2016 HYDROGEN STUDENT DESIGN · PDF fileRegulations, codes and standards ... which will secure...

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2016 HYDROGEN STUDENT DESIGN CONTEST

DEVELOPMENT OF A HYDROGEN POWERED MICROGRID TO

PROVIDE GRID SUPPORT AND FUEL BACKUP POWER

North-West University, Potchefstroom, South Africa

Solar-2-hydrogen (S2H2) microgrid solution

TEAM MEMBERS:

GERHARD HUMAN NEELS LE ROUX FAURE VAN SCHALKWYK

FACULTY ADVISOR:

Dr. DMITRI BESSARABOV

Dr. ANDRIES KRUGER


Table of Contents

1. Executive summary

2. Location, energy profiles and requirements

3. System design

PV system

Fuel cell system

Hydrogen generation and storage

Safety system

Process and instrumentation diagrams

Electrical diagrams

Control sequences

System simulation

Food and energy

FCEV dispenser

4. Cost and economics

5. Safety analysis

Risk analysis

Safety analysis

5. Regulations, codes and standards

6. Operation and maintenance

Operation

Control and communication

Maintenance

7. Environmental analysis

Clearing of vegetation

Visual impact

Resources and emission analysis

Noise analysis

8. Interface design/Customer education


1. Executive summary

The aim of this project was to design a microgrid for support and full backup power of a community. The following requirements are to be to be fulfilled:

The microgrid must solely support a town or military base for 2 days,

Must handle at least 10% of grid demand while it is active,

utilize local resources to produce and store hydrogen, and

be optimized for as little environmental impact as possible.

The system is designed for the Mdeni rural community in The Eastern Cape province, South Africa. The community consist of a school, a clinic, general services such as water supply and sewage, street lights and approximately 100 households. Currently the community is supplied by the local utility. The community is on the end of a very long rural feeder supplied at 11 kV. The rural feeder runs through very mountainous terrain which is often very difficult to access. The community thus has a very weak supply with bad quality of supply and also experiences power outages due to line faults that have lasted up to 2 weeks in the past, although power outages are typically in the range of two to four days. During this time the community struggles with water supply, students in the school loose school days due to bad lighting in classes, the clinic runs on expensive fuel for diesel generators, households are without lights and have to burn candles where children have to read and study at night, and safety at night due to poor visibility is a great concern. A solution is proposed which will secure the electrical supply of this community through the implementation of a hydrogen based micro-grid. The system is designed such that the community can be supplied with electrical energy for at least a two week continuous period and additional short grid outages. The user specification drawn up for the client with short solution discussion is given in Table 1.

Table 1. User specification.

User specifications Proposed solution

1 Supply electrical power for at least two weeks, experienced once per year during very heavy rain season

Install a PV, electrolyser fuel cell system. Store sufficient hydrogen to supply electrical power for a continuous two week period and a combined period of 31 days in combination with solar PV energy.

2 Supply electrical power for at least 3 days, experienced four to five times per year during windy season

3 Supply electrical power during short outages lasting up to 4 hours on average 10X per year.

4 Improve quality of supply Design the system in a UPS setup. The power electronics will maintain quality of supply regardless of the feeding grid. Additionally an inverter/charger with a peak shaving function i proposed to reduce the supply of electrical power from the grid by at least 10%.

5 Reduce community dependence on utility supply. Reduce community electrical bill allowing money to be spent on infrastructure improvement.

6 Improve community situation(uplift) Perform community responsibility

Combine PV modules with growing greenhouse vegetables, known as food and energy.


South Africa is a country with an abundance of solar energy. For this reason a PV system is proposed for the main sources of energy. The peak load of the community is estimated at 41.4 kW, which needs to be supplied even if solar energy is not available. The energy storage medium proposed is based on hydrogen. An electrolyser produces hydrogen using excess energy from the solar PV system. Additionally the electrolyser is also supplied with energy from the connected grid with low cost electrical energy during the night. The hydrogen is stored in tube cylinders and used to generate power using PEM fuel cells during power outages, and also to perform peak shaving during high load times. Peak shaving is primarily implemented to reduce the instantaneous power supplied from the grid to make the grid more stable and also reduce energy costs during peak load times when energy is very expensive.

A food and energy concept is proposed where rooftop PV is installed on free standing structures with enough height and area below the installation to harvest the soil for food production, and accompanying job creation.

Part of the project was to investigate the possibility of having a hydrogen dispenser for a fuel cell electric vehicle (FCEV). This requirement however has been identified not to be a viable addition to the project. The possibility is investigated and a solution is proposed but not included in the proposed design. (Note to reviewer: This is a real community with the problems addressed for the community. The addition of a dispenser for a FCEV is not realistic for a community such as this. For this reason the dispenser is mentioned, investigated but not included.)


2. Location, energy profiles and requirements

Figure 1 shows the location of the community on a map of South Africa.

Figure 1. Mdeni community location.

Figure 2 identifies the area to be supplied by the micro-grid. The community is spread over w large

area.

Figure 2. Area of the community.


The red square in Figure 3 shows the area identified for the installation of the system.

Figure 3. Site identified for PV-hydrogen energy system.

Figure 4 gives the load profile of the community from the 11/400V transformer with the point of

connection for the micro grid being the 400 V side. The system is designed to be able to maintain the

provided load profile of the rural community.

Figure 4. Community weekly energy profile.

The minimum load during night times is approximately 6.4 kW while the maximum peak load

experienced during a week being 41.4 kW. This is also the peak load that will be supplied by the fuel

cells and PV system combination.

Monday Tuesday Wednesday Thursday Friday Saturday Sunday0

0.5

1

1.5

2

2.5

3

3.5

4

4.5x 10

4

kW

h


3. System design

Figure 5 provides a block diagram of the system. The PV system is connected in a grid-tied

configuration to the 400V three phase load side of the supply transformer.

WATER SUPPLY

E-2

P-12

DC

P-32

P-7 P-31

P-26

MINI SUB

400VAC 50HZ

P-1 FC

SYSTEM

P-2

AC/DC/AC

BATERY

BANKH2 COMPRESSOR

E-1

P-13

P-15

P-29

CO

MP

RE

SS

ED

HY

DR

OG

EN

ST

OR

AG

E V-1

ELECTROLYSER

PV SYSTEM400VAC BUS

P-19DC/AC

P-6P-14

P-33

SCHOOL

CLINIC

P-11

P-17 P-23

P-20

P-27

P-34

P-16

P-10

P-24

HOUSES

STREETLIGHTS

P-25

P-9

SERVICES:

SEWAGE

FRESH WATER

Etc.

P-18

P-8

P-4

P-28

P-21

P-22

P-3

P-30

P-5GRID

Future expansion for

fuel cell vehicle and bus re-fueling

Figure 5. Micro grid system block diagram.

Inverter/charge controllers are used are connected in a UPS configuration. The inverter charge

controllers selected have a peak shaving function. The maximum power supply from the grid is

limited. The value selected for this system is 90% of 41.4 kW which is 37.3 kW. These

inverter/charge controllers operate independent of the control system.

Two 7 kW PEM electrolyser units are installed for hydrogen production resulting in a maximum

production capacity of 14 kW. These electrolyser units are controlled by the main controller. The

power from the grid, the power from the PV system, and the power to the load are all monitored by

the MPPT grid tie inverters and inverter/charge controllers. These power values are used by the

controller to control the set points of the electrolyser units. There minimum possible turn down

value is 20% of the nominal ratings, which is 1.4 kW each. The hydrogen production can therefore be

controlled between 1.4 kW and 14 kW. The Fuel cell

Two 30kW fuel cell units are operated in parallel. The output voltage of the fuel cell units is

controlled with a DC/DC converter which controls the output voltage at 48 Vdc. A batteyr bank is

placed in parallel with the fuel cell units on the 48 Vdc bus. The batteries are necessary to absorb

transients and are also used during a switch over event when the power falls away and the fuel cells


have to start up. The batteries will supply the load for the few seconds of the load and are therefore

required to supply the maximum possible load of 41.4 kW.

