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240-56227413 Hydrogen Systems Standard

This document provides standards for hydrogen systems, including health and safety requirements, production quality standards, facility requirements, and other technical specifications. It covers topics such as building design for hydrogen storage, fire protection, purging procedures, hydrogen detection, storage vessel requirements, and roles and responsibilities for monitoring compliance. The document is 45 pages and provides detailed requirements to ensure the safe design, operation and maintenance of hydrogen systems.

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0% found this document useful (0 votes)

287 views45 pages

240-56227413 Hydrogen Systems Standard

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iabhua

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Standard Technology

Title: Hydrogen Systems Standard Unique Identifier: 240-56227413

Alternative Reference Number: 36-803

Area of Applicability: Engineering

Documentation Type: Standard

Revision: 2

Total Pages: 45

Next Review Date: October 2021

Disclosure Classification: CONTROLLED

DISCLOSURE

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

M. Maunye H.J. Van Staden M. Verby

GT-LPS Senior Engineering GT- PEIC Senior Consultant GT-LPS CoE Manager
Technologist

Date: …………………………… Date: …………………………… Date: ……………………………

Supported by

…………………………………..

S. Govender
TC Chairperson

Date: ……………………………

PCM Reference : 240-53458738

SCOT Study Committee Number/Name : Design Low Pressure Services
Hydrogen Systems Standard Unique Identifier: 240-56227413
Revision: 2
Page: 2 of 45

CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 5
2. SUPPORTING CLAUSES ........................................................................................................................................ 5
2.1 SCOPE .............................................................................................................................................................. 5
2.1.1 Purpose ..................................................................................................................................................... 5
2.1.2 Applicability................................................................................................................................................ 5
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 5
2.2.1 Normative .................................................................................................................................................. 5
2.2.2 Informative ................................................................................................................................................. 5
2.2.2.1 International and Local Government References ............................................................................. 5
2.2.2.2 Eskom References ............................................................................................................................ 6
2.3 DEFINITIONS .................................................................................................................................................... 7
2.3.1 Classification ........................................................................................................................................... 10
2.4 ABBREVIATIONS ............................................................................................................................................ 10
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................. 10
2.6 PROCESS FOR MONITORING ...................................................................................................................... 10
2.7 RELATED/SUPPORTING DOCUMENTS ....................................................................................................... 10
3. STANDARD FOR HYDROGEN SYSTEMS ........................................................................................................... 10
3.1 HEALTH AND SAFETY ................................................................................................................................... 10
3.2 SAFE PLANT OPERATING PHILOSPHY....................................................................................................... 11
3.3 GENERAL REQUIREMENTS ......................................................................................................................... 12
3.4 HYDROGEN PRODUCTION QUALITY .......................................................................................................... 12
3.5 PRODUCTION CAPACITY AND HYDROGEN GAS STORAGE CAPACITY ................................................ 13
3.6 HYDGROGEN FACILITIES ............................................................................................................................. 13
3.7 BUILDINGS ..................................................................................................................................................... 13
3.7.1 Building Design or Bulk Storage Walls or Weather Shelter .................................................................... 13
3.7.2 Location and QD (Quantity Distance) Guidelines ................................................................................... 14
3.7.3 Access ..................................................................................................................................................... 15
3.7.4 Signage, Posting and Labelling ............................................................................................................... 15
3.7.5 Layout ...................................................................................................................................................... 15
3.7.6 Safety Showers and Eye Washers ....................................................................................................... 16
3.7.7 Ventilation ................................................................................................................................................ 16
3.7.8 Drains ...................................................................................................................................................... 16
3.8 FIRE PROTECTION ........................................................................................................................................ 16
3.9 PURGING ........................................................................................................................................................ 17
3.9.1 Carbon dioxide purging and Cylinders .................................................................................................... 17
3.9.2 Nitrogen purging ...................................................................................................................................... 18
3.9.3 Air purging ............................................................................................................................................... 18
3.10 HYDROGEN AND HYDROGEN FIRE DETECTION .................................................................................... 18
3.10.1 Hydrogen Detection ............................................................................................................................... 18
3.10.2 Hydrogen Detection Specifications ....................................................................................................... 18
3.10.3 Hydrogen fire detection systems ........................................................................................................... 19
3.11 PROTECTIVE MEASURES FOR SLIPRINGS AND COUPLED EXCITERS ............................................... 19
3.12 MECHANICAL PLANT .................................................................................................................................. 19
3.13 HYDROGEN STORAGE ............................................................................................................................... 20
3.13.1 Bulk storage........................................................................................................................................... 20
3.13.1.1 Vessels .......................................................................................................................................... 20
3.13.2 Hydrogen cylinder supply ...................................................................................................................... 21
3.13.3 Hydrogen cylinder pallets ...................................................................................................................... 22
3.13.4 Mobile hydrogen supply ........................................................................................................................ 22
3.14 PIPING SYSTEMS ........................................................................................................................................ 22
3.14.1 Piping systems ...................................................................................................................................... 22

