to 20 PSIG (1.4 kg/cm2) and then stops for 15 minutes. During this
period, the higher pressure on the hydrogen side of the system pushes any
electrolyte that may have drained into the hydrogen half-cells of the module
through the cell matrix into the oxygen half-cells. This establishes the single
irriguous condition by which the module operates.
1.6.4 Standby
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gas demand (the delivery line from the system is closed off), the internal
pressure of the system will begin to increase above the nominal pressure. When
the pressure reaches reaches110 PSIG (7.7 kg/cm2) the excess hydrogen is
vented. If the pressure reaches 115 PSIG (8.1 kg/cm2) gas generation will stop
The system will remain at pressure, in a standby condition, ready to deliver
hydrogen on demand. When the internal pressure of the system drops to the
nominal system pressure, generation will begin again.
There are (3) back pressure regulators, which serve as the upper and lower limit
controls for the system pressure.
Back pressure regulator BPR3 functions as a relief valve for the system. It is set to
maintain a system pressure below 110 psig (7.7 kg/cm2). When the hydrogen
demand drops to zero or when the hydrogen demand is less than flow produced by
the idle current, the system pressure will rise to the set point of BPR3 and the
excess hydrogen produced will be vented through this regulator.
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The hydrogen and oxygen differential pressure regulators are designed to keep
the hydrogen pressure at 5 to 15 PSIG (0.4 to 1.1 kg/cm2) above the oxygen
pressure. The pressure difference is necessary to maintain the single irriguous
process in the electrolysis module. Both regulators are dome-loaded controllers
that are designed to maintain a specific back pressure in the system depending
on the reference gas pressure in the dome.
The oxygen regulator (DPR2) maintains the correct oxygen pressure using the
hydrogen pressure as a reference. During normal operation, the electrolysis
production rate is controlled to constantly maintain the nominal system hydrogen
pressure. The oxygen regulator references the hydrogen pressure and vents
excess oxygen to maintain the proper oxygen pressure.
The two differential pressure regulators are not adjustable and as such can not
be recalibrated. However, as part of the periodic maintenance schedule, it is
recommended that the regulators be disassembled, cleaned, and checked for
proper functioning.
Solenoid valve SV2 is the system vent valve for depressurizing the generator.
The vent valve releases hydrogen to the hydrogen vent. SV2 activates
automatically during several of the system shutdowns or it can be manually
actuated by depressing the pressure release button on the system control panel.
During venting, the valve pulses to provide a slow, controlled pressure release to
prevent violent pressure fluctuations and possible liquid loss.
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Conditioning of the product gases begins in the condensers. The hydrogen and
oxygen condensers are shell and tube configurations. The gas and vapor
mixture enters the shell side of the condenser and the chilled or cooling water
flows in the tube side. The cooling water requirement is approximately 1 GPM (4
LPM). The cooled gas leaves the shell at a temperature approaching the water
temperature and with the condensate exits from the shell into a trap. The volume
in the trap allows the gas and condensate to separate. The condensate from the
oxygen trap returns directly to the KOH reservoir. Condensate from the
hydrogen trap must first pass through the matrix barrier before draining to the
reservoir.
The bottom of the hydrogen condensate trap includes the matrix barrier. The
matrix barrier allows condensate from the hydrogen trap to return to the
electrolyte reservoir while preventing the flow of hydrogen to the reservoir. A
gas-impervious membrane made of the same matrix membrane used in the
electrolysis module provides the barrier. When saturated with condensate, the
porous matrix material will allow the condensate to be transferred through from
the higher pressure hydrogen side. Acting as a filter, the matrix material tends to
collect particulates that may interfere with the transfer of liquid. Replacement of
the matrix is recommended as part of the periodic maintenance schedule.
The HM-C1D2 generator includes valves for purging the gas plumbing with
nitrogen before starting from zero pressure. A forward pressure regulator (FPR1)
reduces the facility nitrogen pressure input to about 30 PSIG (2.1 kg/cm2) as
indicated by pressure gauge PG5. Two solenoid valves (SV6 and SV7) distribute
nitrogen to the hydrogen and oxygen side plumbing of the generator. Check
valves (CV4 and CV5) prevent the flow of the product gases back into the
nitrogen distribution plumbing when the generator is producing gas.
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Dryers are included for further conditioning of the hydrogen delivery gas. The
drying process uses a molecular sieve bead material that removes water vapor
from the gas by adsorption. The dryers are capable of drying the gas to an
atmospheric dew point of less than -73 C (-100 F), corresponding to a volumetric
concentration of less than one part per million. After the adsorption process, the
molecular sieve beads are automatically regenerated for reuse using a thermal
cycling procedure.
1.7.1 Dryers
The hydrogen dryers also contain a small amount of catalyst that will recombine
any minute amount of oxygen produced in the hydrogen. The recombined
product is water that is adsorbed in the dryer beads.
The dryer ball valve assembly (BV2) is a four-way ball valve operated by an
electrical actuator. The valve directs the hydrogen product gas through the
active dryer while also directing the hydrogen purge gas from the regenerating
dryer to the gas vent. Every six hours the actuator rotates the ball valve,
selecting the opposite dryers for product gas conditioning and dryer purge
venting.
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The dryer system includes a solenoid valve (SV5) for venting the dryers during a
system pressure release. Check valves (CV2 and CV3) are provided to separate
product gas from the purge gas following the drying process. A back pressure
regulator (BPR2) is used to prevent the loss of dryer pressure when the
hydrogen demand is greater than the maximum capacity of the HM system. A
relief valve (RV2) in the dryer delivery plumbing is used to provide a redundant
safeguard against dryer over-pressure. The relief valve is set to open at 130
PSIG (9.1 kg/cm2).
The cooling water, required to cool the electrolyte, and the chilled water, required
for condenser cooling, flow in separate plumbing circuits. This arrangement allows
the operator to use any economical means of cooling for the majority of the heat
load and only a small chilled water source for condenser cooling. Chilled water is
necessary for condenser cooling in order to provide maximum condenser
effectiveness and deliver specified product gas purity. Using the cooling water
source for condenser cooling is permissible if minimum moisture content in the
product gas is not necessary.
The cooling water system includes the heat exchanger and a temperature
regulating valve (BV1). An externally mounted strainer is recommended to protect
the control valve. The condenser cooling water system includes a solenoid valve
(SV3), the oxygen and hydrogen condensers, and a flow adjustment valve (MV3).
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Control of the chilled water to the condensers is accomplished using two valves. A
solenoid valve (SV3) provides the on and off control and a manual valve (MV3) is
used to adjust the flow. Solenoid valve SV3 opens and allows flow only when the
system is running. The chilled water flow is adjusted to approximately 1 GPM using
MV3.
Operator and system safety has been a primary consideration in the design of the
HM system. The system maintains only a small inventory of hydrogen during
operation. This limits any potential danger related to combustible gas storage. The
system is designed to be operated in a well-ventilated environment monitored by a
suitable hydrogen detection device. The system can easily be interlocked to the
hydrogen detection device or any other external alarm device.
The operational features of the system provide for automatic shutdown of the
system should operation deviate significantly from normal design conditions.
Temperatures, pressures, and liquid levels are continuously monitored throughout
the system to assure system operation within the established design conditions.
Latch-out alarms are used to interrupt gas generation should any of the parameters
which are monitored drift outside the allowable range. The cause for shutdown
must be corrected before system operation can continue.
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(FC1) and indicated by a flowmeter (FM1). A filter tank prevents water vapor from
entering the flow stream and a flame arrester prevents a reaction from traveling
back into the system.
There are 17 possible alarms indicated on the system control panel. The
conditions which cause the system to shut down include: high KOH temperature,
high or low reservoir KOH level, low KOH flow, high or low hydrogen pressure, high
or low oxygen pressure, low differential pressure, low prepressurization pressure,
high hydrogen in the oxygen, power supply failure, low feedwater resistivity, loss of
power, high or low ambient temperature, and any external alarm which may be
connected to the system. When one of these conditions occurs, the appropriate
alarm screen will be indicated on the control panel and the system will shut down.
System pressure will automatically be released when the generator shuts down on
low KOH flow, high KOH temperature, high hydrogen in oxygen, high hydrogen or
high oxygen pressure, low differential pressure, and high or low KOH level. All the
other shutdowns will not automatically activate the pressure release. The
automatic pressure release is a partial release to a preset set point. The default
factory set point is 0 PSIG. The full pressure release is initiated by a manual
pressure release from the generator control panel.
The electrical conversion and control subsystems link all the components required
to carry out the electrolysis process and operate the generator as a working
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system. The AC power input is converted into DC power for the electrolysis module
and also stepped down to 115 VAC for system process and control power. After
facility power has been applied to the HM system and the start/reset touch switch is
pressed, the electrical control system automatically directs all system functions.
The wiring diagrams in Appendix B show the numbered wire runs for the generator.
The power supply is contained in a cabinet separate from the hydrogen generator.
It is a current control DC power supply with an output of up to 300 amps DC. AC to
DC conversion is accomplished with a full wave, full control bridge rectifier. A
constant current regulator is used to maintain a steady-state DC output current
within plus or minus 1 percent of rated current. A voltmeter and ammeter are
located on the front panel to display the DC voltage and current applied to the
electrolysis module. The power supply also contains several auxiliary transformers
for supplying 115 AC for generator control power and pump power. Overload
protection devices on the power supply include fuses for the SCRs, temperature
switches for the transformer and SCRs, and several circuit breakers.
Operation of the power supply is controlled from the generator. Terminals for
stop/start, current control inhibit, and variable current control are available on the
power supply and wired to the generator. A separate main power switch, installed
in close proximity to the generator, actuates the power supply electrical power.
Current control inhibit of the DC power and proportional control of the current is
managed by the generator's programmable controller. Other connections from the
power supply to the generator include the 115 AC output for control power and
pump power, power supply alarm signal and the DC power output for electrolysis.