Exact specification of components are given in the next sections. Specification sheets for all the

major components are also provided.

PV system Refer to Figure 22 for PV system line diagram. Using the PVSol Premium 2016 solar PV system design

software the following solar information is obtained. Figure 6gives the average energy per month.

Figure 7 gives the energy forecast.

Figure 6. Monthly solar PV energy production for the site.

Figure 7. PV energy yearly profile.

The designed system takes into consideration weather conditions such as is shown in Figure 8. Figure

8 shows a day with very low energy production and days with very high energy productions within

one month period. The minimum daily energy for the year is 14.5 kWh while the maximum daily

energy production is 261.7 kWh.

Jan Feb Mar Apr Mar Jun Jul Aug Sep Oct Nov Dec0

1000

2000

3000

4000

5000

6000

kW

h

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec0

5

10

15

20

25

30

35

kW

h


Figure 8. Diversity of energy profile for same month due to weather.

Figure 9 illustrates the PV layout designed with PVSol design software. The PV modules are fixed on

free standing structures facing exactly North at a tilt angle of 30o.

Figure 9. PV module layout.

The specifications of the PV system are:

Module area: 229.9 m2, <30o, 36.4 kWp, 140 PV Modules

PV module: CHSM6610M-260, ASTROnergy (Chint Solar), 260 W

MPPT/Inverter: Sunny Tripower 25000TL-30, SMA Solar Technology AG, 25 kW

MPPT/Inverter: Sunny Tripower 10000TL-20, SMA Solar Technology AG, 10 kW

Oct

0

5

10

15

20

25

30

kW

h


Figure 10 gives a 3D representation of the free standing system.

Figure 10. 3D representation of PV modules.

Figure 11shows the different PV strings. The system consists of 3 strings of 20 modules and 2 strings

of 20 modules connected Sunny Tripower 25000TL-30, and two individual strings of 20 modules

connected to the Sunny Tripower 10000TL-20. The individual strings are illustrated in different colors

in Figure 11. A single line diagram of the solar system is provided later in Figure 22.

Figure 11. PV strings.


Inverter/charge controller Refer to Figure 23, Figure 24 and Figure 25 for the inverter/charger connections to 48 V DC bus, grid

connection and the load connection.

The specifications of the inverter/charger are:

6 x Victron Energy Quattro Inverter/Charger 48/10000/140-100/100

The single phase units are connected two in parallel on each phase of the three phase system and

synched to supply 3 phase to the load and from the grid. Refer to Figure 24 and Figure 25 for

connections.

Fuel cell system Refer to Figure 18 for the fuel cell system P&ID and Figure 20 for the fuel cell system external

cooling system.

Specifications of the fuel cell modules selected are:

2 x Hydrogenics HD30 HyPM systems. The modules are integrated into systems.

The fuel cell module mechanical connections are given in Figure 12 and the control, communication

and electrical connections are given in Figure 13.

Hydrogen side out

Fuel cell power

module

Air side out Cooling out

Air side in Hydrogen side in Cooling in

Figure 12. Fuel cell mechanical connections.

Load

Fuel cell power

module

Coolant pump

control

(PWM and Enable)

Electrical input

(24 V)

Controller (CAN)

Control, Monitoring and power interface

Figure 13. Fuel cell control and electrical connections.


Batteries selected for the system are Hoppecke OGI for their high instantaneous current capabilities.

Battery specifications are:

24 X 9OSP.HC 765 with a C1 rating of 482 Ah.

This results in a installed capacity of 23 kWh. During fuel cell startup the batteries will be required to

supply maximum 4100 for 8 seconds. This requires 3.1 kWh at a maximum possible current of 862 A.

The fuel cell takes 5 seconds to start up from OFF, and 3 seconds to reach full power.

Hydrogen generation and storage Refer to Figure 17 and Figure 19 for the hydrogen generation and storage systems respectively.

The specification of the hydrogen generation system is:

2 x ProtonOnsite Hogen S Series S40 PEM electrolyser

The system is designed to incorporate the two S40 units into a complete hydrogen production

system. The complete systems consists of a water supply system and a ventilation system. The

ventilation system is designed to passively cool and heat the ventilation air to maintain the unit

within specified operating temperatures. A heater is incorporated for scenarios where negative

temperatures might be reached.

Figure 14 shows the hydrogen air-driven booster. The air compressor is a 5.5 kW air-compressor. The

air-compressor will also be used for locals in the community to inflate car and bicycle wheels as

needed. The booster is selected for it’s cost and durability. The booster selected is large enough to

be able to maintain the low flow. Due to the low flows this type of compressor is durable.


Figure 14. Hydrogen air-driven booster.

Figure 15 shows the hydrogen booster operating point.

Figure 15. Hydrogen booster chart..

For storage stackable tube cylinders capable of 200 bar operating pressure is utilised. Figure 16

shows a picture of the stackable tube cylinders. Each set of tubes stores 45 kg hydrogen at 200 barg.


6 sets of tubes are required in total. They will be stacked two sets of three with all of them

connected in parallel.

Figure 16. 3m3 Tube cylinders.

Safety system Refer to Figure 26 for the line diagram of the automatic shutdown system. Several hydrogen sensors

and smoke detectors are hard-wired to shut down the system when activated. Activation of any of

the hydrogen sensors and smoke detectors will results in the main hydrogen supply valves closing

and both electrolyser being shut down. An externally provided emergency stop button will also

perform the same actions.

The main controller measures pressures and temperatures. The system will shutdown when an

unacceptable temperature and/or pressure is detected anywhere in the system.

Process and instrumentation diagrams Figure 17 gives the P&ID for the hydrogen generation system.


E-29

P-92

Atmosphere

From Atmosphere

(Ventilation Intake)

P-84

E-32

S-3

P-77

C-VF-003E-37 E-31

P-94

C-AF-005

P-57

P-59

P-105

E-36

P-83P-112

P-93

P-95

V-67

SP-82

C-WJ-006

C-WT-007

C-SP-008C-WH-010

C-EL-012

H2O drain

E-33

P-99

P-107

To storage systemP-87

400V L1 phase

P-64

S-2

P-89P-65

P-75

H2 vent to

atmosphere

P-113

P-111

O2 vent

P-85

P-47

Ventilation vent to

atmosphere

P-62

V-68

P-88

P-78

P-86

P-109

V-74

P-90P-66 P-74Coupling

N2 Purging

E-27

C-ST-009

P-70

P-71

P-101

V-69

P-60

P-72

P-61

P-100

V-72

P-103

E-26

P-81

C-PP-002

400V L3 phase

400V L3 phase

400V L3 phase

400V L3 phase

P-56

P-51

E-35

EIF

10

.0P-110

P-96

I-125

LG

301

P-102

V-70

P-97

H2O drain

V-71

E-30

P-52

P-108P-80

E-28P-79Coupling

Water refill

V-73

P-76P-69

V-75

P-104

P-114

P-106

Overflow

Overflow

Accu

me

lato

r

P-54

C-EL-011

E-34

P-73 P-53

P-55

O2 vent

P-67

P-68

P-58

P-63

P-48

400V L2 phase

S-1

P-49

P-91

P-98

P-50

Figure 17. Hydogen generation system P&ID.

Figure 18 gives the P&ID for the fuel cell system.


Figure 18. Fuel cell system P&ID.


Figure 19. Storage system P&ID.

Figure 20. Fuel cell cooling system P&ID.


Electrical diagrams Figure 21 gives a block diagram of the micro grid system layout.

PV

Grid-tie

MPPT

H2

generator

Fuel

cell

Load(Existing

infrastructure)

Existing

grid

H2

storage

Lead-acid

batteries Electrical

Mechanical (H2)

Figure 21. Micro grid block diagram.

