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6. HYDROGEN GENERATING PLANT.

6.1 INTRODUCTION
In the Hydrogen Generating Plant Hydrogen and Oxygen are obtained
from water by the process of electrolysis. As pure water possess least
conductivity, NaOH solution is added to water to form the required electrolyte
solution. The electrolyte will be in the ionized form. Hydrogen ions (H +) and
sodium ions (Na+) will have positive charge and hydroxyl ions (OH will have
negative charge. By applying an electric potential between the two
electrodes in the electrolyte, the ions start to shift to opposite poles. H + and
Na+ ions move to negative pole (Cathode) and OH- move to positive pole
(Anode).
At cathode the H+ ion discharges itself and becomes hydrogen atom.
NaOH Na+ OH

H2O H+ OH

+
H eH
H H H2
In the anode the OH ion discharges its excess electrons and form
oxygen atom.
2OH

2e Oo H2O

Oo Oo O2
The discharged electrons at the anode flow, to the cathode through
external circuit. Na+ ions do not take part in the electro chemical reaction.
Since the water is consumed and the quantity of the caustic soda remains
constant it is necessary to makeup water continuously.

6.2 TECHNICAL DATA STAGE-1

Capacity of the plant.

: 8M3/hr at 40mm of WC

Total no. of cells.

: 10

Purity.

: 99.5% to 99.7% H2

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: 98.5% to 99.3% O2
Electrolyte.

: 20% NaOH 1.2g/cc

: 99.58% purity.
: 0.38% Na2CO3
: 0.014% NaCl.

Electrodes.

: Nickel plated M.S. anode.

: M.S. Cathode.

Diaphragm.

: Asbestos.

No. of electrodes/cell.

: 4 anodes and 5 cathodes.

Rated Current.

: 2000 A.

Rated Voltage.

: 2.5 V.

Cooling water.

: 5kg/cm2 at 30oC raw water.

6.3 TECHNICAL DATA STAGE-1I

Capacity of the plant.

: 10 NM3

Total no. of cells.

: 14

Purity.

: 99.6% to 99.7% H2
: 98.5% to 99.3% O2

Electrolyte.

: 20% NaOH 1.2g/cc,

Specific gravity.

: 1.18-1.25
: 99.58% purity.
: 0.38% Na2CO3
: 0.014% NaCl.

Electrodes.

: Nickel plated M.S. anode.

: M.S. Cathode.

Diaphragm.

: Asbestos.

No. of electrodes/cell.

: 4 anodes and 5 cathodes.

Rated Current.

: 2000 A.

Rated Voltage.

: 2.5 V.

Cooling water.

: 5kg/cm2 at 30oC raw water.

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6.4 DESCRIPTION OF THE PLANT

The electrolyser unit consists of 10 cells arranged in rows of 5 cells
each. A cell is a shell made of M.S. and contains 9 bells or frames. Each bell
contains a positive and negative anodes are nickel plated to a dull finish.
Each cell is constituted by 5 cathodes and 4 anodes. These electrodes are
suspended from the bells by the leads made of nickel-plated copper rods.
These leads are fixed to an electrode block and pass through steel tubes
insulated with an inner ebonite sleeve. The steel tubes shield the copper rods
from the electrolyte. The hydrogen and oxygen gases that are generated rise
to their individual headers. These headers are connected with those of
adjacent cells in series by S shaped pipes through small glass tubes. All the
gas bells are welded to form a single block and the cells are mounted on
insulators from each other by glass tubing and rubber tubing connecting the
S shaped tubes of each cell. A DM water line to feed the cell and a cooling
water line to feed the jacket are provided with inlet and outlet valves. A level
gauge to Indicate electrolyte level and thermometer pockets are provided.
A scrubber tank is provided to clean the caustic mist from the
generated gases and also to make up DM water to the cells maintaining a
constant backpressure to the cells. DM water to the above tank is obtained
from a DM water day tank.
The gases that are generated in the cells rise through the S tubes to
enable electrolyte fall out during its travel and enter the top of the scrubber
tank to the respective compartment and reach the bottom, from where they
get scrubbed through in order to get rid of the caustic mist. The gases
coming out of the scrubber let to the LP gasholder or vented out. Gauges are
provided in the scrubber to indicate the gas pressure and flow before and
after the scrubber. A float valve is also provided in the scrubber to maintain
optimum level of DM water in the tank.
Two LP gasholders of 30 M 3 capacity have been provided to store
hydrogen. Oxygen is vented out in the process. The gasholder is an inverted
cylindrical vessel (referred to as bell), which is kept suspended inside a water
filled circular vessel by the action of counter weights moving over a pulley