The HM system uses a programmable controller for managing the operation of the
system. The controller allows the system to operate with no need for an operator to
do manual switching, make adjustments, or continuously monitor the process. The
controller has been programmed to do the switching, make the adjustments, and
monitor the system to maintain efficient and safe operation. System process
conditions (temperature, pressure, and level) are input directly to the programmable
controller and output signals are directed to the process control devices (power
supply, valves, and pumps). All the process functions, such as feedwater addition,
cooling water flow, and electrolysis rate, are handled by the controller. Should
process conditions stray beyond the allowable bounds, the controller will stop gas
production and indicate the appropriate shutdown alarm.
available for input or output modules. Memory units are separate devices that plug
into the CPU. The HM-C1D2 uses a 8K word EEPROM unit for program and data
memory. Seven input and output modules are used in the generator.
The input and output wiring to the programmable controller is shown in the wiring
diagrams (Appendix B). The inputs are either 115 VAC on/off signals, 0-10 VDC
analog signals or direct thermocouple voltages. The on/off inputs include two KOH
level switches (feedwater add, high level), the KOH flow switch, two external alarms
(normally open, normally closed), and the power supply alarm. The three analog
inputs are from the hydrogen, oxygen, and dryer pressure transducers, with a fourth
analog input from the feedwater quality monitor. Four thermocouple inputs include
the temperatures for KOH control, module outlet, hydrogen in oxygen catalyst, and
internal ambient air.
Outputs from the programmable controller are either on/off, triac 115 VAC power;
on/off, transistor 5 VDC signals; or 0-10 VDC analog signals. On /off outputs
control the KOH pump, condenser water valve, feedwater pump, vent valves,
feedwater valve, temperature control valve, dryer selection and purge valves,
nitrogen purge valves, dryer heaters and power supply inhibit. An analog output
controls the power supply current.
The front of each on/off input and output module on the programmable controller
has small LED lights to indicate when an input signal is being powered and when
an output is on. The HM operator can use these indicators to monitor system
operation, and to check on these input and output functions. Much of the operating
sequence can be reviewed by observing these lights. A listing of the inputs and
outputs, and where they initiate or terminate, is shown below.
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software. Both the programmer and the PC software are available for purchase.
The HM control program is written as a general program that uses data from a
stored data file for specific pressure, temperature, and other process parameters.
In this way, the process operation can be varied by simply altering the system data
without rewriting the program. The system data can be revised while the system is
running and can be customized for a specific application.
The main circuit breaker to the power supply must be closed for the system to
receive electrical power. Turning on a switch, which must be installed near
HM-C1D2 generator location, will activate a contactor that energizes the circuits in
both the hydrogen generator and the power supply.
When the system is at zero pressure the start sequence will include a purge and
prepressurization period. Pressing the "Start/Reset" touch switch on the
"Generator Ready" screen will begin operation and the following will occur:
2. Solenoid valve SV7 opens to provide a nitrogen purge of the oxygen side
plumbing of the generator. An increase in the oxygen pressure should be
seen.
4. The hydrogen pressure in the system rises and the oxygen pressure
follows maintaining about a 3 to 10 PSIG (0.7 kg/cm2) pressure difference.
The hydrogen pressure continues to rise until it reaches 20 PSIG (1.4 kg/cm2). At
this pressure, SV6 will close and the system will begin a 15-minute
prepressurization period. During prepressurization, the 900 second time period (15
minutes) is seen counting down on the "Pre-pressurizing" screen. A 3 to 10 PSI
(0.7 kg/cm2) pressure difference should be maintained during this period.
Hydrogen pressure may drop as electrolyte is forced over to the oxygen side on the
system and the hydrogen volume expands. Solenoid valve SV6 will cycle on and
off to maintain the prepressure condition.
After prepressurization the electrolysis process can begin and the following will
occur:
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1. The KOH pump is energized and the pump begins to circulate KOH. The
flow switch (FS1) is actuated to indicate proper flow conditions.
3. The inhibit signal to the power supply actuates and power is applied to the
electrolysis module and gas generation begins.
As operation continues, the system pressure builds at the maximum production rate
allowed by the temperature of the electrolyte. Full 100 percent maximum current is
not available until the electrolyte temperature reaches the acceptable operating
temperature of 55 C.
System pressure increases until it reaches the first back pressure regulator (BPR1)
set point. Next, the dryers begin pressurizing. The dryer assembly is filled until the
system pressure reaches the second back pressure regulator (BPR2) set point.
Hydrogen is now available to be delivered. When the internal pressure reaches the
nominal system pressure of 100 PSIG (7.0 kg/cm2) the production rate is regulated
to meet the demand rate imposed by the user. If the demand for gas exceeds the
production capacity of the generator, the second back pressure regulator, BPR2,
will maintain the internal system pressure and the flow of gas is limited to the
maximum capacity of the generator. If there is no demand, the pressure will rise
until the set point of BPR3 is reached. If BPR3 is set above 115 PSIG (8.1 kg/cm2)
standby pressure is reached and gas generation stops. The "Generator Standby"
screen displays on the touch screen display showing the hydrogen and oxygen
pressures. When demand for hydrogen resumes and the generator pressure drops
to the nominal system pressure, gas generation starts again, the "Generator
Operating" screen redisplays on the touch screen and the production rate is
regulated to meet the demand. If the generator is turned off when at pressure, the
pressure will be retained and the system can restart without requiring
prepressurization.
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The dryer assembly begins its timing sequence after the dryers have been
pressurized. The dryers are not pressurized until the generator is running at
pressure and hydrogen can be delivered to the dryers through the generator back
pressure regulator (BPR1). When the pressure transducer (PT3) in the dryer
system senses adequate dryer pressure, the dryer sequence begins.
The dryer timing sequence begins with the on-line dryer delivering hydrogen at
pressure for 6 hours while the regenerating dryer is being heated for 90 minutes at
atmospheric pressure. After 90 minutes of heating, the regenerating dryer is
allowed to cool for four and half hours before it goes on line. During heating and
cooling a small portion of the dry product gas purges through the regenerating dryer
to the hydrogen vent. Thirty-six minutes before the regenerating dryer is to go on
line, the vent valve for the purge (SV4) is closed and the regenerating dryer begins
to build pressure. When the dryer ball valve switches to bring the regenerated
dryer on line, both dryers are at equal system operating pressure allowing for a
smooth transition between dryers. The dryers now switch on line and regenerating
duties for the remaining 6 hours for a complete 12 hour cycle.
Except for the 30 minute pressurizing period before dryer switch over, the actual
dryer sequence will restart wherever the 12 hour cycle was interrupted when the
system was last shutdown. This prevents one dryer from becoming saturated from
repeated, short time on-line duty. When a restart occurs within the 30 minute
pressurizing period before dryer switch over, the sequence starts at the beginning
of the period to allow time for both dryers to reach system operating pressure.
The dryer sequence status can be seen by pressing the "Dryer Sequence" touch
switch on the "Generator Operating" screen. The screen indicates
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A touch screen display panel and LED lights on the programmable controller allow
the operator to monitor the gas generating process. The status of various process
conditions can be displayed and operational sequences can be observed. Close
monitoring of the generator operation provides the operator with useful information
for determining overall system condition and detecting possible problems.
A touch screen panel mounted on the front door of the generator control box
displays process conditions. This display is programmed to communicate directly
with the programmable controller to provide operational data monitoring and
operator control input. The display is used to indicate production rate, feedwater
pump timing, purge status, prepressure timing, gas pressures, process
temperatures, elapsed time, system data set points, shutdown alarms and
troubleshooting summaries.
During normal operation, the "Generator Operating" screen displays the hydrogen
production rate from 17 to 100 percent of capacity as regulated by the controller.
The pressure release is manually activated from this screen by pressing the
"Pressure Release" touch switch. When the system is in the standby mode the
touch screen will display the "Generator Standby" screen. The water add graphic is
shown whenever the pump is running during the feedwater addition process. When
the system is started with no residual hydrogen pressure, the screen displays the
"Pre-pressurizing" screen while counting down the 900 second timing during the
prepressurization period. If a shutdown occurs, the display will flash and indicate
the specific shutdown condition.
The touch screen display can be prompted to indicate various process conditions.
Generator temperatures and pressures can be accessed from most touch screen
by pressing the "Temperature Display" or "Pressure Display" touch switch. The
pressure release is activated from most screens by pressing the "Pressure
Release" touch switch. The dryer sequence status and system information screens
can be accessed from the "Generator Ready" or "Generator Operating" screen by
using the appropriate touch switch. The system information screen displays the
elapsed time the generator has accumulated while generating gas and contains
touch switches which lead to more system related information or functions.
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LED lights on the AC input and relay output modules of the programmable
controller can be used to monitor system operation. During normal operation, Slot
1 input LEDs 4, 6 and 8 should be lit. The loss of any of these three LEDs will
indicate either a high KOH level, low flow or normally closed external alarm. LED 3
will light when the reservoir requires feedwater and go out when the level switch is
reset. All other Slot 1 LEDs light to indicate alarm inputs. When LED 9 is lit the
normally open external alarm is set. LED 12 will light during a power supply alarm.
The output LEDs simply light up to indicate which process component is being
actuated. Indications for Slot 2 outputs are listed below:
Output LED 0 lights when the KOH pump is ON and the condenser
water valve (SV3) is OPEN.
Output LED 1 lights when the feedwater pump is ON.
Output LED 2 lights when the generator vent valve (SV2) is OPEN
during a pressure release.
Output LED 3 lights when the feedwater valve (SV1) is OPEN.
Output LED 4 lights when the dryer vent valve (SV5) is OPEN during
pressure release.
Output LED 6 lights when the power supply is supplying current.
Output LED 7 lights when the system is in the run or standby mode.