CONTROLLED DISCLOSURE
When downloaded from the EDMS, this document is uncontrolled and the responsibility rests with the user to ensure it is in line
with the authorised version on the system.
Hydrogen Systems Standard Unique Identifier: 240-56227413
Revision: 2
Page: 3 of 45

3.14.2 Supports ................................................................................................................................................ 23

3.14.3 Piping for hydrogen ............................................................................................................................... 23
3.14.4 Bending and forming piping................................................................................................................... 23
3.14.5 Double block-and-bleed ........................................................................................................................ 23
3.15 COMPONENTS ............................................................................................................................................. 24
3.15.1 Joints in piping and tubing ..................................................................................................................... 24
3.15.2 Threaded joints ...................................................................................................................................... 24
3.15.3 Flagged joints ........................................................................................................................................ 24
3.15.4 Silver braze joints .................................................................................................................................. 25
3.15.5 Soft solder joints .................................................................................................................................... 25
3.15.6 Pipe connections ................................................................................................................................... 25
3.15.7 Flanges .................................................................................................................................................. 25
3.15.8 Flexible hoses ....................................................................................................................................... 25
3.15.9 Expansion joints .................................................................................................................................... 25
3.15.10 Valves .................................................................................................................................................. 26
3.15.10.1 Excess Flow Valves (EFVs) ........................................................................................................ 26
3.15.10.2 Emergency Isolation Valves (EIVs) ............................................................................................. 26
3.15.10.3 Isolating Valves ........................................................................................................................... 26
3.15.10.4 Gas Cylinder Valves .................................................................................................................... 27
3.15.10.5 Non Return Valves (NRVs) ......................................................................................................... 27
3.15.11 Gauges ................................................................................................................................................ 27
3.15.12 Hydrogen venting ................................................................................................................................ 27
3.15.13 Transfer connections ........................................................................................................................... 27
3.15.14 Compressor machines ........................................................................................................................ 28
3.15.15 Hydrogen dryers .................................................................................................................................. 28
3.15.16 Generator hydrogen dryers ................................................................................................................. 29
3.15.17 Condensate traps ................................................................................................................................ 30
3.15.18 Cooling water systems ........................................................................................................................ 30
3.16 OVERPRESSURE PROTECTION OF STORAGE VESSELS AND PIPING SYSTEMS ............................. 30
3.16.1 Safety Valves......................................................................................................................................... 30
3.17 PRESSURE REGULATOR ........................................................................................................................... 30
3.17.1 Supplemental pressure relief ................................................................................................................. 31
3.17.2 Failure modes ........................................................................................................................................ 31
3.18 ELECTRICAL CONSIDERATIONS ............................................................................................................... 31
3.18.1 Electrical installation .............................................................................................................................. 31
3.18.2 Bonding and grounding ......................................................................................................................... 31
3.18.3 Electric motors ....................................................................................................................................... 31
3.18.4 Transformer ........................................................................................................................................... 32
3.18.5 Electrical controls .................................................................................................................................. 32
3.18.6 Electrical connections and cabling ........................................................................................................ 32
3.19 CONTROLS AND INSTRUMENTATION ...................................................................................................... 33
3.19.1 Plant operation and instrumentation ..................................................................................................... 33
3.19.2 Mass flow meter .................................................................................................................................... 34
3.19.3 Analysing Apparatus (Indicating)........................................................................................................... 34
3.19.4 Alarms and tips ...................................................................................................................................... 35
3.20 PRODUCTIONS QUALITY AND QUANTITY MANAGEMENT..................................................................... 35
3.20.1 Electrolytic cells ..................................................................................................................................... 36
3.20.2 Before storage ....................................................................................................................................... 36
3.20.3 After storage .......................................................................................................................................... 36
3.20.4 At the generator ..................................................................................................................................... 36
3.20.5 Additional plant monitoring requirements .............................................................................................. 37
3.21 CORROSION PROTECTION ........................................................................................................................ 37
3.22 MAINTAINABILITY ........................................................................................................................................ 37
3.23 MATERIALS FOR HYDROGEN SERVICE ................................................................................................... 37
4. AUTHORISATION .................................................................................................................................................. 38

5. REVISIONS ............................................................................................................................................................ 38
6. DEVELOPMENT TEAM ......................................................................................................................................... 38
7. ACKNOWLEDGEMENTS ...................................................................................................................................... 39
APPENDIX A .............................................................................................................................................................. 40
8.1 ANNEXURE A.1 MATERIAL DATA SPECIFICATION .................................................................................... 40
8.2 ANNEXURE A.2 HYDROGEN EMBRITTLEMENT ......................................................................................... 40
8.2.1 Low Temperature Effects ........................................................................................................................ 41
8.2.1.1 General............................................................................................................................................ 41
8.2.2 Low-Temperature Embrittlement ............................................................................................................. 42
8.2.3 Thermal contraction ................................................................................................................................. 42
8.2.4 Material Suitability for Hydrogen Service ................................................................................................ 42
APPENDIX B .............................................................................................................................................................. 45
9.1 HYDROGEN GENERATING PLANT FACTORY ACCEPTANCE TESTING GUIDELINE ............................. 45