Figure 22 gives the line diagram of the PV system.


Figure 22. PV system single line diagram.


Figure 23 gives the 48 V DC bus connections.

48 V DC bus

VR

LA

Ge

l B

atte

ry b

an

k 1

HyP

M H

D3

0 N

o. 1

CB

6

F1

CB

7

CB

1

CB

2

CB

3

CB

5

VR

LA

Ge

l B

atte

ry b

an

k 2

F2

HyP

M H

D3

0 N

o. 2

CB

4

CB

8

24

V P

ow

er

su

pp

ly

CB

9

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 1

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 2

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 3

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 4

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 5

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No. 6

Figure 23. 48 DC bus connections.

Figure 24 gives the 400V AC grid side connections.

CB

26

CB

23

CB

25

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 1

CB

24

CB

27

400 V 3ph grid AC bus

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 2

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 3

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 4

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 5

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No

. 6

CB

28

L1

L2

L3

Figure 24. 400 V grid connections.


Figure 25 gives the 400V AC load side connections.

400 V 3ph load AC bus

Hyd

rog

en

ge

ne

rato

r 1

SM

A S

un

ny T

rip

ow

er

25

00

0T

L-3

0

Exis

tin

g lo

ad

CB

18

CB

20

Co

olin

g p

um

pC

B1

4CB

10

CB

11

CB

13

CB

12

Hyd

rog

en

ge

ne

rato

r 2

CB

19

CB

15 C

B1

6

SM

A S

un

ny T

rip

ow

er

10

00

0T

L-2

0

CB

17

CB

22

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

1

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

2

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

3

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

4

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

5

Qu

attro

In

ve

rte

r/ch

arg

er

10

kV

A

No.

6

CB

21

Au

xili

arie

s

L1

L2

L3

Figure 25. 400 V load connections.

Figure 26 Gives the safety shutdown system.

NC NCNC NC

H2

SENSOR

H2

SENSOR

H2

SENSOR

SMOKE

DETECTOR

SMOKE

DETECTOR

NC

48 TO 24 Vdc

POWER SUPPLY VENTILATION

FAN ON

FLOW

SWITCH

ON

24V DC

RADIATOR

FANS

K001

START E-STOP

DC +

DC -

K002 H2 SUPPLY

SOLINOID VALVE

RAD

FANS

RELAY

24V DC -

24V DC +

K003

SYSTEM OFF

ELECTROLYSER

NO1 ON

ELECTROLYSER

NO2 ON

K002

K002

Figure 26. Safety shutdown system.


Figure 27 illustrates the inputs and outputs of the main controller.

Ventilation fan ON/OFF

Radiator fan 1 ON/OFF

Temperature

Pressure

Current

Radiator fan 1 control (0-10V)

System off

DC +

DC -

Cooling pump ON/OFF

Cooling pump ON/OFF

Radiator fan 2 ON/OFF

Radiator fan 2 control (0-10V)

+

-

00

- 0

70

8-1

11

1-1

7 INP

UT

S

OU

TP

UT

S

Ventilation fan control (0-10V)

Voltage

18

-24

Ely 2 control (0-10V)

Ely 2 control (0-10V)

Figure 27. Main controller inputs and outputs.


Control sequences Figure 28 gives the control sequence logic for the micro system decision making.

START

SOC < 30%

SOC > 100%

NO

YES

NO

YESFUEL CELL IN IDLE

MODE

ELECTROLYSER IN

IDLE MODE

FUEL CELL IN LOAD

ASSIST MODE

ELECTROLYSER IN

GRID ASSISTED

MODE

PRESS

STOP

INITIATE STOP FOR

FUEL CELL

CONTROL

INITIATE STOP FOR

ELECTROLYSER

CONTROL

DISABLE QUATTRO

PEAK SHAVING

MODE

ELECTROLYSER IN

GRID ASSISTED

MODE

FUEL CELL IN LOAD

ASSIST MODE

INITIATE START

FOR FUEL CELL

CONTROL

INITIATE START

FOR

ELECTROLYSER

CONTROL

GRID HEALTHY

YES NO

SOC = 0%

FUEL CELL IN

ISLAND MODE

ELECTROLYSER IN

PV ASSISTED MODE

ENABLE QUATTRO

PEAK SHAVING

MODE

POWER DOWN

INITIATE

GRID HEALTHY GRID FAIL

DISABLE

Figure 28. Micro grid control sequences.

When the system is started the fuel cell and electorlyser systems will power up and be placed in idle

mode.

While the grid is healthy:

the fuel cell will not operate if the hydrogen storage SOC is below 30%. If the hydrogen supply is at

100% the hydrogen generation unit will shut down. Above 30% the fuel cell will perform peak

shaving of 10%. Below 100% the hydrogen generation unit uses any excess PV energy to produce

hydrogen. Additionally the unit produces hydrogen at nights while ensuring the peak load always

remains below 15 kW.

When the grid fails:

The fuel cell will supply the load until the hydrogen storage SOC reaches 0%. During that time the

hydrogen generation unit will only produce hydrogen if there is an excess of PV energy available.

The system will be shut down when:

the SOC reaches 0% after which a manual startup is required,


the E-stop is pressed,

hydrogen is detected, or

smoke is detected.

System simulation Simulations are provided using the load data provided and the solar system design data. Figure 29

shows the system operation for a week where there is a very weak sunshine day in the middle of the

week. This is for a grid supply scenario. The grid keeps on supplying the load as normal. Every day at

during the peak time the FC is shown to reduce the grid requirement by 10%. The PV system, during

the day reduces the daily energy supplied by the load by an additional amount.

Figure 29. System energy profile during grid supply.

Dec0

0.5

1

1.5

2

2.5

3

3.5

4

4.5x 10

4

kW

h

PV

Fuel cell

Electrolyser

Load

Grid

SOC


Figure 30 gives the simulated scenario for a 2 week period.

Figure 30. System energy profile during grid failure.

Figure 31 shows the simulated annual operation of the fuel cell.

Figure 31. Simulated FC operation.

Figure 32 shows the simulated annual hydrogen storage SOC.

Dec0

0.5

1

1.5

2

2.5

3

3.5

4

4.5x 10

4

kW

h

PV

Fuel cell

Electrolyser

Load

Grid

SOC


0.5

1

1.5

2

2.5

3

3.5

4

4.5x 10

4

kW

h


Figure 32. Hydrogen storage SOC.

Systems statistics:

Simulations performed show the annual load energy requirement to be 134 283 kWh. PV system

annual energy supply is calculated to be 62 067 kWh.

The electorlyser uses annually 38 820 kWh.

The fuel cell performs annual peak shaving of 1544 kWh. The micro-grid can supply the specified

load for 39 days in a 365 day cycle. This results in the fuel cell supplying 9 726 kWh during grid

failure.

The total annual energy supplied from the grid is 80 183 kWh. 54 100 kWh (134 283-80 183) annually

is supplied from the PV-electrolyser-fuel cell micro grid. During normal grid operation 40 %

(54 100/134 283) of the annual energy is supplied by the micro grid. An additional 9 726 kWh is

supplied during grid failure for 39 days.

Food and energy Figure 33 illustrates the proposed food and energy concept to be implemented at the Mdeni

community. Food and energy combined the electricity generation with roof integrated PV modules

with growing greenhouse vegetables. The addition of the food and energy concept allows the

community to grow food which will be used for the community and sold at road stalls for the locals

and travelers. Additionally jobs are created. 11 tons of vegetables can be produced per annum while

5 additional jobs are created generating an income for 5 households in the community.


0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

SO

C


Figure 33. Proposed food and energy illustration.