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The HM-C1D2 hydrogen generator cabinet has been designed for operation in
Class I, Division 2, Group B locations as defined by the National Fire Protection
Association (NFPA), Document 70, which is the USA National Electrical Code
(NEC). The generator power supply is separate from the generator cabinet.
Unless otherwise specified, the power supply includes standard electrical
components and is intended for installation in an UNCLASSIFIED area.
NFPA 70 definitions are provided in article 500, and equipment requirements begin
in article 501. Teledyne interprets and follows these requirements based on a
knowledge of widely accepted practices, specialized training, and exposure to a
variety of installation situations involving hazardous materials.
Under the NFPA, Class I designates the hazardous material as a gas. Group B
pertains to the properties of hydrogen and similar materials regarding the
requirements of an explosion-containing enclosure. Division 2 defines the area as
one in which flammable material is handled in closed systems and is not normally
present in the environment. Flammable material is present only in the event of a
failure leading to leakage, and such failures are not simultaneous with activation of
exposed ignition sources. The presence of hazardous material is assumed to be
for a relatively short time.
The above is analogous to the IEC requirements as defined in IEC 79-0. The
classification is Group IIC, Zone 2, T6. Group II refers to the application as not
mine related. The C is similar to Group B under the NFPA, and Zone 2 is defined
nearly identically to Division 2. T6 refers to the ignition temperature of the material,
which is handled in the specific requirements of the NFPA. The design
philosophies of the NFPA and IEC are the same, as are most of the equipment
requirements. Teledyne follows the NFPA requirements in detail.
In Division 2 (zone 2) locations, the hazardous gas is not normally present in the
environment. The electrical equipment is specified such that a failure is required to
expose an ignition source. Any device that can provide ignition (arcing or hot
surfaces) under normal operation is required to have isolating or protective design
feature. Devices that are not ignition sources in normal operation are permitted in
Division 2 locations within standard electrical enclosures, and are usually not
required to be especially marked. Wiring in Division 2 locations may be in rigid
conduit or via one of several cable types, including tray cable.
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Holes in the generator frame base plates are provided for securing the frame with
either 5/16-inch (8 mm) or 3/8-inch (10 mm) anchor bolts. A floor drain should be
provided at the rear of the generator near the plumbing service panel. A minimum
access spacing of 4 feet (1.2 m) is required around all sides of the installation.
Enough access should be provided in the front of the installation to allow for the
removal and replacement of the electrolysis module.
The power supply and the generator are shipped in separate crates. The crates
may contain several smaller packages inside. After uncrating the generator and
power supply, inspect for damage to the external components and fittings. Check
that the pressure gauges, meters, control panel components, and plumbing
interface panel fittings have not been damaged during shipment. Open and inspect
all small packages. Report any damage to the shipper. Replace or repair
damaged items before attempting to operate the system.
The generator weighs about 1000 LB (450 kg). A floor walker or conventional lift
truck is recommended for moving the frame. Standard fork clearance has been
provided at the base of the frame. When moving, be certain the forks protrude all
the way under the frame structure so that the tips are visible at the rear.
All of the plumbing connections to the HM system are made at the plumbing
interface panel located at the rear of the generator. The electrical interconnections
from the power supply to the generator are routed through the rear of the generator
frame. Installation of these connections should conform to the local plumbing and
electrical codes that prevail. The input requirements for the facility connections are
summarized in Table 2-1.
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Nitrogen Purge
Pressure Range 50 to 350 PSIG (3.5 to 25 kg/cm2
Consumption 200 liters (7 ft3) Per start
2.3.1 Feedwater
The feedwater connection at the lower rear of the generator is a 3/8-inch Swagelok
bulkhead union. A feedwater filter assembly supplied with the generator is attached
directly to the feedwater connection. The feedwater source is connected to the
filter inlet. All feedwater tubing should be either stainless steel or polypropylene.
Steel, black iron, galvanized iron, or copper are not acceptable materials for
feedwater supply tubing.
The cooling water inlet and outlet connections are 3/4-inch NPT pipe fittings. A
strainer should be installed in the inlet line to protect the temperature regulator and
heat exchanger from dirt, scale, or foreign matter that could interfere with the
seating of the valve or clog the heat exchanger. It is also recommended that
isolation valves be fitted in the facility cooling water supply for maintenance
purposes.
The condensers use approximately one GPM (4 LPM) of water. Generally, the
cooling water source can be used for condenser cooling. However, chilled water
used for condenser cooling will provide maximum condenser effectiveness and
may be required, in special cases, to ensure specified gas purity.
The condenser cooling water inlet and outlet connections are 3/8-inch Swagelok
bulkhead unions.
Hydrogen and oxygen vent gas must be directed outside before being released to
the atmosphere. The vents should exhaust at least 10 feet (3 m) above the outside
ground level and should be positioned to provide protection of property and
personnel from contact with caustic mist or liquid (KOH) in the event of a system
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All vent lines should be stainless steel tubing. The hydrogen vent connection is a
1/4-inch Swagelok bulkhead union. The oxygen vent connection is a 3/8-inch
Swagelok bulkhead union. Vent line length should be minimized to prevent
excessive flow restriction during system shutdown. When using 1/4-inch tube
hydrogen vent and 3/8-inch tube oxygen vent, each vent line must be no longer
than 20 feet.
The hydrogen delivery connection on the upper rear panel is a 1/4-inch Swagelok
bulkhead union. The dryer delivery port is also a 1/4-inch Swagelok bulkhead
union connection. It is recommended that stainless steel tubing be used for all
product gas delivery lines.
A high in-rush capacity breaker or fused switch box for the appropriate sized
service is required for interfacing the generator power supply to the facility main
power service bus. For operator convenience and in conformance with local codes,
a switch box for the power supply contactor control switch is to be located in the
classified area near the generator. The contactor control switch is wired to power
supply terminals 1 and 2. The switch serves to turn all power to the generator on
and off.
Nitrogen gas is used as the pressure source for purging. The nitrogen should be of
a high purity industrial grade. A pressure regulator must be used to maintain the
pressure at the connection to the HM generator to between 50 to 350 PSIG (3.5 to
25 kg/cm2. The consumption of nitrogen during a startup is approximately 200
standard liters (7 ft3). The nitrogen gas connection is a 1/4-inch Swagelok bulkhead
union. It is recommended that stainless steel tubing be used to connect the
generator to the nitrogen gas source.
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The electrolysis power cables, control power wires and several control circuit wires
must be connected between the generator and the power supply to complete the
installation. Connect the power cables to the DC output terminals in the power
supply. MAKE ABSOLUTELY SURE THE DC POWER CABLES ARE
ATTACHED TO THE CORRECT POSITIVE (+) AND NEGATIVE (-) LUGS.
REVERSE POLARITY WOULD RESULT IN A VERY DANGEROUS SITUATION.
The generator must be grounded to the power supply using the ground strap
attached to the module negative endplate. Attach the free end of the ground strap
to one of the bolts securing the main transformer to the power supply cabinet.
The control power and control circuit wires are all contained in a multiconductor
cable and are to be attached to terminal board TB2 in the generator. This cable
must also be fed to the power supply and each wire connected to the control
terminal board in the power supply. Each wire is colored for its appropriate terminal
location. The correct terminal connections from TB2 to the power supply are listed
in Table 2-2
The HM has connections available for either normally open or normally closed
external alarm contacts. When connecting normally closed alarm contacts, first
remove the jumper between TB1 terminals 6 and 7. Connect the normally closed
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
contacts to TB1 terminals 6 and 7. Connect normally open alarm contacts to TB1
terminals 6 and 8.
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3.1 General
Successful operation requires that the generator be provided with the correct input
sources and output connections. These installation requirements are described in
Section 2. A preliminary check to verify that facility sources and connections are
proper should be made before every startup. Before the initial startup of a
generator, several additional checks are also required.
The startup and run operations of the HM generator are fully automatic. The
start\reset and pressure release touch switches on the touch screen display are the
only manual inputs required to operate the system. The process control and
sequencing that directs the generator start and run operation is described in
Section 1. Section 1 also describes the use of the input and output LEDs on the
programmable controller for monitoring system operation.
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The start mode allows the system to build up the internal pressure required for
hydrogen to be delivered at pressure. The start mode includes a period of
prepressurization to force any electrolyte collected in the hydrogen half-cells of the
module back into the oxygen side. The system goes through prepressurization
only when starting from a zero or near zero pressure condition. When the system
starts from a pressurized condition, prepressurization is skipped.
Facility power and feedwater must be available to the system for it to operate. The
main circuit breaker to the power supply must be closed for the system to receive
electrical power and the programmable controller must be in the run mode. Turning
on the power supply contactor control switch energizes the control circuits in both
the hydrogen generator and the power supply. To bring up the "Generator Ready"
screen, press the "Alarm Reset" touch switch on any shutdown screen that
displays. Press the "Start/Reset" touch switch and the system starts operating.
System operation begins with a 30 second nitrogen purge of the oxygen side
plumbing of the generator. Following the purge, the hydrogen side plumbing of the
generator is pressurized to establish prepressurization. On the "Generator
Purging" screen the pressure on the hydrogen side will begin to rise and the
oxygen pressure should follow maintaining about a 3 to 10 PSI pressure difference.
When the hydrogen pressure reaches 20 PSIG (1.4 kg/cm2) the 15-minute
prepressurization period begins as indicated by a 900 second countdown on the
"Pre-pressurizing" screen.
The generator has been programmed to control the electrolysis production rate in
relation to both system pressure and temperature. The maximum production rate
of the HM is limited until the electrolyte control temperature is within the operating
control range. The limitation is proportional to the difference in electrolysis module
inlet temperature and minimum electrolyte control temperature. The electrolysis
production rate is varied to constantly maintain the nominal system hydrogen
pressure. At hydrogen production demands of 17 to 100 percent of the maximum
capacity of the generator, the current to the electrolysis module is varied
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
proportionally so that the production rate matches the demand while maintaining
the nominal system pressure. At production demands of less than 17 percent, the
generator will match the demand by venting any excess hydrogen through BPR3. .