FIGURES
Figure 1: Hydrogen Concentration ............................................................................................................................. 17
Figure 2: Double Block-and-Bleed Arrangement ........................................................................................................ 24

TABLES
Table 1: Hydrogen embrittlement susceptibility of some commonly used metals ...................................................... 41
Table 2: Suitability of some selected materials for hydrogen service ........................................................................ 43
Table 3: (Continued): Suitability of some selected materials for hydrogen service.................................................... 43

1. INTRODUCTION
This document consists of the Standard applicable to the Hydrogen Systems within Eskom.

2. SUPPORTING CLAUSES

2.1 SCOPE

2.1.1 Purpose
Hydrogen is used at the power station as a cooling medium for large two-pole and four-pole generators.
A need has been identified for a document which contains general and specific information relating to the
hydrogen plant, hydrogen reticulation system and generator hydrogen cooling system. This document
defines the minimum requirements for selection of equipment and materials to meet the need, purpose,
functions and safety requirements of these hydrogen systems.

2.1.2 Applicability
This document shall apply throughout Eskom Holdings Limited Divisions.
a. This Standard addresses Eskom's requirements for hydrogen production plant installations,
associated controls, measuring equipment, storage vessels, reticulation system, generator hydrogen
cooling system and plant safety.
b. This standard is applicable to the generator cooling system and includes the inert gas purging
system of the generator.
c. Immediate compliance is required for safety critical items to ensure safe plant operation.
d. Within one year of the authorisation of this standard, compliance of all existing plant shall be
evaluated and future upgrades and/or refurbishment planned accordingly.
e. Within three years there shall be compliance to this standard, or alternatives as authorised by the
Chief Officer.
f. The safety requirements stipulated in this standard are also applicable to hydrogen gas supply
companies. Hydrogen supplied to Eskom, will be accepted only from plants that meets the minimum
safety requirements stipulated in this specification.

2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.

2.2.1 Normative
None

2.2.2 Informative

2.2.2.1 International and Local Government References

[1] NASA Standard NSS 1740.16, Safety Standard for Hydrogen and Hydrogen Systems: Guidelines
for Hydrogen System Design, Materials, Selection, Operations, Storage, and Transportation.
National Aeronautics and Space Administration, Washington, DC, USA
[2] IGC 15/961E, Gaseous Hydrogen Stations. Industrial Gases Council, Brussels, Belgium
[3] NFPA 50A, Standard for Gaseous Hydrogen Systems at Consumer Sites. National Fire Protection
Association, Quincy, MA, USA, 1999
[4] NFPA 50B, Standard for Liquefied Hydrogen Systems at Consumer Sites. National Fire Protection
Association, Quincy, MA, USA, 1999

[5] ANSI/AIAA G-095-2004, American Institute of Aeronautics and Astronauts, Guide to Safety of
Hydrogen and Hydrogen Systems, American National Standard Institute, Reston, VA, USA, 2005
[6] DOL, Occupational Health and Safety Act 85 of 1993, Labour Relations Act, South Africa, 1993.
[7] ASME B31.3-1996, Process Piping.
[8] PD 5500:2015 Specification for unfired fusion welded pressure vessels.
[9] SANS 10108, The Classification of Hazardous Locations and the Selection of Apparatus for use in
such locations.
[10] NFPA 850, Recommended Practice for Fire Protection for Electric Generating Plants and High
Voltage Direct Current Converter Stations.
[11] SANS 10119, Reduction of Explosion Hazards Presented by Electrical Equipment Segregation.
Ventilation and Pressurization.
[12] SANS 10140, Identification Colour Markings (parts 1 to 4).
[13] SANS 1507, Electric cables with extruded solid dielectric insulation for fixed installations
(300/5000V to 1900/3300V).
[14] SANS 1574, Electrical cables — Flexible cords.
[15] SANS 1123, Pipe Flanges.
[16] OHS Act [85 of 1993], Occupational Health and Safety Act of South Africa.
[17] ISO 11114, Transportable gas cylinders- Compatibility of cylinder and valve material with gas
contents.
[18] ISO 11625, Gas cylinders – Safe handling.
[19] ISO 13769, Gas cylinders – Stamp marking.
[20] ISO 16111, Transportable gas storage devices – Hydrogen absorbed in reversible metal hydride
[21] ISO 22734-1, Hydrogen generators using water electrolysis process —Part 1: Industrial and
commercial applications.