FCEV dispenser Figure 34 shows that it is approximately 40 km between the Mdeni community and Maclear, the

nearest town. Figure 35 shows the winding road to the town while Figure 36 shows people walking

the distance. A possible addition to the project can be a bus that transports people once a week to

and from the town. Currently however, busses require a considerable amount of hydrogen. The

requirement of hydrogen will be mainly for the bus with the town power being second. This will

result in power becoming a risk again. Power supply is ranked higher than transport since farmers

driving trucks, pickups and tractors with trailers regularly transport workers to and from town.

Although this would be a very valuable addition to the project, it simply is not viable and ranked

lower than a firm power supply.

Figure 34. Distance from Mdeni community to nearest town.


Figure 35. Winding road to the town.

Figure 36. People walking the distance.


4. Cost and economics

The financial analysis of this project is one of the important aspects to verify that the chosen

technology is feasible. The approach followed includes all of the cost known about this technology

and environment. Costs are done in USD. Where prices are provided in South African Rands, they

were converted to USD using an exchange rate of R14.47 to the USD.

Table 2 show the capital and operation and maintenance analysis of the system. The return on

investment is shown in Error! Reference source not found. over a period of 20 years.

Table 3 shows the investment with Figure 38 show in a return on investment in 14 years. For this

system there is no real loss of income when the power is interrupted so there is no real benefit that

could generate an income other than the savings made due to the PV system and the possible

revenue generated from the food and energy. Table 3 shows LCE of $2.35 and $2.27 for 20 years and

25 years respectively. Without the food and energy the system will not payback in any period.


Table 2: Financial analysis

Technical Operating Parameters and Specifications

Hydrogen Production Facility Design Capacity (kg of H2/day) 6

Reliability (include maintanance) 0.90

Plant Output (kg/year) 700

Financial Input Values

Assumed start-up year 2016

Current year for costs 2016

Start-up Time (years) 0.4

Plant life (years) 30

Analysis period (years) 20

Interest rate on debt, if applicable (%) 10.50%

Debt Period (years) 20-25

Decommissioning costs (% capital investment) 1%

Capital Costs - Base Station

36.4 kW Solar PV plant $ 36 940.00

2 x 7 kW PEM electrolyser systems $ 175 000.00 Turn Key system

Greenhouse capital costs $ 75 000.00

Site Preparation $ 50 000.00

Engineering & design ($) $ 50 000.00

Hydrogen Storage 200kg $ 85 000.00 1x200kg

BOP $ 50 000.00

Intrumentation and control $ 34 694.00

Project contingency ($) $ 50 000.00

Total Depreciable Capital Costs $606 634

Non-Depreciable Capital Costs

Cost of land ($/acre) $ -

Land required (acres) 0.5

Land Cost ($) -$

Decommissioning costs $ 6 066.34

Total Non-Depreciable Capital Costs 6 066.84$

Total Capital Costs $ 612 700.84

O&M

Facility plant staff (number of FTEs) 2

Burdened labor cost, including overhead ($/man-hr) $20

Production Facility Labor cost, $/month $ 9 920.00

G&A rate (% of labor cost) 3%

G&A ($/month) 24.80$

Licensing, Permits and Fees ($/month) $ 83.33

Property tax and insurance rate (% of total capital investment/month) 0.3%

Property taxes and insurance ($/month) 153.18$

Production Maintenance and Repairs ($/month) $ 153.18

Total Fixed Operating Costs ($/month) 10 356.52$

O&M over 20 and 25 years including inflasion $ 2 500 694.58 $ 3 123 589.73

Financial Analysis

Micro grid

Notes

1 % capital investment

Complete PV farm

Infrastructure-Buildings, Fence, ect.

Assumed to be supplied by customer


Table 3. Investment model.

Figure 37: Levlised cost of eenrgy

Figure 38. 15 year return on investment.

25 years 20 years

Total capital cost over 20 and 25 years $ 612 700.84 $ 612 700.84

Interest rate 10.5 10.5

Periods (years) 25 20

Monthly Installment 5 785.01$ 6 117.08$

Monthly profit from food and energy 1 937.00$ 1 937.00$

Energy save (4508 kWh/month @ $ 0.1/kWh) 450.80$ 450.80$

Total income + saving $ 2 387.80 $ 2 387.80

Levilised Cost of Energy 2.35 2.27

Investment


5. Safety analysis

Hydrogen safety at micro grid hydrogen system is carefully considered taking in account any possible

hazards or failure modes. For an explosion to exist there must be an ignition, fuel and combustible

material. Possible risks areas were identified and are addressed in detail in the following sections.

This system being in a community already contributes a risk of tampering. The entire system will be

fenced in and access controlled. Additionally, all hydrogen components are to be fenced in an

second fence.

Risk analysis

5.1 Ignition sources

At the hydrogen system, ignition can be due to an electrical spark, open flame or a heat source

above Hydrogen’s auto ignition temperature. All of these should thus be removed or reduced.

Spark sources where H2 can accumulate are removed by using vapour proof lights. All the electrical

installation at the hydrogen system should be done according to appropriated standards to reduce

possible sparks. By installing the electrical components and cables as low as possible, and below the

H2 pipes, the installation is made inherently safe. The low density of H2 will cause any leaked H2 to

flow upwards due to the buoyancy forces acting on it. It is thus low risk that the H2 and the electric

installation should come into contact.

Open flames should be guarded against through appropriate signage, personnel training and access

control to the system. All customers entering the site should note by appropriate signage that no

open flames are allowed.

5.2 Fuel and combustible material

In this case the fuel is oxygen and the combustible material is H2. It is impossible to remove the fuel

but possible to reduce the concentration of H2. Hydrogen is combustible when in a concentration

between 4% and 74%. The concentration can be managed through proper ventilation.

When taking into account the maximum amount of H2 stored on site and the size of the room, it is

determined that the maximum concentration can only be 0.6%. Thus it is not necessary to add any

additional ventilation. It is proposed that some autonomous ventilation, e.g. wind powered, be

added. This will also ensure that there is no place where hydrogen can accumulate if these are

installed at the highest point of the fuel cell and hydrogen production containers.

5.3 Hydrogen storage

Hydrogen is stored in tube cylinders. The cylinders should be inspected as per regulations and only

handled by qualified persons. The correct personal protection equipment (PPE) should be worn. The

cylinders should be fixed securely and the correct signage, as per regulations, should be installed.

5.4 Emergency exits, procedures


Emergency, evacuation routes and procedures should be indicated as per national regulations. The

appropriate firefighting equipment should be installed and marked as per regulations.

5.5 Personnel safety

All authorised persons entering the site should use appropriate PPE for the task they plan to

perform. All persons must wear appropriate PPE during construction and maintenance. Access to

the site is being controlled at all times. Only authorised persons should be allowed to enter.

All persons working at the system should receive appropriate training including operating and

emergency procedures. Even though the system has been designed to operate autonomously,

operators should have a clear idea of what to do in case of an emergency.

Areas where flammable gasses are classified to aid with the selection and installation of equipment

that is to use in that area. However electrolyser procured for this project is designed to operate in a

non-hazardous area.

Safety analysis

The system be classified as non-hazardous area if the ventilation system supplied enough fresh air to

dilute hydrogen to a concentration of lower than 0.8% (20% of the LEL of hydrogen) in the event of

an accident. Pressure release valves are installed at varies locations to prevent unwanted pressures.

Table 4 shows a cause and effect analysis for the control system:

Table 4: Cause and effect analysis.

CAUSE (FAULT) EFFECT (PRECAUTION)

1 Hydrogen leak detected Go to shutdown procedure

2 Smoke detected Go to shutdown procedure

3 Ventilation system fail Go to shutdown procedure

4 Any valve malfunction Go to startup mode and retry valve

5 Abnormal temperature Go to shutdown procedure

6 Abnormal high pressure Go to shutdown procedure

Two emergency shutdown buttons is be fitted to shut down the system immediately in the event of

an accident.