At production demands greater than 100 percent, the generator produces at the
maximum rate and the system pressure is allowed to drop to the set point of back
pressure regulator BPR2.
If the internal pressure of the system rises beyond the set point of BPR3, gas
generation will stop when the pressure reaches 115 PSIG (8.1 kg/cm2). LED 6 on
the Slot 2 controller module will go out. The system will remain at pressure, in a
standby condition, ready to deliver hydrogen on demand. The touch screen will
display a "Generator Standby" screen showing hydrogen and oxygen pressures.
When the internal pressure of the system drops to the nominal system pressure,
generation will begin again. Standby Mode allows uninterrupted operation of the
system in the event of a drifting or improperly set BPR3. Operating in this mode
for extended periods of time is not recommended.
During operation, the ammeter on the power supply should indicate a module
current of between 50 and 280 amps depending on the gas demand required by
the user. The corresponding module voltage will depend on the module size and
several operating factors. The module voltmeter should indicate within the range
listed below in.
As the system runs, the KOH temperature leaving the heat exchanger (TC1) is
maintained within the allowable KOH temperature control range. The proportional
control for the temperature regulator is initially programmed for a KOH temperature
range of 60 to 65 C. The temperature regulator valve, BV1, will step open and
close as required. Valve position and electrolyte temperature can be monitored on
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
the "Temperature Control Valve Position" screen, which is accessed from the
"System Information" screen on the display.
The feedwater subsystem will intermittently add water during normal operation.
Feedwater is periodically added to the reservoir when required as shown by the
lighting of Slot 1 input LED 3 and Slot 2 output LEDs 1 and 3. Feedwater addition
is indicated by a 30 second filling representation on the touch screen display. The
frequency of feedwater addition is dependent on the rate of consumption that will
vary according to the gas delivery demand and the rate of electrolysis. The
feedwater quality monitor should be indicating an acceptable green-light condition
for a minimum 200k ohm-cm resistivity.
The Hydrogen in oxygen temperature rise should be less then 20 C when the
generator is operating and delivering gas at or near full capacity. The temperature
rise will be significantly more when the system running at low demand. The
Hydrogen in oxygen sensor requires a constant 100 cc/min flow of oxygen.
At least one dryer pressure gauge should be at pressure during normal operation.
Dryer sequence status can be monitored by pressing the "Dryer Sequence" touch
switch on the "Generator Operating" screen. Except for the 30 minute pressurizing
period before dryer switch, output LED 4 on the Slot 6 module should be on
showing the dryer purge valve open. Depending on the sequence timing, LED 2 or
3 could be on indicating a dryer heater on.
A data or log book should be assigned to the generator for documenting daily
operating data. The recorded data provides useful information for routine
maintenance and general diagnostics of operating problems. The information
should be recorded on at least a 24-hour interval.
Generator operation can be stopped at any time by simply turning off the power
supply contactor control switch. The generator will remain at pressure when power
is removed. To relieve system pressure, power must be on and the pressure
release switch is pressed. The touch screen will display the "Pressure Release"
screen showing hydrogen and oxygen pressures. Slot 2 output LEDs 2 and 5 will
light to indicate opening of the vent valve.
3.8 Shutdowns
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
safe and reliable operation. There are 17 conditions that cause system shutdown
while running. Each shutdown condition is identified by a flashing shutdown screen
on the display. Although the shutdown condition is known, the actual cause may
require additional investigation. Pressing the "Troubleshooting Guide" touch screen
on the shutdown screen provides possible causes for the specific shutdown
condition. Also, Section 5 of this manual is provided as a troubleshooting guide for
determining the origin of a shutdown. The shutdown conditions are listed below in
Table 3-2 . with the origin and the set point for the alarm as initially programmed
when delivered.
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4.1 General
There are four general precautions that should be observed before working on the
system:
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1. Always turn the electrical power off at the facility breaker. The AC to DC
power supply circuit breaker may still be on line when the system is turned
off at the power supply contactor control switch. A defective electrical part
could allow DC power into the gas generator with the unit turned off.
3. Check that the system hydrogen and oxygen pressures are at zero.
Operational failures can occur which may trap gas in the system.
4.2 Electrolyte
The system requirement for frequency of electrolyte change depends mainly on the
quality of the feedwater supplied to the system. Acceptable electrolyte purity is
based on feedwater with a minimum allowable electrical resistivity of 200k ohm-cm
at 25 C (77 F). If electrolyte purity is not maintained, system fouling may result,
leading to possible electrolysis module damage. Checking the electrolyte specific
gravity periodically is recommended as a method of monitoring electrolyte
concentration. If the specific gravity is not within the allowable range, the
electrolyte should be changed or the concentration corrected.
The KOH used in the electrolyte solution must be the equivalent of a reagent grade
chemical. When mixed to a 25 weight percent solution, the electrolyte must have a
potassium carbonate (K2CO3) content of less than 0.6 weight percent and a total
iron and heavy metals content of less than 10 PPM. Generally, commercial or
industrial grades of KOH do not meet these requirements. Acceptable grades of
KOH are usually available as a 45 weight percent liquid or as 85 weight percent
pellets. The American Chemical Society (ACS) requirements for reagent
potassium hydroxide in the solid form are:
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
At 45 weight percent the above requirements would translate into the following:
Containers of a suitable material must be used for handling and storing KOH.
Aluminum, zinc, brass, bronze, copper, and glass are attacked by KOH and are not
suitable for use. Stainless steel or polypropylene containers are recommended.
Adequate eye protection and rubber or plastic gloves should be worn when
handling KOH. Sufficient ventilation should be available, particularly when handling
hot KOH, which can produce noxious fumes. A safety shower and an emergency
eye wash should be conveniently located in the event of a major KOH spill. It is
recommended that a 5 to 10 liter (1 to 3 gallons) container of saturated boric acid
solution be available for emergency use on skin irritations. The solubility of boric
acid at room temperature is approximately 50 grams (35 cc) per liter of water. The
boric acid solution may also be used as a wash to neutralize KOH on components
or parts that have been removed and must be handled.
The HM system requires a 25 weight percent aqueous solution of KOH for proper
operation. The weight percentage of the freshly mixed electrolyte may vary by two
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The required electrolyte volume for each of the various size HM systems is listed
below in Table 4-3. Also listed are the KOH and water quantities required to mix the
electrolyte volume from either the 45 wt % liquid or the 85 wt % solid. The 45 wt %
solution is diluted in a ratio of 1.16 liters of water per liter of 45 wt % KOH. The
solid KOH pellets are mixed in a ratio of 2.40 liters of water per kilogram of 85 wt %
KOH.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
Heat will be produced when diluting concentrated KOH, particularly when solid
KOH pellets are used. Combine the two ingredients slowly, adding the KOH to the
water to prevent a violent reaction. It is recommended to mix with all but a small
amount of the required water quantity and allow this solution to cool. After cooling,
the concentration can be adjusted with water while measuring the specific gravity
until the required 25 wt % is obtained.
The HM is filled with electrolyte through the KOH reservoir. The fill procedure
requires the proper 25 wt % solution of KOH.
1. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
level switch assembly to the top port of the reservoir. Carefully remove
the level switch assembly from the reservoir.
3. Fill the system with the specified volume of 25 wt % electrolyte (see Table
4-3).
4. Remove the funnel. Check that the gasket on the reservoir port is in the
proper position. If the gasket has been damaged it must be replaced.
5. Insert the level switch assembly into the reservoir. Attach and hand
tighten the hinged Tri-Clover clamp.
The specific gravity of the electrolyte should be periodically checked. Also at this
time all the electrolyte plumbing should be inspected for any evidence of leaks. A
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The procedure for checking the electrolyte specific gravity requires a container that
will hold a one-half liter sample and also accommodate the hydrometer. The
hydrometer must have a range of 1.100 to 1.300. A thermometer will be needed.
A funnel and a short drain line with a 3/8-inch Swagelok fitting are also required.
1. Release all gas pressure from the system before opening the reservoir.
2. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
level switch assembly to the top port of the reservoir. Carefully remove
the level switch assembly from the reservoir.
3. Attach the drain line to the KOH drain port located in the lower rear of the
unit.
5. Measure and record the specific gravity and temperature of the electrolyte
sample.
7. Remove the funnel. Check that the gasket on the reservoir port is in the
proper position. If the gasket has been damaged it must be replaced.
8. Insert the level switch assembly into the reservoir. Attach and hand
tighten the hinged Tri-Clover clamp.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
Ratios and Quantities for Producing 25% Solution provides a guide for adjusting
an out of tolerance solution. Mixing ratios and quantities to produce 1 liter are listed
for mixing a 25% solution by either diluting a concentrated solution or increasing the
concentration of a weak solution.
Table 4-4 Mixing Ratios and Quantities for Producing 25% Solution
Diluting Concentrated Solution with Water
To produce 1 liter
of solution use:
Existing Mixing Ratio cc cc
KOH % cc Water/cc Existing Existing Water
26 0.050 954 48
27 0.101 911 92
28 0.153 871 133
29 0.205 834 171
30 0.259 800 207
31 0.313 767 240
32 0.368 737 271
33 0.424 710 301
34 0.480 683 328
35 0.537 659 354
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
Using a drain line with a 3/8 Swagelok fitting, drain the system as follows:
1. Attach the drain line to the KOH drain port located in the lower rear of the
unit.
2. Using the drain valve (MV1), slowly begin draining the electrolyte.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
level switch assembly to the top port of the reservoir. Carefully remove
the level switch assembly from the reservoir.
5. Open the drain valve to allow the electrolyte to start draining again.
6. After completely draining the system close the drain valve and remove the
drain line.
1. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
level switch assembly to the top port of the reservoir. Carefully remove
the level switch assembly from the reservoir.