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system. Gas enters the gasholder chamber through a seal pot and pipes
leading to the above chamber. So also the gas flowing from the gasholder to
the compressor flows through the outlet pipe in the chambers is to trap the
water droplets that may be carried over either to or from the gasholder in its
flow path.
The gas holding bells have a movement depending upon the gas
pressure that gets built up in them. Limit switches are provided to monitor
the movement of these bells and they also give alarms at high or low
positions, beside tripping the compressor impermissible low level or shutting
down the plant at the impermissible high level. When the bell roof is at the
maximum high position the pressure will be about 100 mm w.c. Continuous
flow of water to the outer vessel is maintained with an overflow in order to
ensure a constant level in the outer vessel.
Two single acting four stage double crank reciprocating vertical
compressors have been installed to compress the gas and fill it up in the
cylinders at a pressure of 150 Kg/cm 2. The capacity of each compressor is
rated at 20 M3/Hr. one compressor only will be normally in service at a time.
The gas is drawn by the compressor from the gasholder through a knock out
drum with demister pads where entrapped water droplets and the stray
particulars get removed from the gas stream. After being compressed
hydrogen passes through oil and water filters to get dried. The dry hydrogen
then passes through a de-oxy unit, which is made up of a bed of palladium
coated over porous alumina. This bed acts as a catalyst to enable any trace
oxygen in the gas stream to react with hydrogen and form water. However
this reaction increases the temperature of the gases so from the outlet of the
de-oxy unit the gas passes through the water coolers and then to a Puri-Drier
unit.
The unit consists of two vertical columns containing silica gel as
absorbent. After passing through this dryer the gas flow to the gas where the
cylinders are mounted to get filled. Provision is also available to keep one
column of puridrier in service and the other under regeneration if it is
saturated with moisture. For regeneration the concerned heater is switched
on and the hot gas coming out passed through the water cooler and then

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back again to LPG holder. Number of such cycles during a period of say half
an hour will completes the regeneration process after which the heater will
be switched off. The process can now be changed over leading the gas after
the puridrier to the gas post for filling of cylinders.

6.5 OPERATING INSTRUCTIONS

6.5.1 PRE START OPERATIONS.
1. Alkali solution should be prepared from rayon grade caustic soda
(NaOH) (20% or 1.3 G/cc) in the Alkali tank. All the suspended
impurities are strained before filling the cells.
2. Remove the drain valves of all the valves and remove the dust by
blowing air. Wash the tank and rinse it with DM water. Fill up alkali
solution up to 5cm from top by the hand pump.
3. Fill up the gas scrubber tank 100 mm of DM water in the sump.
4. Wash and fill up the DM water day tank flush the pipelines.
5. Checkup the other equipments like dryers, filters etc.
6. The following items are to be checked.

6.5.2 RECTIFIER ROOM

1. Main switch and rectifier switch

- OFF

2. Supply voltage

- 415 V

3. Transformer oil level

- Normal

4. Regulator (Auto transformer) position

- Minimum

6.5.3 CELL ROOM

1. Cell level

- 5 cm from top

2. Specific gravity

- 1.2 g/cc

3. Temperature of electrolyte

- Below 65o C

4. Delivery and vent valves for H2 & O2

- Closed

5. Cooling water supply

- Normal

6. Scrubber level

- 100 mm

7. Seal pots level

- Normal

8. Day Tank level

- Adequate

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6.5.4 LP GAS HOLDER

1. All the delivery suction valves and drain
valves from the cells and to the seal pots - Closed

6.5.5 CYLINDER MANIFOLD

All the valves closed

6.5.6 H2 COMMPRESSOR
1. Cooling water supply

- Normal

2. Oil level in crank case

- Up to the mark

3. Suction and discharge valves

- Closed

4. Lub oil system

- Normal

6.5.7 DRIER AND PURIFIER UNITS

Ready for operation.

6.6 STRATING OPERATIONS

1. Open the valve from day tank to scrubber tank.
2. Check the electrolyte level in all the cells. 5 cm from top.
3. Switch on the AC supply check the voltage.
4. Check for the auto Transformer setting and switch on the rectifier and
check the polarity.
5. Raise the load gradually to 500A and wait for hour.
6. Open the vent valve for H2 and O2. Check for any H2 leak in the joints.
7. Check for any local heating in the bus bar joints.
8. Note the electrolyte temperature.
9. Increase the load every half an hour 250A. Observe for any abnormal
voltage rise.
10.

At 1500A load take a sample and analyse. Purity should be above

99%, temperature about 5oC more than ambient. Maximum allowed is

65o C.
11.