2.2.2.2 Eskom References

[22] CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations.
[23] 32-303 Requirements for the Safe Processing, Storage, Removing and Handling of Asbestos and
Asbestos Containing Material, Equipment and Articles.
[24] 240-114767031, Specification for the Identification of the Contents of Pipelines and Vessels.
[25] 240-101712128 (Standard for the Internal Corrosion Protection of Water Systems, Chemical Tanks
and Vessels and Associated Piping with Linings).
[26] 240-56536505, Management of Hazardous Locations.
[27] 240-53114002, Engineering Change Management Procedure.
[28] 240-53114193, Occurrence and Incident Management Procedure.
[29] 36-681, Generation Plant Safety Regulations.
[30] NWS 1409, Specification for Indoor Resin-Encapsulated Dry-Type Transformers.
[31] NWS 1551, Asynchronous Electric Motors.
[32] RES/RR/01/14931, TSI Research Report, Status of the Hydrogen Plants within Eskom, S Wilshire,
Nov 2001.
[33] 240-54937450, Fire Protection and Life Safety Design Standard.
[34] 240-56737448 Fire detection and life safety design standard.
[35] CGA G-5, Hydrogen.
[36] CGA G-5.3, Commodity Specification for Hydrogen.
[37] CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations.
[38] RES/RR/01/14931, TSI Research Report, Status of the Hydrogen Plants within Eskom, S Wilshire,
Nov 2001
[39] CGA G-5.5, Hydrogen Vent Systems.
[40] CGA G-5.6, Hydrogen Pipeline Systems.
[41] CGA G-5.8, High Pressure Hydrogen Piping Systems at Consumer Locations.

[42] NASA Standard NSS 1740.16, Safety Standard for Hydrogen and Hydrogen Systems: Guidelines
for Hydrogen System Design, Materials, Selection, Operations, Storage, and Transportation.
National Aeronautics and Space Administration, Washington, DC, USA.
[43] IGC 15/96/E, Gaseous Hydrogen Stations. Industrial Gases Council, Brussels, Belgium.
[44] 240-56356396: Earthing and Lightning Protection Standard.
[45] 240-56227443: Requirements for Control and Power Cables for Power Station Standard.
[46] 240-76368574: High Security Mesh Fencing.

2.3 DEFINITIONS
Definition Description
The Alternating Current component of a Direct Current (DC) supply. This is
AC Ripple possible in cases where the DC is obtained from a rectified AC supply. It is
easiest measured using a multi-meter set for AC voltage measurement.
Arrested Flame Combustion process which is stopped or flame which is put out
The dew point of a gas that is at atmospheric pressure, normally regarded as
1bar or 101 kPa. Generally, plant dew point measurements are at higher
Atmospheric Dew Point
pressures and will need to be adjusted, through calculations, to provide an
atmospheric dew point value.
Authorised Inspection Person responsible for the plant (normally the Government Ticket Holder) refer to
Authority (AIA) definition in vessels under pressure regulations.
Regulations, requirements or standards that have been made binding and
Code
mandatory by a local or national government or design standard organisation.
Component Any discrete part of a complete item or system.
Space not normally occupied by personnel NOTE Confined space has limited or
restricted openings for entry and exit, may lack adequate ventilation, and may
Confined Space
contain or produce "dangerous air contamination". Therefore, it may not be safe
for entry.
Confinement Physical restriction, sufficient to influence the combustion process.
Water spray system that is used to keep equipment, especially hydrogen storage
Deluge System vessels, cool in the event of a fire and fire extinguishing in high risk areas in
which hydrogen is used.
Exothermic chemical reaction coupled to a shock wave that propagates through a
detonable mixture or medium.
Note 1 the thermal energy of the reaction sustains the shock wave, and the shock
Detonation wave compresses unreacted material, producing the high temperatures
necessary to drive the reaction. Note 2 the detonation process is characterised by
a propagation speed that is greater than the speed of sound in the unburned
mixture.
Explosion limit maximum and minimum concentrations of a gas, vapour, mist,
spray or dust, in air or oxygen, for stable detonation to occur.
Detonation Limits
Note the limits are controlled by the size and geometry of the environment, the
concentration of the fuel, as well as the means by which ignition occurs.
The temperature, for a given pressure, at which a relative humidity of 100% will
be reached. At this point the water vapour- and partial-pressures are equal and
Dewpoint
condensation will take place if the temperature is further reduced or the pressure
increased.
Inert component within a gas mixture that reduces the concentration of the
Diluent
remaining (active) materials
Entrainment Process in which the flow of a gas pulls or draws liquid droplets along with the