2. Attach the drain line to the KOH drain port located in the lower rear of the
unit.
3. Remove the cap from the 1/4 inch Swagelok cross located near the top of
the hydrogen condensate trap. Attach the pressure source to the cross.
Slowly pressurize the hydrogen side of the system to 10 PSIG (0.7
kg/cm2).
5. After completely draining the system, close the drain valve and remove
the drain line. Release the pressure from the pressure source, remove
the pressure source, and replace the Swagelok cap.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The power cable connections to the module end plates should be removed and
inspected. Clean the contact surface of the end plates and the connector lugs with
sandpaper or similar material to remove any oxide layer. Examine the area where
the lug is attached to cable for evidence of corrosion. If required, clean these
surfaces also. Reinstall the cable lugs to the end plates and tighten the set screws
if required.
The electrical resistance between each tie rod and the end plate should be checked
to be sure the tie rod insulation is adequate. A megohmmeter operating at 250V
minimum (1000 V maximum) is required to make this measurement. Attach one
lead of the megohmmeter to either end plate. Remove the protective cap on each
tie rod end and measure the resistance. The electrical resistance of each tie rod to
the module end plate should be greater than 50 megohms. If a tie rod fails this
requirement, the insulating washers must be removed and cleaned or replaced.
Only remove and replace washers from one tie rod at a time. Retorque the tie
rod to 400 inch pounds (45 Nm) before loosening another. If one or more tie rods
are loosened for servicing, the compression of the module should be checked using
the module retorquing procedure.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
While the system is operating, impurities from the feedwater may begin to deposit
in the KOH ports of the negative end plate. If the deposits become large, they may
dislodge into the inlet manifold of the module. Periodically the inside of the module
should be inspected for accumulation of these deposits and cleaned out if
necessary.
The system must first be drained of KOH. After draining, be sure the power has
been turned off at the facility breaker. Remove the KOH inlet and outlet piping to
the electrolysis module. The inlet pipe runs from the heat exchanger to the
negative end plate of the module. The outlet pipe runs from the module endplate to
the KOH reservoir. Remove the tube from the hydrogen outlet fitting.
Using a flashlight, inspect the module inlet and outlet manifolds and the end plate
ports. If a deposit is present at the ports, clean this area using a soft absorbent
cloth over a rubber-gloved finger or a soft round bristled brush. Avoid pushing the
material into the module manifold. Backflush the module with distilled or deionized
water to remove any deposits accumulated in the manifolds. Use a low pressure
water source, flowing the water into the outlet fitting of the module and catching the
water at the inlet fitting. To improve draining, remove the bolts securing the
insulators to the module and slightly raise the positive endplate.
Inspect the O-ring in the each of the fittings before reinstalling the KOH piping.
Replace the O-ring if it is cut or deformed. After reinstalling the KOH piping,
thoroughly clean and dry the module as outlined in the external inspection
procedure.
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The porous matrix material in the matrix barrier tends to collect particulates that will
eventually interfere with the transfer of liquid. It is recommended that the matrix be
periodically replaced. The matrix should also be replaced if it is suspected of being
the cause of a hydrogen to oxygen cross leak.The complete hydrogen condensate
trap/matrix barrier assembly is remove from the system for matrix barrier
replacement. Disconnect the 3/8-inch Swagelok fitting at the gas outlet near the
top the trap. Disconnect the CPV fitting on the top of the assembly and the CPV
tee near the bottom under the lower flange and remove the assembly (see Figure
4-1). Remove the six flange bolts and separate the assembly. Remove and
discard the matrix material. Wash the two nickel plaque discs with distilled or
deionized water. Plaque that is cracked or damaed should be replaced.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The matrix barrier is reassembled dry using new asbestos matrix material. Care
should be taken when handling the dry asbestos matrix to avoid inhaling asbestos
fibers. A respirator should be worn during and hands washed immediately after
assembly of the matrix barrier. The matrix material must be wetted before it is
reinstalled in the system. The matrix barrier will function properly only when it is
wet. Before reinstalling the matrix barrier assembly, add about 50 cc of feedwater
to the fitting on top of the assembly.
The cross leak check is a diagnostic procedure that is used to determine the extent
and location of a suspected hydrogen to oxygen cross leak. A cross leak can occur
in the electrolysis module or the matrix barrier. The procedure requires a supply of
inert gas, such as nitrogen, as a low pressure source.
2. Temporarily remove the drain tube that connects the bottom of the oxygen
condensate trap to the CPV tee located below the matrix barrier and the
tube running from the CPV tee to the reservoir. Remove the CPV from the
bottom of the matrix barrier.
3. Two plastic tubes with CPV connectors have been supplied with the
generator. Connect one plastic tube to the fitting at the bottom of the
matrix barrier and the other plastic tube to the CPV fitting in the side of the
reservoir. Place the free ends of both plastic tubes in a container of water
so that gas flow can be observed. Plug the open CPV fitting at the bottom
of the oxygen condensate trap.
4. Assure that the drain valve MV1 is closed and that the top port on the
KOH reservoir is closed.
5. Remove the cap from the 1/4-inch Swagelok cross located near the top of
the hydrogen condensate trap. Connect a gas pressure source to the
cross. Slowly pressurize the hydrogen side of the system until the
hydrogen pressure gauge indicates a pressure of 5 to 10 PSIG (0.4 to 0.7
kg/cm2).
6. If gas begins to bubble from the tube leading to the bottom of the matrix
barrier, then the matrix barrier is leaking and should be replaced.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
7. Allow 10 minutes for gas from a module leak to bubble from the tube
leading to the KOH reservoir. If gas flow is observed, measure the flow
rate to determine the extent of the leak. This measurement can be made
by simply measuring the water displaced in an inverted graduate over a
specific time interval.
8. After checking for leaks, remove the plastic tubes, reconnect the 3/8 inch
tubes, replace the cap on the Swagelok cross, and refill the system with
electrolyte.
The maximum allowable cross leakage for each of the various size modules is
listed below in Table 4-5 Maximum Allowable Module Cross Leakage. If the
leakage rate measured in the cross leak check exceeds the maximum, the module
must be replaced.
2. Place a plastic basin or tub under the bottom of the reservoir and the KOH
pump head large enough to fit the piping run between the two. Loosen
and remove the large nut on the CPV fitting on the inlet to the KOH pump.
Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
KOH filter assembly to the bottom port of the reservoir. Carefully remove
the filter assembly from the reservoir.
3. Refer to the parts diagram ,Figure 4-2 KOH Filter. Remove the nut,
washers, and center locating retainer from the center shaft. Remove and
clean or discard the filter element.
4. Install a new or cleaned filter element with new EPT gaskets. Install the
center retainer, washers, and nut. Tighten the nut.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
5. Inspect the gasket for the bottom reservoir fitting and the O-ring for the
pump inlet fitting. If the gasket or O-ring has been damaged it must be
replaced.
6. Reposition the filter assembly into the reservoir. Position the pump inlet
fitting and tighten the CPV fitting nut. Attach and hand tighten the hinged
Tri-Clover clamp.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The feedwater filter is located outside of the gas generator cabinet on the plumbing
service panel. Figure 4-3 shows all the parts of the filter.
1. After turning off the feedwater supply, drain the filter by opening the drain
valve at the bottom of the filter bowl.
2. Remove the hex nut supporting the bowl and remove the bowl.
3. Slide the element retainer off the tie rod. Remove and discard the filter
element.
4. Place a new filter element over the centering boss in the head of the
housing and slide the element retainer onto the tie rod.
5. Place the bowl and the head O-ring against the filter head and thread the
hex nut with O-ring onto the tie rod. Finger tighten the hex nut
approximately one turn after the O-rings have begun to compress.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-19
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
It is recommended that the KOH pump be periodically inspected for wear. The
procedure requires complete disassembly of the pump and is most conveniently
scheduled during the electrolyte change. Pump inspection may also be necessary
if operational problems within the pump are suspected.
The procedure for removing and disassembling the KOH pump for inspection is
listed below. Refer to the parts diagram, Figure 4-4.
4. Remove the four screws holding the connecting bracket to the pump
motor. Separate the connecting bracket from the pump motor and remove
the pump housing with the connecting bracket from the generator.
Considerable resistance will be felt when separating the magnetic
coupling between the drive and driven magnets.
5. Place the connecting bracket and pump head assembly on a flat surface,
laying the motor connecting flange of the connecting bracket down flat on
the surface.
6. Remove the 6 screws from the pump head and carefully remove the pump
head. The bonded spindle assembly is attached to the head and is easily
broken.
7. The bonded spindle assembly is connected to the pump head using a left-
hand threaded insert. Rotate the hex head on the insert clockwise to
remove the spindle.
The pump is now apart and can be inspected for excessive wear. Check the
impeller bushing for wear on the thrust bearing surface and within the internal
diameter of the bushing. Check that the bond on the spindle assembly is tight.
Replace any broken or excessively worn parts.
The assembly and reinstallation procedure for the KOH pump is the reverse of the
steps listed above. The spindle assembly can be tightened into the pump head by
using a 3/4-inch (19 mm) socket slipped over the spindle and tightening by hand.
Inspect the rubber O-ring for the pump housing before reinstalling and replace if
defective. Also inspect the O-ring seals in the inlet and outlet CPV fittings and
replace if either is cut or deformed. Tighten the 6 pump head screws to 50 inch
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
pounds (6 Nm). Be careful when reassembling the connecting bracket to the pump
motor. The motor and connecting bracket may bang together from the force of the
magnetic coupling. Tighten the 4 bracket connection screws to 75 inch pounds (8.5
Nm).
4-21
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
There are several different valves and regulators used in the HM system. Regularly
scheduled inspection and maintenance is recommended only for the differential
pressure regulators. Procedures for the remaining valves and regulators are used
when required as a result of operational problems or component failure.