Increase the load 2000 A. Check for purity.

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12.

Open the seal pot inlet valve and lower vent value of the seal for

H2.
13.

Close the vent valve at gas scrubber tank and open the LPGH

supply valve for H2. Now the gas will flow to seal pot. Vent the gas
outside for about 10 minutes. Ensuring that all unwanted gases have
gone out close the drain valves and open the valve to LPG holder.
14.

Now vent out the air in the LPG holder and ensure that only pure

gas is stored. This is to be done by filling the holder and venting it out
to atmosphere through the crown of the bell or through the drain of the
outlet seal pot. Repeat this for 4 or 5 times and check the purity. It
should be above 99%. Then close the drain valves and fill up the LPG
Holder.
15.

Once the purity of the gas is established it is suitable for

compressor. Once the bell reach the upper limit, the suction valve to
the compressor through the seal pot is opened. Drain valve is also
opened. This is to ensure the purging of entrapped air out. After some
time drain valve is closed and valve to knock put drum is opened. Here
also the drain valve is kept opened for some time to purge air.
16.

Before starting the compressor, the cooling water supply to

compressor should be ensured.

17.

Purge the compressor, drier and purifier units with dry Nitrogen.

18.

Connect 6 cylinders in the header and open all the valves.

19.

Start the vacuum pump and evacuate the gas in the cylinder.

20.

Keep the purge valve open and start the compressor and purge

the gas. After a few seconds close the purge valve and charge the
cylinders.
21.

After filling disconnect the cylinders.

22.

After the filling is over stop the compressor.

6.7 NORMAL OPERATION

1. Sample of O2 & H2 are to be taken and analyzed 3 or 4 times a shift and
should be recorded.
2. Cell level is to be observed and maintained.

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3. Measure and record the temperature and specific gravity of the each
cell every hour. It should be between 55 o C to 60o C and the maximum
allowed is 65o C.
4. Check the pressure (5Kg/cm2) and temperature (30oC) of the cooling
condensate water at the header. The cooling condensate flow to the
cells are to be monitored.
5. If the specific gravity at any cell reduce below 1.18g/cc add a little
caustic solution if necessary.
6. The seal pots are to be drained frequently (once in a shift).
7. The loads should be kept 2000A always.
8. The cells containers are to be kept clean and washed with DM water.
9. If any scum has collected because of the dust or reaction of caustic
with atmosphere CO2 it should removed by wooden brush.
10.

Maximum allowed Na2CO3 content is 4% and NaCl is 2% in the

electrolyte.

6.8 SWITCHING OFF THE PLANT

1. For scheduled shut down ensure that LP Gas Holder is more that 75%
full, compressor stopped and filling over.
2. Check the cell level and open the vent valve at the gas scrubber and
close the delivery valve to the LPG Holder. Close the DM water feed
valve from scrubber tank.
3. Gradually reduce the load on the cells by turning down the regulator.
Reduce first to 1500A from 2000A. Wait for 5 minutes. Similarly reduce
the load to 1000, 500 and zero in a similar manner.
4. Switch off the rectifier main switch and switch off the fan motor.
5. Afterwards close the vent valve also close all the inlet and outlet valves
of LPG Holder.
6. If the shutdown period is long it is advisable to purge the purifier and
compressor with N2.

6.9 SHUTDOWN DUE TO POWER FAILURE

1. Close all the suction and delivery valves to and from LP Gas Holders.
2. Close the valve from gas scrubber tank to LPG Holder.

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3. Bring the regulator position to zero.

4. Wait for the supply resumption and follow the procedure mentioned
above for starting the plant. The loading of the cells are to be carried
out step by step of 500A but a time gap of 15 minutes has to be
followed. Check purity of gases every time.

6.10 TROUBLE SHOOTING

While operating the plant it is possible to meet with certain problems,
which can be solved without shutting down the plant sometimes or may
require a shutdown. Some of the probable causes are listed below.

6.10.1 OXYGEN PURITY LESS THAN 99%

Causes:

Faulty cell or cells, diaphragm puncture, corrode electrodes, too

low or too high temperature.

Remedy:

Identify the cell or cells. Shutdown the plant. By pass the cell and
start the plant. Cell may be opened and defect rectified. Before
tripping the plant collect 4 or 5 sample at steady load.

6.10.2 DM WATER FLOW INTO THE CELLS NOT UPTO THE

LEVEL
Causes:

Obstruction in the feed line, frothing may cause obstruction in the

take off pipe too long a shunt down and settling of solid caustic at
inlet.

Remedy:

Remove obstruction and forth in the pipe.