6. Regulations, codes and standards

Safety standards will be complied with. HVAC is crucial in hazardous zone classification reduction.

Standards and guidelines identified for production, transportation, and fueling stations include:

IEC EN1127-1 for the classification of explosive atmospheres: Explosion prevention and

protection.

TC197 WG11 and ISO TS20100 for fueling station guidelines [5].

SAE-TIR-J-2600 for vehicle fuelling connection devices [5].

SAE-TIR-J2601 for refueling protocols [5].

SAE-TIR-J-2719 for fuel specifications [5].

SAE-TIR-J-2799 for 700 bar refueling connection devices and vehicle to station

communication [5].

ASME B31.3 process piping codes and standards [5].

NFPA 70 national electric codes and standards [5].

NFPA496 for purged enclosures [5].

NFPA497M for the classification of gases, vapors, dust for electrical equipment in hazardous

(classified) zones [5].

NFPA55 for the storage, use, and handling of compressed gasses and cryogenic fluids in

portable and stationary containers, cylinders, and tanks [5].

NFPA 2 vehicle fuel system code [5].


7. Operation and maintenance

Operation

The system is completely autonomous. When necessary a competent person should be contacted if

any issues arise.

Start-up

This is performed with the push of the start button. The system will not start if hydrogen or smoke is

detected.

Grid supply

In this mode the grid supply is available. The electrolyser will produce hydrogen until the hydrogen

storage SOC reaches 100%. The fuel cell will perform peak shaving if the hydrogen storage SOC is

above 30%.

Compression

The compressor operates while hydrogen is being produced. The compressor comprises of

mechanical switches which turns off the compressor when the inlet pressure goes below 10 barg

and the outlet pressure reaches 200 barg.

Battery charge

A small battery bank is used for fuel cell startup and transients. These batteries are constantly

charged and only operate for a few seconds at a time.

Shutdown

Emergency shutdown buttons are presents which will shut down and make the system safe when

pressed. Additionally conditions monitored will also be used by the main controller to shut down the

system when it is neceaasry.

Control and communication


The operation and control of the system implements a Siemens S7-1200 SIMATIC modular

Controller. The benefits of this system includes: flexible in use, openness in hardware and software

configuration, rugged and maintenance free.

Sensors monitor and control all power, temperatures, flows, hydrogen supply and pressures in the

system as well as all possible safety conditions.

Maintenance

An inspection of the system is performed once monthly. The hydrogen sensors are to be tested

once monthly. Any irregularities will be addressed immediately. Air filters will be replaced every 3

months, or for sites with dust problems, this can be reduced to every month if necessary.

All major components follow the maintenance intervals specified in their individual maintenance

manuals.


8. Environmental analysis

Prior to the implementation of the project an Environmental Impact Report (EIR) may be requested.

This report will serve to inform all relevant public agency decision makers as well as the general

public of the possible environmental effects the project might have and ways in which these effects

can and will be minimized. The report will provide a general description of the projects technical,

economic and environmental characteristics with special reference to possible environmental

impacts which will be discussed for all phases of the project ranging from the proposal phase to the

implementation phase. A preliminary desktop analysis concluded that possible environmental

impacts that should be considered are:

The clearing of vegetation for the establishment of a photo-voltaic power plant;

The possible visual impact of the site development;

Pollution and energy loss as a result of the water electrolysis (PEM electrolyser) process, and

finally;

Noise pollution caused by compressors.

A preliminary analysis for the abovementioned envisaged impacts is discussed in more detail.

Clearing of vegetation

The site proposed for the system is an open piece of land with no vegetation and no endangered

species present. Vegetation will be added through the food and energy project.

Visual impact

The visual impact associated with the project is considered minimal. The PV system and

accompanying containers will be esthetically designed to fit into the setup and environment.

Resources and emission analysis

Figure 39: Well-to-Wheel analysis illustration.


Because the process is adding solar energy, the addition to air pollution footprint is minimal. Air

pollution is actually reduced due to the reduction of the load reliance on grid energy which is fossil

fuel based.

Noise analysis

A source of noise pollution is the compressors that will be used to compress hydrogen gas. This

compressor will be installed inside a container which should damper the noise generated by the

machine. The compressor will further only be used during certain times of the day and use will be

discouraged during nighttime. Compressor noise ranges from approximately 90 LwA to 110 LwA

expressed in dB. Figure 40 shows the change in noise level over distance for a compressor producing

110 LwA and excludes the effects of ambient noises, the dampening effect caused by the container

and the influence of buildings and other physical structures.

Figure 40: Change in compressor noise over distance.

The noise experienced at 45 LAeq can be compared to the noise experienced in a typical office

space, which is acceptable for most people. The worst case scenario will be noise generated at 58

LAeq between within 50m of a compressor. Considering that the propagation of the sound will be

reduced by the container, buildings and structures in the area, it can be concluded that the

compressors should not have a significant effect on noise pollution in the areas.

Therefore, no significant irreversible environmental changes or significant environmental effects

that cannot be managed are apparent for this development.

0

10

20

30

40

50

60

70

50m 100m 150m 200m 300m

Change in compressor noise over distance

Noise in LAeq (dB)


9. Community education and awareness

The project will provide the opportunity to educate learners about various components of hydrogen

systems and safety, PV systems, and food growing via the food and energy. The location of the

system is selected to be at the school in order to subject the learners to the system. The learners

and people in the community will be provided information about the technologies through the

schools. In this manner the educators are empowered and the learners are educated, and the

people in the community are made aware of the difference that they are making by having such a

system.

For Global Market

* Measurement tolerance +/- 3%** Estimated

Warranted power output STC (Pnominal)

Rated voltage (Vmpp) at STC

Rated current (lmpp) at STC

Open circuit voltage (Voc) at STC

Short circuit current (Isc) at STC

Module effi ciency

Rated output (Pmpp) at NOCT

Rated voltage (Vmpp) at NOCT

Rated current (Impp) at NOCT

Open circuit voltage (Voc) at NOCT

Short circuit current (Isc) at NOCT

Temperature coeffi cient (Pmpp)

Temperature coeffi cient (Isc)

Temperature coeffi cient (Impp)

Temperature coeffi cient (Vmpp)

Temperature coeffi cient (Voc)

Normal operating cell temperature (NOCT)

STC rated output (Pmpp)*

PTC rated output (Pmpp)**

0/+5 Wp

ELECTRICAL SPECIFICATIONS

- 0.47%/K

+0.035%/K

- 0.042%/K

- 0.433%/K

- 0.328%/K

47±2°C

Maximum system voltage (UL/IEC)

Number of diodes

Maximum series fuse rating

1000VDC ***

6 (or 3)

15 A

Standard sorted output

EN

CHSM6610M Series

DatasheetCrystalline PV Module

260 Wp

232.2 Wp

260 Wp

31.19 V

8.38 A

38.39 V

8.70 A

15.9%

188.4 Wp

27.73 V

6.79 A

34.94 V

7.18 A

265 Wp

236.8 Wp

265 Wp

31.49 V

8.44 A

38.55 V

8.74 A

16.2%

192.1 Wp

28.06 V

6.84 A

35.08 V

7.21 A

270 Wp

241.4 Wp

270 Wp

31.82 V

8.51 A

38.70 V

8.77 A

16.5%

195.7 Wp

28.36 V

6.90 A

35.22 V

7.24 A

275 Wp

246.0 Wp

275 Wp

32.09 V

8.57 A

38.85 V

8.79 A

16.9%

199.3 Wp

28.68 V

6.95 A

35.36 V

7.25 A

280 Wp

250.6 Wp

280 Wp

32.56 V

8.60 A

39.16 V

8.85 A

17.2%

202.9 Wp

29.10 V

6.97 A

35.64 V

7.30 A

260 265 270 275 280

*** Option: 1500VDC for special requirement in advance

80.20%

0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5

Linear Performance Wanrranty100.00%

95.00%

90.00%

85.00%

80.00%

75.00%

97.00%

RELATED PARAMETERS QUALIFICATION AND LINEAR WARRANTIES

Product standard IEC 61215, 61730 / UL 1703

1st year

2nd~ 25th years

Extended product warranty

Output decline 3%/year performance Pmpp (STC)