gas flow.
Note: this is of special concern in the vent system for a liquid hydrogen storage
vessel, and is most likely to occur with rapid vent rates. It is undesirable because
of the considerable volume expansion of the liquid, which would have an effect on
the vent rate, including the vent capability of relief devices, and the loss of the
liquid product that occurs.
Rapid equilibrium of pressure between the region of energy release (system) and
its surroundings.
Explosion Note: explosions can occur through mechanical failure of vessels containing high-
pressure fluids (which includes a gas) or through rapid chemical reactions
producing large volumes of hot gases (see detonation limits).
Group of buildings or equipment used for specific operations at one geographic
Facility
location.
Ability to sustain a failure without causing loss of equipment, injury to personnel,
Fail-Safe
or loss of operating time.
Rapid chemical reaction that produces heat and light; sustained burning as
manifested by any or all of the following: light, flame, heat, and smoke; stationary
Fire flame with the flammable mixture fed into the reaction zone.
Note hydrogen flames are nearly invisible in daylight and are without smoke,
unless other materials are entrained in the flames.
Degree to which a material is easily ignited in an oxidising atmosphere;
Flammability concentration of a fuel in an oxidiser below which a burning reaction cannot be
sustained.
Lower (LFL) and upper (UFL) vapour concentrations of fuel in a flammable
mixture that will ignite and propagate a flame.
Flammability Limits NOTE 1: These limits are functions of temperature, pressure, diluents and ignition
energy.
NOTE 2: These limits are usually expressed as percent (volume fraction).
Deleterious changes in the physical properties of a metal that exposure to
Hydrogen Embrittlement
hydrogen can produce.
Cause to burn or to catch fire
Ignite Note: the process involves the raising of a substance to its ignition point (the
minimum temperature at which a substance will continue to burn without
additional application of external heat).
Ignition Energy Energy required to initiate flame propagation through a flammable mixture.
Maximum gauge pressure permissible in a storage vessel (at its top) or piping
system for a designated temperature.
Note 1: the MAWP is the basis for the pressure setting of the pressure-relief
Maximum Allowable
devices protecting the vessel or piping system.
Working Pressure (MAWP)
Note 2: the MAWP may also be the maximum allowable operating pressure rating
of pressure vessels manufactured in accordance with national pressure vessel
codes.
Normal Temperature and
Temperature of 273,15 K and absolute pressure of 101,325 kPa
Pressure (NTP)
NRV Valve Valve that operates on differential pressure and allows flow in one direction only
Overpressure In a blast wave pressure above atmospheric pressure
Within a containment structure pressure that exceeds the maximum allowable
Overpressure
working pressure of the containment structure
Device that is used in a system to regulate the pressure to a set value
Pressure Regulator
Note: the regulator limits a variable high-pressure input to a constant lower-

pressure output.
Basic safety device used to prevent the pressure within a system from exceeding
the MAWP
NOTE 1: This device is installed so that excessive pressure within the
containment structure can be relieved before damage to the containment
Pressure-Relief Device structure occurs.
NOTE 2: A pressure-relief device is typically a spring-loaded valve that will open
at a set pressure or
Temperature or a rupture disk that contains a membrane designed to rupture at a
set pressure.
Process used to remove or displace gases.
Purge Note for example, before admitting hydrogen to a system, the air in the system is
removed to avoid the formation of a combustible mixture within the system.
Relationship between quantity of flammable or explosive material and distance
separation from the exposed object(s) that provide(s) a defined type of protection.
Note 1: these relationships are based on levels of risk considered acceptable for
the stipulated exposures and are tabulated in appropriate q-d tables.
Q-D Quantity Distance Note 2: relationships include separation distances for safe operations between
facilities, roadways, etc. And total quantities of energetic materials that can
interact in a given location.
Note 3: this approach to safety is commonly used for hydrogen in aerospace and
military applications.
Quench Terminate a chemical reaction or the propagation of a flame.
Gap dimension required to prevent the propagation of an open flame through a
Quenching Distance
flammable fuel/air mixture.
Between electrodes spark gap between two flat parallel-plate electrodes at which
Quenching Gap ignition of a combustible fuel/air mixture is suppressed NOTE: Smaller gaps
totally suppress spark ignition.
The passage gap dimension required to prevent propagation of an open flame
Quenching Gap
through a flammable fuel/air mixture that fills the passage
Redundancy Use of more than one independent means to accomplish a given function
Exposure to the possibility of injury or loss as applies to safety.
Risk Note: risk is a function of the possible frequency of occurrence of an undesired
event, of the potential severity of resulting consequences, and of the uncertainties
associated with the frequency and severity.
Non-metallic material
Soft Goods Note: for example polymers, coatings or lubricants. In a valve, the term soft goods
would refer to items such as the seals, possibly the seat, and the 0-rings.
Generally agreed-upon set of criteria specifically designed to define a safe
product, practice, mechanism, arrangement, process or environment based on
Standard
currently available scientific and experimental knowledge concerning the relevant
subject or scope.
Mixture of reactants in a chemical reaction that optimises production of the
Stoichiometric Mixture
reaction products.
Assembly of components in which hydrogen is delivered, stored or used.
Note 1: a system can include components such as storage vessels, piping,
System valves, pressure-relief devices, pumps, expansion joints and gauges.
Note 2: a system can refer to a new site, a new facility at a site, or a new
installation at a facility.

2.3.1 Classification
Controlled Disclosure: Controlled Disclosure to External Parties (either enforced by law, or
discretionary).