Access to the upper interior of the HM generator can be achieved by simply lifting
off the top. All the gas handling components are positioned in the top of the
frame and are accessible with the top removed. Many of the components are
closely arranged in a preassembled hydrogen valve assembly, shown in
assemble . It is easier to get access to an individual component within the
assembly by first removing the entire assemble and then removing the
component.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-23
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The feedwater add valve (SV1) and vent valve (SV2), as well as the dryer purge
and vent valves (SV4, SV5) and nitrogen purge valves (SV6, SV7) are all two-way
stainless steel solenoid valves. They are normally closed valves (without power to
the coil they are closed). There is also one brass solenoid valve in the system.
Valve SV3 is the shut off valve for the condenser cooling water. It uses a
diaphragm arrangement to help seal the valve closed. Replacement coils are
available for all the solenoid valves. The valve coil is easily replaced with the valve
remaining in line. A repair kit is available to rebuild each solenoid valve. The
internal core, gaskets, and springs can be replaced to restore a defective valve to
working condition.
Both the stainless steel and brass solenoid valves are similar in construction and in
the procedure for repair. FIGURE 4-6 and FIGURE 4-7 show the parts and
assembly sequence for these valves. To replace a coil, first remove the top on the
junction box and disconnect the electrical connections. Remove the retaining clip
and lift off the complete solenoid assembly. Replace the solenoid assembly on the
valve, rewire to the electrical connections, and replace the top on the junction box.
4-24
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-25
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
4-26
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
Inspecting and rebuilding a solenoid valve requires removing the valve from the
system. Remove the top on the junction box and disconnect the electrical
connections. Remove the retaining clip and lift off the complete solenoid assembly.
Loosen the Swagelok fittings and remove the valve from its location. Loosen the
solenoid base using a wrench on the hex shaped shoulder and remove the
subassembly. The internal parts of the valve can now be inspected. Valve SV3
also includes a valve bonnet held down by four screws. To inspect the diaphragm
subassembly, remove the screws and the bonnet.
Clean and inspect all the internal parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits), clean the valve body and the
parts with a boric acid solution followed by distilled or deionized water. If any part is
found defective, it is recommended to replace all the parts that are available in the
spare parts kit.
Prior to reinstalling the valve, check for operation and leakage. Connect live
electrical power to the terminals in the junction box and listen for a metallic click that
indicates that the solenoid is operating. Apply a 100 PSIG (7.0 kg/cm2) gas source
at the valve inlet port and check for leakage with the valve closed. The valve will
leak if an internal part is defective or the parts have not been reassembled in the
correct sequence.
The hydrogen and oxygen differential pressure regulators (DPR1 and DPR2) are
the critical components for assuring a pressure difference between the hydrogen
and oxygen sides of the system. These two regulators should be inspected if the
differential pressure drifts outside the acceptable 5 to 15 PSIG (0.4 to 1.1 kg/cm2)
range. The parts and assembly sequence for the regulators are shown in Figure
4-8 and Figure 4-9. Regulator rebuild kits, which include the diaphragms, O-rings,
and springs, are available for both regulators. The regulators must be removed
from the system for inspection and rebuilding. Loosen all the Swagelok
connections to the fittings on the regulator and remove the regulator with the fittings
attached. Remove the 6 screws attaching the regulator bonnet to the regulator
body. The internal parts of the regulator can now be inspected. Clean and inspect
all the internal parts. If there is any evidence of KOH or potassium carbonate (white
crystalline deposits), clean the regulator body and all the parts with a boric acid
solution followed by distilled or deionized water. If the O-ring seat or a diaphragm is
torn or deformed, the part should be replaced. If it is suspected that the regulator
has not been performing properly, then all the parts available in the regulator
rebuilding kit should be replaced. Carefully reassemble all parts in their proper
sequence. It is important that the correct alignment of all the internal parts be
maintained during assembly.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-29
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
After reinstalling the regulators in the system, check for proper operation and
leakage during system operation. As the system begins to generate gas and
system pressure rises, the pressure differential should remain between 5 and 15
PSIG (0.4 to 1.1 kg/cm2). After the system is in the run mode, check each regulator
for external leaks using a liquid leak detector solution or soap solution.
The back pressure regulators BPR1, BPR2 and BPR3 are identical. A spare parts
kit is available for rebuilding the back pressure regulators. If a regulator is
defective, it should be removed for repair or replacement.
The procedure for removal and repair is listed below. Refer to the parts diagram,
Figure 4-10.
3. Loosen the bonnet ring using a 2-inch wrench. Remove the bonnet ring.
The internal parts of the regulator can now be inspected.
5. The stem O-ring is removed from the diaphragm button after removing the
retaining ring.
6. The valve seat is removed by unthreading the seat retainer from the
regulator body using a large screwdriver.
7. Clean and inspect all the internal parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits), clean the regulator body
and all the parts with a boric acid solution followed by distilled or deionized
water.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-31
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The assembly and reinstallation procedure for the back pressure regulator is the
reverse of the steps listed above. The valve seat is installed with its chamfered
side towards the diaphragm assembly. The threaded bonnet ring should be
tightened to 50-55 foot-pounds (68 - 75 Nm).
Adjustment of the back pressure regulators is made with the system running at
operating temperature. Turning the knob clockwise raises the setpoint and counter-
clockwise lowers the set point. BPR2 must be fully open before adjusting BPR1.
The check valve (CV1) and relief valve (RV1) in the generator are both the same
type of spring loaded poppet valve. There is no routine maintenance for the check
valve. If a problem is suspected with the check valve, it must be replaced. The
relief valve in the generator (RV1) and also in the dryer system (RV2) are simply
adjustable versions of the check valve.
The relief valve should be periodically checked to assure that the 130 PSIG (9.1
kg/cm2) set point is maintained. The valve is best checked by removing it from the
system. After removing the valve slowly apply a pressurized gas source to the inlet
fitting on the valve and check for gas flow through the valve at 130 PSIG (9.1
kg/cm2). If flow is not evident at 130 PSIG (9.1 kg/cm2) or the valve opens at a
lower pressure, then the valve must be readjusted.
1. Refer to Figure 4-11. Insert a 5/32-inch hex key wrench into the locking
screw at the valve outlet and loosen the locking screw.
2. Turn the locking screw until the hex key wrench slides through into the
adjusting screw.
3. Turn both screws until the 130 PSIG (9.1 kg/cm2) set point is reached.
Turning clockwise increases the set point.
4. Retract the hex key wrench into only the locking screw and lock it against
the adjusting screw.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-33
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The flow controller (FC1) is set to maintain a flow of 100 cc/min to the hydrogen in
Oxygen probe. To adjust the set point, first unscrew and remove the cover over the
metering valve. With the system running, use a 5/64-inch hex key wrench and
adjust the valve setting so that the flow rate is 100 cc/min as measured by the
flowmeter (FM1).
All the parts within the controller are shown in Figure 4-12. To inspect the internal
parts, use a large wrench to unscrew and remove the bonnet ring. If there is any
evidence of KOH or potassium carbonate (white crystalline deposits), clean the
controller body and all the parts with a boric acid solution followed by distilled or
deionized water. If any part is found defective, it should be replaced. The metering
valve is replaced as a complete unit.
The assembly and reinstallation procedure for the flow controller is the reverse of
the above procedure.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
4-35
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The molecular sieve beads in the filter tank should be periodically replaced. The
beads used in the filter tank should be deactivated beads that are saturated to
ambient moisture conditions. Deactivated beads may be prepared from dry beads
by first wetting the beads with clean water. This must be done with caution as dry
beads become very hot when wetted. Next, spread the beads out on a clean
surface and simply allow them to dry to ambient conditions.
1. Loosen the Swagelok connections on the end fittings and remove the tank
from the system.
2. Remove the threaded fittings from both ends of the tank. Clean the
screen strainer in each of the fittings.
3. Empty the molecular sieve beads out of the filter tank. Wash the tank out
using clean water and allow it to dry.
4. Replace one of the end fittings, applying two turns of Teflon pipe sealant
tape to the threads before installing.
5. Fill the tank with molecular sieve beads leaving enough space for the
screen strainer on the second end fitting.
6. Replace the second fitting using Teflon tape. Reinstall the filter tank in the
system.
A simple check of probe sensitivity should be made periodically. With the system
running, remove the cover over the metering value on the flow controller (FC1).
Using the hex key wrench, increase the oxygen flow rate through the controller and
monitor the temperature reading on the pyrometer. The temperature should begin
to rise, verifying that the catalyzed probe is still active. If there is no response, the
probe must be replaced. Readjust the flow controller so that the flow rate is 100
cc/min as measured by the flowmeter (FM1). Replace the metering valve cover.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
The system pressure test is a diagnostic procedure that is used to verify system
integrity before the system is started. The extent and location of a suspected gas
leak on an operating system can be determined by simply turning the power off,
observing the pressure gauges, and using a liquid leak detector or soap solution to
locate the leak. The procedure listed below requires a source of pressurized inert
gas such as nitrogen.
1. Turn off system power and drain the system of all electrolyte.
2. Remove the cap from the 3/8-inch Swagelok cross located next to the
oxygen differential pressure regulator and use it to cap the oxygen vent
port.
3. Remove the cap from the 1/4-inch Swagelok cross located near the top of
the hydrogen condensate trap. Use the cap to seal the 1/4-inch Swagelok
hydrogen dryer delivery port.
4. Close the flow controller (FC1) by removing the metering valve cover and
turning the valve in using a 5/64-inch hex key wrench.
5. Connect the pressure source to both the cross at the hydrogen trap and
the cross at the oxygen differential pressure regulator.
6. Slowly pressurize the generator to 125 PSIG (8.8 kg/cm2) verifying that the
hydrogen and oxygen pressure gauges rise together.
7. Using a 3/4 inch (19 mm) open end wrench, periodically turn the hex on
the dryer ball actuator back and forth to quickly pressurize both dryers.