Output decline 0.7%/year performance Pmpp (STC)

Number of cells / cell arrangement

Cell type

Cells dimension

Packing unit

Weight of packing unit

monocrystalline

60 / 6 x 10

6”

25 modules

508 kg / 1120 lbs

10 years

MECHANICAL SPECIFICATIONS

Outer dimensions (L x W x H)

Frame technology

Module composition

Weight (module only)

Front glass thickness

Junction box IP rating

Cable length / diameter (UL)

Cable length / diameter (IEC)

Maximum load capacity

Fire performance (UL/IEC)

Connector type (UL/IEC)

Front view

Glass / EVA / Backsheet (white)

3.2 mm / 0.13 in

IP 65 (above)

1000 mm / 39.37 in / 12 AWG

1000 mm / 39.37 in / 4 mm²

5400 Pa

Type 1 (UL) or Class C (IEC)

MC type 4 compatible

MODULE DIMENSION DETAILS

Side view Frame cross sectionRear view

© Chint Solar (Zhejiang) Co., Ltd. All rights reserved.Specifications and designs included in this datasheet are subject to change without notice.

100

mm

/0.3

28 fe

et

1300 P / 10-2015

18.4 kg / 40.57 lbs

Aluminum, silver anodized

1648 x 990 x 40 mm64.88 x 38.98 x 1.57 in

990 mm/3.248 feet 40 mm/0.131 feet

946 mm/ 3.104 feet

32 mm/ 0.105 feet

11 mm/ 0.036 feet

Mounting hole

6-Φ5.5 mm / 0.018 feet

16-3.5 mm x8.5 mm/ 0.011 feet x0.028 feet

6-7 mm x11.5 mm / 0.023 feet x0.038 feet

Drainage hole

Ground hole

1000

mm

/3.2

81 fe

et

40 m

m/0

.131

feet

198

mm

/0.6

50 fe

et

824

mm

/2.7

03 fe

et

1648

mm

/5.4

07 fe

et

Model Article No. (IEC) Article No. (UL)

ARTICLE NUMBER (per panel)-(NOVA) CHSM6610M Series

(NOVA) CHSM6610M-260





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NENEN50438,NRS097-2-1,PEA2013,PPC,RD1699/413,RD661/2007,Res.n°7:2013,SI4777,UTEC15-712-1,VDE0126-1-1,VDE-AR-N4105,VFR2014

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Technical dataSunny Tripower

10000TLSunny Tripower



17000TLInput (DC)Max.DCpower(@cosϕ=1) 10200W 12250W 15340W 17410WMax.DCvoltage 1000V 1000V 1000V 1000VMPPvoltagerange 320V–800V 380V–800V 360V–800V 400V–800VDCnominalvoltage 600V 600V 600V 600VMin.DCvoltage/startvoltage 150V/188V 150V/188V 150V/188V 150V/188VMax.inputcurrent/perstring A:22A,B:11A/33A A:22A,B:11A/33A A:33A,B:11A/33A A:33A,B:11A/33ANumberofMPPtrackers/stringsperMPPtracker 2/A:4,B:1 2/A:4,B:1 2/A:5,B:1 2/A:5,B:1Output (AC)ACnominalpower(@230V,50Hz) 10000W 12000W 15000W 17000WMax.ACapparentpower 10000VA 12000VA 15000VA 17000VANominalACvoltage;range 3/N/PE,230V/400V;160V–280VACgridfrequency;range 50,60Hz;–6Hz,+5Hz 50,60Hz;–6Hz,+5Hz 50,60Hz;–6Hz,+5Hz 50,60Hz;–6Hz,+5HzMax.outputcurrent 16A 19.2A 24A 24.6APowerfactor(cosϕ) 0.8leading...0.8laggingPhaseconductors/connectionphases/powerbalancing 3/3/— 3/3/— 3/3/— 3/3/—EfficiencyMax.efficiency/Euro-eta 98.1%/97.7% 98.1%/97.7% 98.1%/97.7% 98.1%/97.7%Protection devicesDCreverse-polarityprotection/reversecurrentprotection ●/electronic ●/electronic ●/electronic ●/electronicESSswitch-disconnector ● ● ● ●ACshortcircuitprotection ● ● ● ●Groundfaultmonitoring ● ● ● ●Gridmonitoring(SMAGridGuard) ● ● ● ●Galvanicallyisolated/all-polesensitivefaultcurrentmonitoringunit —/● —/● —/● —/●DCovervoltageprotectortypeII ○ ○ ○ ○Stringfailuredetection ● ● ● ●Protectionclass/overvoltagecategory I/III I/III I/III I/IIIGeneral dataDimensions(W/H/D)inmm 665/690/265 665/690/265 665/690/265 665/690/265Weight 65kg 65kg 65kg 65kgOperatingtemperaturerange –25°C...+60°C –25°C...+60°C –25°C...+60°C –25°C...+60°CNoiseemission(typical) www.SMA-Solar.com www.SMA-Solar.com www.SMA-Solar.com www.SMA-Solar.comInternalconsumption:(night) 1W 1W 1W 1WTopology transformerless transformerless transformerless transformerlessCoolingconcept OptiCool OptiCool OptiCool OptiCoolElectronicsprotectionrating/connectionarea(asperIEC60529) IP65/IP54 IP65/IP54 IP65/IP54 IP65/IP54

Climaticcategory(perIEC60721-3-4) 4K4H 4K4H 4K4H 4K4HFeaturesDCconnection:SUNCLIX ● ● ● ●ACconnection:screwterminal/spring-typeterminal —/● —/● —/● —/●Display:textline/graphic —/● —/● —/● —/●Interfaces:RS485/Bluetooth ○/● ○/● ○/● ○/●Warranty:5/10/15/20/25years ●/○/○/○/○ ●/○/○/○/○ ●/○/○/○/○ ●/○/○/○/○Certificatesandpermits(moreavailableonrequest) CE,VDE0126-1-1,Enel-GUIDA,G83/1-1*,PPC,AS4777,EN50438**,C10/C11,IEC61727

*Inplanning,**DoesnotapplytoallnationaldeviationsofEN50438●Standardfeatures○Optionalfeatures—NotavailableProvisionaldata,asofMarch2010–dataatnominalconditionsTypedesignation STP10000TL-10 STP12000TL-10 STP15000TL-10 STP17000TL-10

Accessories

RS485interfaceDM-485CB-10

DCovervoltageprotector(typeII),inputADCSPDKIT1-10

DCovervoltageprotector(typeII),inputsAandBDCSPDKIT2-10

www.victronenergy.com

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Two AC inputs with integrated transfer switch The Quattro can be connected to two independent AC sources, for example the public grid and a generator, or two generators. The Quattro will automatically connect to the active source.

Two AC Outputs The main output has no-break functionality. The Quattro takes over the supply to the connected loads in the event of a grid failure or when shore/generator power is disconnected. This happens so fast (less than 20 milliseconds) that computers and other electronic equipment will continue to operate without disruption. The second output is live only when AC is available on one of the inputs of the Quattro. Loads that should not discharge the battery, like a water heater for example can be connected to this output.

Virtually unlimited power thanks to parallel operation Up to 6 Quattro units can operate in parallel. Six units 48/10000/140, for example, will provide 54 kW / 60 kVA output power and 840 Amps charging capacity.

Three phase capability Three units can be configured for three phase output. But that’s not all: up to 6 sets of three units can be parallel connected to provide 162 kW / 180 kVA inverter power and more than 2500 A charging capacity.