2.4 ABBREVIATIONS
N/A

2.5 ROLES AND RESPONSIBILITIES

None

2.6 PROCESS FOR MONITORING

None

2.7 RELATED/SUPPORTING DOCUMENTS

 Annexure A — Material Data Specification
 Annexure B — Hydrogen Generating Plant Factory Acceptance Testing

3. STANDARD FOR HYDROGEN SYSTEMS

3.1 HEALTH AND SAFETY

 The conditions of the Occupational Health and Safety Act (OHS Act) in its entirety shall apply. This
document shall not be interpreted in any way which contravenes the requirements of the OHS Act.
Should any inconsistencies arise, these should be brought to the attention of the Group Technology
Department.
 All hydrogen systems shall comply with 240-56536505, Management of Hazardous Locations.
 The following are considered to be critical to the safe operation of hydrogen plant and no plant shall
operate without meeting these requirements:

a. Oxygen content measurement of produced Hydrogen after the cells on atmospheric

electrolysers.
b. Hydrogen purity after the dryers including oxygen content (before bulk storage).
c. Minimum flow through analysers is ensured.
d. Hydrogen leak detection.
e. Water seals (or flashback arrestors) on all vents.
f. Approved area classification.
g. Hydrogen fire detection.
h. Hydrogen in oxygen measurement on the oxygen stream.
i. Dew point on generator.
j. Minimum quantity of inert gas connected to perform emergency purge on production and
generators.
k. Emergency depressurisation system on generators with flashback arrestor.

 Hydrogen Plant meets the criteria of "Level 1" as per the Engineering Change Classification. Any
modifications to this plant must comply with 240-53114002, Engineering Change Management
Procedure.
 Specifically, Regulation 18 (Major Hazard Installation) of the OHS Act is relevant to Hydrogen Plant.
Inter alias, the following shall be noted:

a. A Risk Assessment shall be carried out at intervals not exceeding five years on all hazardous
installations by an Approved Inspection Authority.
b. The Risk Assessment shall be reviewed "forthwith if there is any reason to suspect that the
preceding assessment is no longer valid".
c. "Temporary Installations" are to be considered "installations" at their points of departure and
arrival. Consequently, tube-trailers shall be considered "installations" and the above mentioned
Risk Assessments shall specifically address the tube trailer supplies.
d. There shall be a readily available emergency plan, reviewed not less than every three years and
formally tested at least once per year. This plan shall be submitted to local relevant government
department for approval.
e. Any activation of the emergency plan shall be reported to Chief Inspector (Department of
Labour) and all near misses shall be recorded in a register that is available for inspection.
f. All certificates required by the OHS Act shall be available on site.
g. The area housing the hydrogen plant and associated equipment shall be classified in
accordance with SANS 10108 and classification of the area shall be conducted by a
Government Approved Inspection Authority.
h. All equipment supplied for permanent installation, as well as any portable equipment used from
time to time, shall be suitable for operating in classified area (as per 4.1.5). Specification for all
equipment used shall make specific reference to the use in Hydrogen containing areas.
i. The Generation Division's Plant Safety Regulations shall apply.
j. All equipment utilised in the classified area, shall conform to meet the level of classification e.g.
tools, clothing, shoes etc. shall be non-static.
k. Hot work procedures shall be compiled for all maintenance and testing conducted in the
hydrogen plant. This shall be incorporated into the power station permit to work system.
l. Asbestos used shall be managed in accordance with the relevant Eskom Corporate Directive
(ESKADAAI8, The Safe Processing, Storage, Removing and Handling of Asbestos and
Asbestos Containing Materials) and Procedure (ESKPVAAG5 Requirements for the Safe
Processing, Storage, Removing and Handling of Asbestos and Asbestos Containing Material,
Equipment and Articles).

3.2 SAFE PLANT OPERATING PHILOSPHY

The occurrence of a flammable or explosive hydrogen-air/oxygen mixture must be classified as a level 1
incident in accordance to 240-53114193 “Occurrence and Incident Management Procedure”. A
flammable or explosive hydrogen-air/oxygen mixture may not be vented before a detailed plan, design
and procedure has been approved via “240-53114002, Engineering Change Management Procedure”
before execution, except on a hydrogen cooled generator where an approved emergency procedure
must be in place.

Ensure the minimum volume of diluent as stipulated in this standard, to execute an emergency generator
purge must be connected to the distribution manifold, before a generator is filled with hydrogen.
Generator hydrogen leakage must be monitored on-line or manually on a daily basis. When the leakage
exceeds the maximum value as indicated by the original manufacturer a risk assessment in accordance
to 36-962 “Plant Risk Assessment and Reporting”. Only if the risk can be mitigated to a level of no risk
of injury or risk to life, may the generator remain on load.

In the case where hydrogen is produced on site, by means of water electrolysis, safe plant operation of
the generator must be ensured by implementing the following philosophy:

 The hydrogen purity in the generator must always be maintained above the high flammability limit of
hydrogen and oxygen mixture of 96 % hydrogen purity and 4% oxygen.
 Running the generator at hydrogen purity levels lower than 96 % is allowed only if the oxygen
content of the gas is measured and the oxygen measured is less than 4 %.