6.10.3 EXCESSIVE PRESURE IN DELIVERY PIPE FROM

SCRUBBER TANK
Causes:

Due to water in the delivery pipe, low level of water in gas

scrubber tank.

Remedy:

Drain off the water through seal pot, check guide and roller and
remove obstruction. The float may not be working or it may be
attended.

6.10.4 EXCESSIVE PRESSURE IN INDIVIDUAL CELLS

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Causes:

Forth in the cells, obstruction in the off take pipes.

Remedy:

Remove

the

forth,

remove

the

header

flange

and

clean

obstruction in off take pipe.

6.10.5 ELECTROLYTE LEVEL FLUCTUATING IN THE CELLS

Causes:

Frothing in the cells.

Remedy:

Clean the frothing.

6.10.6 EXCESSIVE FROTHING IN THE CELLS

Causes:

Due to impurities getting into the cells.

Remedy:

Remove forth at low temperature. If frothing continues check for

the electrolyte purity. If it is not to specifications change the
electrolyte after tripping the plant.

6.10.7 CELL VOLTAGE ABOVE NORMAL

Causes:

Specific gravity of electrolyte, higher carbonate content more

than 4%, coating over electrode and increased resistance.

Remedy:

Check and correct the specific gravity. If Na 2CO3 is more change

the electrolyte. If electrodes are coated clean them after tripping
the plant.

6.10.8 SUDDEN DROP OF GAS PURITY

Causes:

Short circuit in cells.

Remedy:

Check the voltage of individual cell. If it above 1.6V and check for
temperature rise if it above normal bypass the cell.

6.10.9 SUDDEN DROP OF LOAD

Causes:

Rectifier fan must have tripped Blowing off of some fuses. Fault in
transformer or single phasing.

Remedy:

Bring the regulator to zero. Check the fan and fuses and restart.
In case of transformer fault check the transformer. Check for all
the lamps and replace faulty fuses. Check for 3-phase voltage.

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6.10.10 SEAL IN GAS SCRUBBER TANK BLOWING OFF LPG

HOLDER NOT FILLING IP
Causes:

Leak in delivery line, struck up bell in LPG Holder.

Remedy:

Locate the leak and remove, Replace the struck up bell.

6.10.11 MANOMETER IN GAS WASHING TANK SHOWING NO

READING
Causes:

No water in seal or gas scrubber tank, leak in the gas lines.

Remedy:

Fill the scrubber tank, detect the leak and rectify them.

6.10.12 SOME IMPORTANT HINTS

1. The cell body should be washed in case there is any splash of caustic
on the body.
2. No dust should be allowed to be collected at the cell tops. In case of
dust collection they should be removed. It is advisable to blow the cells
with air.
3. Smoking, carrying flame inside the plant, gas cutting and welding are
strictly prohibited.
4. LP Gas Holder water level should be maintained always.

6.11 CONTROLS AND ANNUCIATIONS

6.11.1 CONTROL CUBICLE
It is provided in the control room with the following equipments.
1. DC Voltmeter (0 40V) DC Ammeter (0 3000A).
2. Auto Manual switch, current setting potentio meter.
3. Raise Lower Switch, Diode fail alarm.
4. Accept and Reset Push button, Compressor select switch with start
Stop Push button Temperature scanner conductivity monitor.
5. Annunciation panels with the following windows are also provided.
LPGI High
LPGI Low

LPG-II High
LPG-II Low

LPGI Very High

LPG-II Very High

LPGI Very Low

LPH-II Very Low

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Outlet Pressure High

Inlet Pressure Low

Temperature High

Cooling water flow Low

Trace Oxygen purity High

Hydrogen Purity Low.

6.11.2 CONSTANT CURRENT CONTROLLER

The controller will provide constant current output by controlling a
motorized autotransformer tap. The controller has both automatic and
manual control facilities selected by a selector switch. Manual control is
possible by Raise Lower switch. This mode of operation can be used during
initial adjustments and also during emergencies. The regulator can be
operated by handle in case of motor fault.
The automatic control is achieved by means of two relays operated by
an amplified error signal. The signal from the current transformer is rectified
by means of a single-phase bridge rectifier and applied to the transistor
amplifier. The amplifier output controls two relays energize the motor to
move one way or the other. If the output is larger than required valve that
relay will operate which moves the motor to reduce the output. Similarly if
the actual output is less than the required valve, the other relay will operate
moving the motor in opposite direction so as to increase the output. In both
the cases as soon as the output is reached the error becomes too small the
relay is de energized and the motor stops. Provision is made to give
intermittent supply to the motor, which reduces overshooting.