PowerControl – Dealing with limited generator, shoreside or grid power The Quattro is a very powerful battery charger. It will therefore draw a lot of current from the generator or shoreside supply (16 A per 5 kVA Quattro at 230 VAC). A current limit can be set on each AC input. The Quattro will then take account of other AC loads and use whatever is spare for charging, thus preventing the generator or mains supply from being overloaded.

PowerAssist – Boosting shore or generator power This feature takes the principle of PowerControl to a further dimension allowing the Quattro to supplement the capacity of the alternative source. Where peak power is so often required only for a limited period, the Quattro will make sure that insufficient mains or generator power is immediately compensated for by power from the battery. When the load reduces, the spare power is used to recharge the battery.

Solar energy: AC power available even during a grid failure The Quattro can be used in off grid as well as grid connected PV and other alternative energy systems. Loss of mains detection software is available.

System configuring - In case of a stand-alone application, if settings have to be changed, this can be done in a matter of

minutes with a DIP switch setting procedure. - Parallel and three phase applications can be configured with VE.Bus Quick Configure and VE.Bus System

Configurator software. - Off grid, grid interactive and self-consumption applications, involving grid-tie inverters and/or MPPT

Solar Chargers can be configured with Assistants (dedicated software for specific applications).

On-site Monitoring and control Several options are available: Battery Monitor, Multi Control Panel, Ve.Net Blue Power panel, Color Control panel, smartphone or tablet (Bluetooth Smart), laptop or computer (USB or RS232).

Remote Monitoring and control Victron Ethernet Remote, Victron Global Remote and the Color Control Panel. Data can be stored and displayed on our VRM (Victron Remote Management) website, free of charge.

Remote configuring When connected to the Ethernet, systems with a Color Control panel can be accessed and settings can be changed.

Quattro 48/5000/70-100/100

Quattro 24/3000/70-50/50

Quattro Inverter/Charger 3kVA - 10kVA Lithium Ion battery compatible

Color Control panel, showing a PV application

Victron Energy B.V. | De Paal 35 | 1351 JG Almere | The Netherlands General phone: +31 (0)36 535 97 00 | Fax: +31 (0)36 535 97 40 E-mail: [email protected] | www.victronenergy.com

Quattro 12/3000/120-50/50 24/3000/70-50/50

12/5000/220-100/100 24/5000/120-100/100 48/5000/70-100/100

24/8000/200-100/100 48/8000/110-100/100

48/10000/140-100/100 PowerControl / PowerAssist Yes Integrated Transfer switch Yes AC inputs (2x) Input voltage range: 187-265 VAC Input frequency: 45 – 65 Hz Power factor: 1 Maximum feed through current (A) 2x 50 2x100 2x100 2x100

INVERTER Input voltage range (V DC) 9,5 – 17V 19 – 33V 38 – 66V Output (1) Output voltage: 230 VAC ± 2% Frequency: 50 Hz ± 0,1% Cont. output power at 25°C (VA) (3) 3000 5000 8000 10000 Cont. output power at 25°C (W) 2400 4000 6500 8000 Cont. output power at 40°C (W) 2200 3700 5500 6500 Cont. output power at 65°C (W) 1700 3000 3600 4500 Peak power (W) 6000 10000 16000 20000 Maximum efficiency (%) 93 / 94 94 / 94 / 95 94 / 96 96 Zero load power (W) 20 / 20 30 / 30 / 35 45 / 50 55 Zero load power in AES mode (W) 15 / 15 20 / 25 / 30 30 / 30 35 Zero load power in Search mode (W) 8 / 10 10 / 10 / 15 10 / 20 20

CHARGER Charge voltage 'absorption' (V DC) 14,4 / 28,8 14,4 / 28,8 / 57,6 28,8 / 57,6 57,6 Charge voltage 'float' (V DC) 13,8 / 27,6 13,8 / 27,6 / 55,2 27,6 / 55,2 55,2 Storage mode (V DC) 13,2 / 26,4 13,2 / 26,4 / 52,8 26,4 / 52,8 52,8 Charge current house battery (A) (4) 120 / 70 220 / 120 / 70 200 / 110 140 Charge current starter battery (A) 4 (12V and 24V models only) Battery temperature sensor Yes

GENERAL Auxiliary output (A) (5) 25 50 50 50 Programmable relay (6) 3x 3x 3x 3x Protection (2) a-g VE.Bus communication port For parallel and three phase operation, remote monitoring and system integration General purpose com. port 2x 2x 2x 2x Remote on-off Yes Common Characteristics Operating temp.: -40 to +65˚C Humidity (non-condensing): max. 95%

ENCLOSURE Common Characteristics Material & Colour: aluminium (blue RAL 5012) Protection category: IP 21 Battery-connection Four M8 bolts (2 plus and 2 minus connections) 230 V AC-connection Screw terminals 13 mm2 (6 AWG) Bolts M6 Bolts M6 Bolts M6 Weight (kg) 19 34 / 30 / 30 45/41 45

Dimensions (hxwxd in mm) 362 x 258 x 218 470 x 350 x 280 444 x 328 x 240 444 x 328 x 240

470 x 350 x 280 470 x 350 x 280

STANDARDS Safety EN-IEC 60335-1, EN-IEC 60335-2-29, IEC 62109-1 Emission, Immunity EN 55014-1, EN 55014-2, EN 61000-3-3, EN 61000-6-3, EN 61000-6-2, EN 61000-6-1 Automotive Directive 2004/104/EC Anti-islanding See our website 1) Can be adjusted to 60 HZ; 120 V 60 Hz on request 2) Protection key: a) output short circuit b) overload c) battery voltage too high d) battery voltage too low e) temperature too high f) 230 VAC on inverter output g) input voltage ripple too high

3) Non-linear load, crest factor 3:1 4) At 25˚C ambient 5) Switches off when no external AC source available 6) Programmable relay that can a.o. be set for general alarm, DC under voltage or genset start/stop function AC rating: 230 V / 4 A DC rating: 4 A up to 35 VDC, 1 A up to 60 VDC

Digital Multi Control Panel A convenient and low cost solution for remote monitoring, with a rotary knob to set PowerControl and PowerAssist levels.

Blue Power Panel Connects to a Multi or Quattro and all VE.Net devices, in particular the VE.Net Battery Controller. Graphical display of currents and voltages.

Computer controlled operation and monitoring Several interfaces are available: - MK2.2 VE.Bus to RS232 converter Connects to the RS232 port of a computer (see ‘A guide to VEConfigure’) - MK2-USB VE.Bus to USB converter Connects to a USB port (see ‘A guide to VEConfigure’) - VE.Net to VE.Bus converter Interface to VE.Net (see VE.Net documentation) - VE.Bus to NMEA 2000 converter - Victron Global Remote The Global Remote is a modem which sends alarms, warnings and system status reports to cellular phones via text messages (SMS). It can also log data from Victron Battery Monitors, Multis, Quattros and Inverters to our VRM website through a GPRS connection. Access to this website is free of charge. - Victron Ethernet Remote To connect to the Ethernet. - Color Control panel (see picture on page 1) Behind the color LCD a Linux microcomputer runs open source software. The Color Control (CCGX) provides intuitive control and monitoring for all products connected to it. The list of Victron products that can be connected is endless: Inverters, Multis, Quattros, all our latest MPPT solar chargers, BMV-700, BMV-600, Lynx Ion + Shunt and more. The information can also be forwarded to our free remote monitoring website: the VRM Online Portal.

BMV-700 Battery Monitor The BMV-700 Battery Monitor features an advanced microprocessor control system combined with high resolution measuring systems for battery voltage and charge/discharge current. Besides this, the software includes complex calculation algorithms, like Peukert’s formula, to exactly determine the state of charge of the battery. The BMV-700 selectively displays battery voltage, current, consumed Ah or time to go. The monitor also stores a host of data regarding performance and use of the battery. Several models available (see battery monitor documentation).