 Consideration should be given to the response time and the accuracy of the analysers being utilised.
 As part of gas purity, analysing the minimum and maximum flow through the analysers, must be
monitored and interlocked with the gas analysers to provide a true reading of the gas inside the
generator.
 As part of gas purity, analysing the minimum and maximum flow through the analysers must be
monitored and interlocked with the gas analysers to provide a true reading of the gas inside the
generator.
 The contamination limits referred to in ISO 22734-1, Hydrogen generators using water electrolysis
process —Part 1:Industrial and commercial applications is only applicable during a transient state,
during steady state operation the contamination limits shall be below 1%.
 The delivery gas purity for bulk storage shall be > 99, 5%.The contamination of H 2 in O2 and vice
versa measured directly after the cell stack should less than 1, 6% during the transient state and
less than 1% during the steady state.
 In the event of excess contamination, one of the following two actions is required:

 Where there is no automated vent facility, the entire plant shall be tripped with an alarm to the
control room.
 Where there is an automated vent facility, the out of specification condition shall be alarmed and
the hydrogen vented until the quality returns to specification.

3.3 GENERAL REQUIREMENTS

As hydrogen production plants incorporate elements of the Mechanical, Civil, Chemical, Electrical and
Control & Instrumentation Engineering, sound engineering practices from these disciplines shall be
applied.
At all times the original requirements of the manufacturer with respect to operating and maintenance of
the plant shall be adhered to.
Local procedures shall be compiled, and approved by the Power Station Manager, addressing the
following:
a. General plant safety requirements.
b. Plant start-ups.
c. Plant shutdowns.
d. Emergency conditions, including management of explosive mixtures.
e. Preventative maintenance requirements.
f. Corrective maintenance.
g. Test and inspection requirements.
h. Purging and safe isolation requirements.
i. Alarm response procedures.

3.4 HYDROGEN PRODUCTION QUALITY

a. Hydrogen purity shall be a minimum of 99,5 % by volume during the steady state measured after the
electrolyser of production and the ISO 22734-1 referenced limits shall not be exceeded during
transient states. These limits are applicable through the production range minimum to maximum.
b. The dew point of produced gas must be measured before bulk storage (i.e. after compressing and
drying) and shall be better than -50°C at NTP. The hydrogen generation plant shall be designed to
produce hydrogen with this dew point and a deviation from this quality is due to a plant irregularity
and must be addressed. The production plant can be kept in service until the dew point reaches -
10°C when it is expected to stop production.
c. Measurement points, and measurement requirements, are provided in Section 4.19 of this standard.
All measurement lines that are vented to atmosphere shall be fitted with flash-back protection.

d. The hydrogen production plant shall be designed to produce hydrogen that is free of ammonia,
hydrazine and any other impurities, which could be harmful to the materials used in the construction
of the electrical generators and their cooling systems. Specifications for raw materials required to
achieve this requirement shall be included in the relevant maintenance instruction document.
e. The moisture content of the hydrogen fed to the generator shall ensure that the dew point at the
generator operating pressure shall be at least 20°C below the lowest temperature to which the
generator can be exposed.

3.5 PRODUCTION CAPACITY AND HYDROGEN GAS STORAGE CAPACITY

Hydrogen Gas storage capacity shall be based on the greater of the design versus the actual
consumption figures. Hydrogen Gas storage capacity shall be determined on the following basis:
a. A quantity of two fills of hydrogen for the largest generator with the turning gear in operation; and
b. A sufficient quantity for seven (7) days of normal consumption of all generators,
c. Where there is insufficient surplus storage capacity to allow for statutory inspections of or
maintenance on, storage vessel without contravening the requirements above, there shall be a
sufficient alternative backup supply on site.
d. To give added security against the consequences of a breakdown of the hydrogen production plant
or the reticulated hydrogen system, a seven (7) days' supplementary supply of hydrogen, based on
normal consumption for all generators, shall be safely stored on site in cylinders.
e. Contingency plans shall be implemented with a gas supply company to ensure rapid delivery of
replacement cylinders.
f. Hydrogen production rate shall be sufficient to enable the minimum storage capacity to be achieved
within 7 days, with all generators in service and allowing for a single generator fill within this 7 day
period.
g. The hydrogen generation plant shall be able to increase production to 100 % of design capacity
within 8 hours.
h. The operating philosophy of each plant shall ensure that operation at levels below the minimum
level recommended by the manufacturer is not possible.
i. The energy efficiency as the higher heating value of hydrogen of 142 MJ/kg divided by the total
energy consumed for the entire plant (including dryers) per kilogram of hydrogen produced shall be
better than 70 %, measured at the point of bulk storage taking into consideration all loses for the
process to meet the specified quality and quantity.
j. An explosion proof wall shall be built around each receiver and shall be designed to withstand the
explosion pressure from the receivers.