8. Isolate the pressure source from the system for 15 minutes. At 125 PSIG
(8.8 kg/cm2) the system pressure should not decay more than 5 PSI (0.4
kg/cm2) in 15 minutes.
9. If the pressure does not hold, check for leaks using a liquid leak detector
solution or soap solution and repair. Check that gas is not leaking out the
hydrogen vent.
10. Turn the system power on and press the "Pressure Release" touch switch
to vent the test gas. Replace the two Swagelok caps.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The accuracy of the pressure transducer calibration must be checked using a very
accurately calibrated pressure gauge. The gas gauges on the control panel give an
approximate indication of the system pressures and can be used to determine a
failed pressure transducer. However, these gauges should not be relied on to
check the pressure transducer calibration. The calibration procedure requires a
calibrated pressure gauge and a source of pressurized inert gas such as nitrogen.
2. Remove the pressure transducer from the Swagelok tee in the generator
and hook it up to the pressure source with the calibrated gauge.
3. Pressurize the transducer. Press the "Pressure Display" touch switch and
compare the calibration gauge reading with the pressure reading on the
touch screen display.
Check the transducer calibration at both low and high (up to 150 PSIG) pressures.
The pressure display reading should be within two PSIG of the calibration gauge
reading. A pressure transducer that fails the calibration check must be replaced.
The KOH flow switch (FS1) is located in the KOH plumbing between the heat
exchanger and the electrolysis module. The flow switch is a vane-operated device
that is actuated by the flow of the KOH electrolyte. If the switch is suspected of
being defective, it should be removed to check that the vane is free to actuate.
2. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
flow switch assembly to the tee in the KOH plumbing.
3. Remove the flow switch and check that the vane is free to move.
4. Check that Slot 1 input LED 6 lights when the switch is manually actuated.
If the vane is free to move but the switch does not activate, the internal
switch assembly can be replaced.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
A parts diagram of the flow switch is shown in Figure 4-13. Note that the
alignment of the switch within the flow switch housing is critical.
6. Loosen the set screw using an Allen head wrench and gently pull on the
wiring to remove the switch assembly.
7. After replacing the switch, reinstall the switch assembly to the original
orientation and tighten the set screw.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
Check the flow switch actuation before replacing the flow switch in the system.
Check that the gasket on the Tri-Clover fitting is in the proper position. If the gasket
has been damaged it must be replaced. Insert the flow switch assembly into the
tee in the proper direction. An arrow engraved on the body of the flow switch
housing must be oriented in the direction of the electrolyte flow (towards the
module). Attach and hand tighten the hinged Tri-Clover clamp.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
The feed water pump should not be allowed to run dry for more than 90 seconds or
internal damage may occur. Priming the feed water pump assures that the pump is
supplied with water to prevent damage from running dry. This procedure is also
used to purge the feed water plumbing of inferior water after a low feed water
resistivity shutdown alarm. The cause of the inferior water must be corrected or the
shutdown will be repeated.
Priming the feed water pump and feed water purging proceeds as follows:
1. Attach a drain line to the feed water drain port located in the lower rear of
the unit.
3. Press and hold the "Manual Feed water Pump Switch" touch button on the
"System Information" screen to manually run the pump. When water flows
out of the drain port the pump has been primed. If the system is shutdown
on low feed water resistivity, allow the pump to run until the light on the
water quality probe changes from red to green. Do not allow the pump to
run dry.
A feed water probe that is suspected of not indicating correctly should be removed
and checked. Turn off the feed water supply at the generator and open the feed
water drain port to drain the feed water plumbing. Remove the probe by
unthreading it out of the plastic tee. A dry probe in air should indicate green. If not
the probe should be replaced.
To check that the probe responds, dip the end of the probe containing the two
exposed metal wires (end opposite the indicator light) into a container of tap water.
The indicator light should turn red. If not the probe should be replaced. Keep the
red light lit until Slot 1 input LED 10 comes on to check the feed water quality
monitor. This may take as long as 10 seconds because of a time delay in the
monitor relay.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
Proper dryer regeneration requires an accurately controlled purge rate. The orifice
and check valves must be periodically removed and cleaned to assure the correct
purge rate is maintained. Components for controlling the dryer purge are all
arranged in a preassembled dryer purge control assembly, shown in Figure 4-14.
Removing the entire assembly provides the easiest access to the individual
components within the assembly.
Periodic replacement of the molecular sieve beads in the dryers is not necessary.
However, if misused, the beads can become saturated to a state in which complete
regeneration of a dryer is not possible. The dryers should then be repacked with
fresh molecular sieve. Monitoring product gas humidity will give the operator a
direct indication of the condition of the dryer beads. If the operator is not measuring
product gas humidity and is still concerned about maintaining minimum moisture
content, then periodic molecular sieve replacement is recommended.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
The dryer orifice is located in the dryer purge control assembly (Figure 4-15)
adjacent to the dryers. The orifice connects the output plumbing of the two dryers
just below the dryer filters. To service the orifice, first remove the dryer purge
control assembly. The orifice is in the union fitting connecting the two tees at the
filter outlets. Remove and inspect the orifice fitting. Clean the orifice and the
interconnecting tubing. After cleaning, reassemble all the parts of the assembly
and reinstall in the system.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The check valves which follow the dryer filters (CV2 and CV3) should be serviced
once a year or sooner if a problem is suspected. The yearly service interval allows
the dryer check valves to be cleaned and repaired at the same time the dryer filters
are replaced. After removing the dryer purge control assembly (Figure 4-14), the
valves can be removed for service. Two special tools, an adjusting tool and a nut
driver, are supplied for servicing the check valves. Figure 4-15 shows all the parts
of the check valve.
The cleaning and repair procedure for all of the check valves is as follows:
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
1. Fit the adjusting tool over the spring guide (3-fingered spider) in the outlet
end of the valve. Place the nut driver inside the adjusting tool, loosen, and
remove the lock nut.
2. Insert a screwdriver into the slot in the head of the poppet and use the
adjusting tool to remove the spring guide.
4. Clean and inspect all the parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits) clean all the parts with a
boric acid solution followed by distilled or deionized water.
5. The "Q" ring under the poppet head and the valve spring are available as
replacement parts and should be replaced.
The assembly of the check valve is the reverse of the steps listed above. One side
of the spring guide has a recess on each finger of the spider to center the spring.
The threaded stem of the poppet should be exposed about 1/16 of an inch (1.6
mm) after the lock nut is in place. This will result in a cracking pressure of about 1
PSIG (0.07 kg/cm2).
The dryers must be removed from the system to change the molecular sieve beads
and de-oxo catalyst pellets. Before removing, ensure that the internal pressures
are reduced to atmospheric and the dryers are cool. Remove the orifice/filter
assembly from the Swagelok tees near the top of the dryers. Disconnect the tees
from the dryers and loosen the Swagelok fittings at the bottom inlet port of the
dryers. Remove the protective cover over the heater terminals and disconnect the
electrical leads. Loosen the clamps securing the dryers to the frame assembly and
lift the dryers out of the system.
1. Remove the one-inch fill port on the top of the dryer, invert the dryer, and
empty the contents.
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ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
2. Wash the interior of the dryer with clean water to remove dust and broken
beads. Allow the interior to dry before refilling.
3. Using an ohmmeter, check the continuity of the dryer heater. Also, check
that there are no electrical shorts between the heater and the dryer vessel.
4. Pour 575 ml of molecular sieve into the dryer. The first layer of molecular
sieve should be poured in slowly with the dryer tilted at about 45 degrees.
Upright the dryer in a vertical position after the first layer is poured.
6. Keeping the dryer vertical, repeat the above two steps until 8 layers of
molecular sieve and 8 layers of catalyst have been added to the dryer.
7. Fill the remaining portion of the dryer with molecular sieve until the level is
3.5 inches (9 cm) below the upper edge of the fill port.
8. Apply two turns of Teflon pipe-sealant tape to the threads of the fill port
plug and install the plug.
Reinstalling the dryers in the system is the reverse of the removal procedure. Keep
the dryer in a vertical position at all times. When positioning, ensure that the small
support bracket welded to the dryer is resting on the rail assembly at the lower
dryer clamp.
There is a product gas filter in the outlet plumbing of each dryer in the system.
These filters should be changed once a year or sooner if an acceptable product gas
delivery pressure cannot be maintained.
To replace the filters, first remove the dryer purge control assembly (Figure 4-14).
Remove and replace each filter. Reinstall the completed assembly into the system
and tighten all Swagelok connections.
Maintaining precise position control of the temperature regulating valve is crucial for
accurate cooling water control. The operation of the temperature regulating valve
with varying electrolyte temperature can be monitored on the touch screen display
"Temperature Control Valve Position" screen that is accessed from the "System
Information" screen. Correct positioning of the valve can be checked when the
electrolyte temperature is below the operating control range and the valve is fully
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
closed. The flat of the hexagonal coupling which contains the set screws for
securing the motor and valve shafts is parallel with flow port in the valve. When the
valve is fully closed this flat should be perpendicular to the flow axis of valve. The
heads of the set screws are visible when the valve is fully open and not visible
when the valve is fully closed. If the valve is not fully closed when it should be, use
a 3/4 inch (19 mm) open end wrench and turn the flat of the coupling with the set
screws to the perpendicular position.
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HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
5-1
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
5-2
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
5-3
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
The remaining malfunctions are not directly indicated and will not cause system
shutdown. These problems are generally not as severe as the preceding
shutdowns. However, the symptoms should be recognized and the problem
corrected.