Technical Specifications

HOGEN®

S Series Hydrogen Generation Systems

www.protononsite.com | T 203.949.8697 | F 203.949.8016 | Proton OnSite 10 Technology Drive Wallingford, CT 06492 | [email protected]

S10 S20 S40

DESCRIPTION

On-site hydrogen generator in an integrated, automated, site-ready enclosure. Load Following operation automatically adjusts output to match demand.

ELECTROLYTE

Proton Exchange Membrane (PEM) - caustic-free

HYDROGEN PRODUCTION

Net Production Rate: Nm3/hr @ 0°C, 1 bar SCF/hr @ 70°F, 1 atm SLPM @ 70°F, 1 atm kg per 24 hours

0.265 Nm3/hr 0.53 Nm3/hr 1.05Nm3/hr 10 SCF/hr 20 SCF/hr 40 SCF/hr 4.7 SLPM 9.4 SLPM 18.8 SLPM 0.57 kg/24hr 1.14 kg/24hr 2.27 kg/24hr

Delivery Pressure - Nominal 13.8 barg (200 PSIG)

Power Consumed per Volume of H2 Gas Produced

6.7 kWh / Nm3 17.6 kWh / 100 ft3

Purity (Concentration of Impurities) 99.9995% (Water Vapor < 5 PPM, -65°C (-85°F) Dewpoint, N2 < 2 PPM, O2 < 1 PPM, All Other Undetectable)

Turndown Range 0 to 100% net product delivery

Upgradeability N/A

DI WATER REQUIREMENT

Rate at Max Consumption Rate 0.235 L/hr (0.065 gal/hr) 0.47 L/hr (0.13 gal/hr) 0.94 L/hr (0.25 gal/hr)

Temperature 5°C to 35°C (41°F to 95°F)

Pressure 1.5 to 4 barg (21.8 to 58.0 PSIG)

Input Water Quality ASTM Type II Deionized Water required, < 1 micro Siemen/cm (>1 megOhm-cm) ASTM Type I Deionized Water preferred, < 0.1 micro Siemen/cm (> 10 megOhm-cm)

PD-0600-0061 Rev. C © 2011 Proton Energy Systems, Inc. All Rights Reserved. Proton, Proton OnSite, Proton Energy Systems, and HOGEN are trademarks of Proton Energy Systems, Inc. d/b/a Proton OnSite.

S10 S20 S40

HEAT LOAD AND COOLANT REQUIREMENT

Cooling Air-Cooled; Ambient Air, 5°C to 40°C (41°F to 104°F)

Max. Heat Load from System 1.1 kW / 3,754 BTU/hr 2.2 kW / 7,507 BTU/hr 4.3 kW / 14,673 BTU/hr

ELECTRICAL SPECIFICATIONS

Recommended Breaker Rating 4 kVA 8 kVA 12 kVA

Electrical Specification 205 to 240 VAC, single phase, 50 or 60 Hz

INTERFACE CONNECTIONS *Consult Installation Manual for details*

H2 Product Port 1/4” CPI™ compression tube fitting, SS

H2 / H2O Vent Port 1/2” CPI™ compression tube fitting, SS

DI Water Port 1/4” tube push-to-lock, polypropylene

Calibration-Gas Port N/A

Coolant Supply Port N/A

Coolant Return Port N/A

Drain Port 1/4” tube push-to-lock polypropylene

Electrical Connect to on-board circuit breaker

Communications RS 232, Ethernet

CONTROL SYSTEMS

Standard Features Fully automated, push button start/stop. E-stop. On-board H2 Leak detection. Automatic fault detection and system depressurization.

Remote Alarm Form C relay 2A/30VDC rated switching

Remote Shutdown Circuit breaker shunt trip

ENCLOSURE CHARACTERISTICS

Dimensions, W x D x H (Product / Est. Shipping)

31” x 38” x 42” (79 x 97 x 107 cm) / 38” x 45” x 52” (97 x 114 x 132 cm)

Weight (Product / Est. Shipping) 475 lbs (216 kg) / 650 lbs (295 kg)

Rating IP22

ENVIRONMENTAL CONSIDERATIONS *Do Not Freeze*

Standard Siting Location Indoor, level ± 1°, 0 to 90% RH non-condensing, Non-hazardous/non-classified environment

Storage/Transport Temperature 5°C to 60°C (41°F to 140°F)

Ambient Temperature Range 5°C to 40°C (41°F to 104°F)

Altitude Range - Sea Level to: 1520 m (5000 ft)

Ventilation Proper ventilation must be provided from a non-hazardous area, at a rate in accordance with IEC60079-10, Zone 2 NE

SAFETY AND REGULATORY CONFORMITY

Maximum On-board H2 Inventory at Full Production

0.016 Nm3 / 0.6 SCF / 0.0014 kg

Cabinet Ventilation with Environment NFPA 69 and EN 1127-1, Clause 6.2. Vent fan draws fresh air up to 28 Nm3/min (1000 ft3/min)

Noise dB(A) at 1 Meter < 70

Approvals cTUVus (UL and CSA equivalent), CE (PED, ATEX, LVD, Mach. Dir. EMC), NYFD Approval

OPTIONS

Proton Onsite offers a wide range of options to tailor your HOGEN hydrogen generation system to meet your specific operational requirements. Please contact your local representative to discuss the current list of options available to best fit your needs.

Consult Proton Onsite Applications Department for proper installation guidelines. Specifications subject to change.

HyPM™ HD 30 Heavy Duty Fuel Cell Power Module

Liquid-cooled advanced MEA PEM stack

Integral Balance of Plant

Advanced onboard controls and diagnostics

Comes with low pressure cathode air delivery

-46°C sub-zero shutdown capability

Technical Data Rated Electrical Power 33 kW continuous

Operating Current 0 to 500 ADC

Operating Voltage 60 to 120 VDC

Peak Efficiency 55%1)

Response < 5 s from off to idle < 3 s from idle to rated power

Fuel Dry Hydrogen >99.98%

Oxidant Ambient Air

Coolant De-ionized water (DI H2O) or 60% ethylene glycol / DI H2O

Ambient Temperature -10 to +55°C operating -40 to +65°C storage (<2°C with automated freeze shutdown feature)

Communication CAN v2.0A (standard 11 bit) 1)

Efficiency based on LHV of H2, 25°C, 101.3 kPa, including onboard parasitic loads, excluding radiator fan and water pump

HyPM™ HD30 Typical Performance

1)

Actual delivered product may differ in appearance.

Specifications subject to change without prior notification.

Printed in Canada © Hydrogenics Corporation 2012-04-16

HYDROGENICS Corporation 220 Admiral Blvd, Mississauga, Ont, L5T 2N6 Canada Tel. +1 (905) 361 3660 Fax +1 (905) 361 3626

Rapid start-up and dynamic response

Unlimited start-stop cycling

Robust, rugged and reliable

No water for humidification required

No nitrogen required for shutdown

Physical Dimensions L x W x H2) 605 x 410 x 265 mm

Mass3) 61 kg

Volume3) 66 L 2) Excluding air delivery and optional water pump 3) Including air delivery and optional water pump

Includes Air delivery unit (low pressure blower)

Integration and operation manual

Product Warranty

Optional Coolant pump

Thermal management kit

Diagnostics software

Power electronics components

Applications Urban transit buses

Heavy duty commercial fleet vehicles

Marine

Aerospace

www.hydrogenics.com

[email protected]

HYDROGENICS GmbH Am Wiesenbusch 2, 45966 Gladbeck, Germany Tel. +49 (2043) 944 133 Fax +49 (2043) 944 146

http://www.hydrogenics.com/

mailto:[email protected]

2016 HYDROGEN STUDENT DESIGN · PDF fileRegulations, codes and standards ... which will secure...

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