5-4
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
5-5
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
6-1
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
3
A8
L2/N
4
5
A7
6
JUMPER FOR 115 VAC
7 A6
A5 164-GRN
9
LG
10
A4 201-GRN
11 GR
GROUND
12
A3
032-BLK +
24 VOLTS DC 13 24VDC
TO PRESSURE GROUND
TRANSMITTERS 033-BLK
14
A2
COM
15 24VDC
16
115 VAC COM
A1
17
18
A0
002-WHT
19
20
6-2
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
SLOT NO. 1
115 VAC AC INPUT IA122
TB1
CHANNEL 000
1
B0 00000
2 LS1
006-W HT 0
RED RED
FW ADD NC A0
005-BLK
1 00001
3 007-BLK
B1
009-BLK LS2 2 00002
4 YEL YEL 008-W HT
HIGH LEVEL NC A1
3 00003
5
FS1 B2
010-RED 4 00004
BLK BLK
6 LOW FLOW NO
A2
5 00005
EXT ALARM NC
7
B3
6 00006
012-BLK
8 A3
EXT ALARM
7 00007
NO
011-BLK
9 B4
8 00008
10 A4
9 00009
11 B5
10 00010
013 -BLK A5
12 00011
11
B6
13 12 00012
A6
14 13 00013
B7
15 14 00014
A7
15 00015
16
B8
POW ER 17 NC
SUPPLY
ALARM NO A8
COM
18
TB2 B9
9 NC
19
10
20
014 - BLK
6-3
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
00100
2 A0
016-BLK 0
115 VAC
3
SV3
CONDSR 00101
019-BLK 020-RED A1
4 VALVE 1
5
00102
K2 A2
6 FW PUMP 2
022-WHT 021-BLK
4 3
7
00103
A3
SV2 3
8
024-RED VENT VALVE 023-BLK
9
00104
A4
SV1 4
10
028-RED FEEDWATER 27-BLK
11 00105
A5
SV8 5
12 004-RED FEEDWATER 003-BLK
13 00106
A6
SV5 6
14 026-RED DRYER VENT 025-BLK
00107
15 A7
K6
7
SHUTDOWN
16 168-W HT INDICATOR 167-BLK
14 13
115 VAC COM
17 A8
K5 COM
POWER SUPPLY
INHIBIT
18 030-W HT 029-BLK
4 3
A9
19 NC
K7
RUN
20 INDICATOR
170-W HT 14 13 169-BLK
6-4
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
115 VAC 2
SLOT NO. 3
ANALOG INPUT AD001
10
DEVICE NO. 0
H2 PRESSURE CHANNELS 100-109
0-10 VDC
11
PT1
EXC COM OUT
034- 035-WHT B0
RED V1+ 101
12 037-BLK
036-BLK A0
037-BLK V1-
B1
I1+
PLC O2 PRESSURE
SUPPLY 13 0-10 VDC A1
+ 24 VDC NC
PT2
EXC COM OUT B2
039-WHT
038- V2+ 102
RED 040-BLK
A2
041-BLK V2-
PLC
SUPPLY B3
14
- 24 VDC I2+
DRYER PRESSURE
A3
0-10 VDC
NC
PT3
EXC COM OUT B4
042- 043-WHT V3+
115 VAC RED 103
20 044-BLK A4
COM
V3-
045-BLK
B5
I3+
A5
NC
047-BLK
B6
V4+ 104
052-WHT RESILITE
GRN 3 046-BLK A6
V4-
051-BLK
BLK 2 B7
I4+
050-
RED
RED 1 A7
NC
049-BLK
B8
048-BLK/WHT NC
A8
COM
BLK/WHT BLK
053-BLK B9
COM
9 VOLT
054-WHT
CONVERTER
6-5
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
SLOT NO. 4
ANALOG OUTPUT DA001
DEVICE NO. 1
CHANNELS 110-119
TB2
POWER B0
055-BLK V1+
SUPPLY 7 110
A0
CURRENT 0-10VDC V1-
056-BLK
CONTROL 8 B1
I1+
A1
I1-
B2
P1+
A2
P1-
B3
V2+
111
A3
V2-
B4
I2+
A4
I2-
B5
P2+
A5
P2-
B6
NC
A6
NC
B7
AH1
A7
AL1
B8
AH2
A8
AL2
B9
COM
6-6
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
SLOT NO. 5
TEMPERATURE INPUT
TS001
DEVICE NO. 2
CHANNELS 120-129
B1
NC
A1
NC
TYPE J
MODULE OUTLET 060-WHT
B2
L2+
THERMOCOUPLE + white 122
061- A2
TC2 - red L2-
RED
B3
NC
A3
NC
B4
R+
A4
NC
B5
R-
A5
NC
H2 IN O2 TYPE J
B6
CATALYST + white
062-WHT L3+
123
THERMOCOUPLE 063- A6
- red
TC3 RED L3-
B7
NC
A7
NC
TYPE J
AMBIENT AIR 064-WHT
B8
L4+
THERMOCOUPLE + white 124
TC4 065- A8
- red L4-
RED
B9
NC
6-7
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
SLOT NO. 6
TRIAC OUTPUT OA223
CHANNEL 005
TB1
115 VAC 5
00500
A0
0
00501
A1
1
K3 00502
HEATER #1 A2
2
067-WHT 066-BLK
4 3
00503
A3
K4 3
HEATER #2
069-WHT 068-BLK
4 3
00504
A4
4
15
SV4
071- DRYER PURG 070-BLK 00505
RED A5
5
SV9
200- H2 IN O2 199-BLK
RED FLOW A8
COM
200-
RED
A9
NC
6-8
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
120-BLK
SLOT NO. 7 3
POWER
TRANSISTOR OUTPUT 121-WHT SUPPLY
+ 24 VDC
OD216
079-BLK 4
CHANNEL 006
00600 1 3 MD1
A0
0
PCB1
077-BLK 2 J2-1
122-BLK
9
00601 6
A1 123-BLK J2-2
1 8 7
078-WHT POWER
5 J2-3 SUPPLY
124-BLK
7 - 24 VDC
00602 8
A2 4 J2-4
2
080-BLK
125-BLK
00603 126-WHT
A3
3 081-BLK
129-WHT
00604 1 3 MD2
A4
4
PCB2
160-BLK 2 J2-1
127-BLK
9
A5
00605 6 128-BLK J2-2
5 8
162-BLK 5
166-BLK
J2-3
7
00606 4
A6 163-BLK J2-4
6
00607
A7
7
A8
COM
A9
NC
6-9
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
24 VOLT DC
POWER SUPPLY
+24VDC 24COM
091-WHT
084-BLK 085-WHT 087-BLK 088-WHT
090-BLK
171-BLK 089-BLK
086-BLK 172-BLK
1 2 6 3 4 7 8 5
1 2 6 3 4 7 8 5
6-10
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
TB1
1 TB2
100-BLK
3
101-WHT
4
20
185-BLK TB3
1
186-BLK
2
105-WHT 3
104-BLK L 24VDC POWER SUPPLY N
+ 24 VDC V+ V- - 24 VDC
4
GND
5
6
MD1
90-BLK 7
J1-5
91-BLK 8
J1-6
165- 9
GRN GROUND
102-BLK 103-WHT
10
MD2 NT600S HMI TERMINAL
98-BLK
J1-5
99-BLK
J1-6
6-11
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
106-BLK
12
K2 195-
FW PUMP GRN GROUND
111-BLK
1 2
13
112-BLK FEEDWATER PUMP
113-BLK
14
K3
114-BLK
1 2
15
115-BLK DRYER HEATER #1 116-
RED
16
K4
118-BLK 119-
117-BLK
DRYER HEATER #2 RED
1 2
17
K7
(NO)
RUN INDICATOR 117-BLK
18 175-BLK
9 5
CUSTOMER
19 K6 DRY CONTACT
(NO)
SUTDOW N INDICATOR RELAYS
177-BLK 178-BLK
9 5
20
6-12
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
132- +
7 ORG 5
CURRENT CONTROL, 0-10VDC
133-BLU -
8 6
134-WHT/BLK
9 7
136-GRN/
3 9
BLK L
CONTROL POWER CIRCUIT, 3A
137-ORG/
4 10
BLK N
138-BLU/
11 BLK
11 L
KOH PUMP POWER CIRCUIT, 10A
139-BLK/WHT
12 12 N
140-RED/WHT
13 13
L
141-GRN/WHT FEEDWATER PUMP CIRCUIT, 10A
14 14
N
142-BLU/WHT
15 15 L
DRYER HEATER CIRCUIT, 10A
143-WHT
16 16 N
6-13
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
TABLE 7-1
FIG # ITEM # PID No. DESC
4-1 3 O-RING
4-1 4 SCREEN, FLOW
4-1 5 PLAQUE, NICKEL
4-1 6 MATRIX
4-1 7 PLAQUE, NICKEL
4-13 6 GASKET
4-14 1 GAS FILTER (SILSCO)
4-14 2 VALVE, CHECK (EPT SEAT)
4-2 3 GASKET
4-2 8 KOH FILTER ELEMENT GASKET
4-2 9 KOH FILTER ELEMENT - MODIFIED
4-3 5 Old Feed Water FILTER ELEMENT
4-3 Old FEEDWATER FILTER ASSEMBLY
4-4 1 O-RING,
4-4 4 PUMP INSERT ASSEMBLY
4-4 5 STD IMPELLER & MAGNET ASSY.
4-4 6 EPT O-RING KOH PUMP
4-4 7 IMPELLER MAGNET HOUSING
4-4 11 MOTOR, KOH PUMP
4-5 2 SV2 VALVE, SOLENOID
4-5 4 REGULATOR ASSY., SHUTDOWN
4-8 SHUTDOWN REGULATOR REFURB KIT
4-9 RUN REGULATOR REFURB KIT
A-2 1 PMP-1 KOH PUMP ASSEMBLY
A-2 4 EM-1 MODULE, HS100
A-2 6 TC1, TC2 THERMOCOUPLE PROBE
7-1
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
7-2
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
7-3
ES-M-800 Jan. 2003 HM Generator Operations and Maintenance Manual
7-4
HM Generator Operations and Maintenance Manual ES-M-800 Jan. 2003
Section 8 Attachments
8-1