3.6 HYDGROGEN FACILITIES

The production of hydrogen in Eskom is currently by water electrolysis and the Hydrogen generators
shall comply to ISO 22734-1 Hydrogen generators using water electrolysis process — Part 1:Industrial
and commercial applications with the additional requirements stipulated in this standard superseding the
ISO 22734-1 standard. However, hydrogen can be produced by any alternative means provided it meets
the quality, quantity and operational safety requirement listed in this document. Use of alternative
methods shall be subject to approval by the Generation Technology Department.

3.7 BUILDINGS

3.7.1 Building Design or Bulk Storage Walls or Weather Shelter

a. A weatherproof shelter or canopy in an outdoor location shall be a structure enclosed by not more
than two walls set at right angles and shall have vent space provided between the walls and vented
roof or canopy. Such walls shall be constructed of non-combustible materials

b. A weatherproof shelter or canopy shall be installed over any containerised plant. Buildings or special
rooms in which hydrogen is stored and used (monopropellant) as allowed by the OSHACT shall be
constructed according to the construction regulations. Buildings shall be constructed of non-
combustible materials on a substantial frame. Window panes shall be shatterproof plastic or glass.
To limit the generation and accumulation of static electricity the floors, walls and ceilings should be
designed accordingly, a fire resistance rating of at least two hours is acceptable.
c. The Seismic design of the building shall be in accordance with SANS 10160.
d. Sun shields shall be installed as part of the bulk storage vessels with adequate ventilation and
prevention of hydrogen entrapment.
e. All hydrogen-containing vessels, piping, and other equipment should be protected from potential
sources of shrapnel end explosion walls shall be installed around each bulk storage vessel.
f. All hydrogen-containing vessels, piping, and other equipment being a source of hydrogen release
should be protected from potential sources of shrapnel.
g. Explosion venting shall be provided in exterior wall or the roof only. According to the OHSACT
regarding room volume the venting area shall not be less than 0, 11 m2/ m3. Vents may consist of
one or a combination of the following:

 Walls of light material, lightly fastened outward — opening swinging doors in exterior walls
 Lightly fastened walls or roofs
 Lightly fastened hatch cover

These must be designed to relieve at a maximum internal pressure of 1, 2 kPa. Doors must be
hinged to swing outwards in an explosion and doors must be easily accessible to employees.
Partitions shall be continuous from floor to ceiling and securely anchored. At least one wall shall be
an exterior wall, and the room shall not be open to other parts of the building. Any heating in rooms
containing hydrogen shall be limited to steam, hot water, or other indirect means.

3.7.2 Location and QD (Quantity Distance) Guidelines

a. For new hydrogen generating plant a risk assessment shall be done that considers the location of
the plant relative to the unit and generator transformers and routine traffic, limiting the impact of an
explosion to power generating plant and personnel. The hazards analyses should identify the
primary hazards involved with the installation, such as:1) hydrogen release and burning of a
hydrogen/air mixture, and 2) explosion and fragment projectiles.
b. The AIA must handle the determination of the QD on an individual basis for quantities of hydrogen
less than the minimum specified in the standard of guidelines. Each situation should be evaluated
based on the hazard presented by the specific quantity of hydrogen being considered.
c. The installation and location of hydrogen storage facilities shall conform to OHSACT 103 and NFPA
50A. Hydrogen systems of 84,9 m3 or less, located inside building, shall be situated in the building
so the following criteria are met:

 Adequately ventilated area

 6,1 m from stored flammable materials
 7,6 m from open flames, electrical equipment, or other sources of ignition
 15,2m from ventilation intakes and air conditioning equipment
 15,2 m from other flammable gas storage
 7,6 m from concentrations of people
 More than one system of 84.9 m³ or less may be installed in the same room provided the
system is separated by at least 15.2 m. Each shall meet all the above requirements.

3.7.3 Access
a. Access to the hydrogen plant and bulk storage shall be controlled and the requirements of the
Generation Division's Plant Safety Regulations 36-681shall apply.
b. Employee accessing a hydrogen system must be considered as a potentially hazardous event and
such entrance shall be by authorised personnel only. Employee entering the hydrogen plant of
control areas shall be provided necessary and sufficient clothing, equipment, detection devices, and
respiratory devices as required (OHSACT):
 Access shall be limited to authorised personnel (OHSACT; NFPA) on the hydrogen system.
 Sufficient personnel must be available to perform a hazardous operation safely and in the event
of accident, to obtain help and aid the injured.
 Buildings in which combustible mixtures exist in the atmosphere shall not be entered under any
conditions. Personnel shall be warned of the presence of combustible mixtures or low oxygen
concentrations (OHSACT). Warning systems such as approved vapour detectors sensors, and
continuous sampling devices shall be employed to ensure that the plant environments is safe.
The warning and detection devices shall operate audible and visible alarms. These systems
shall be designed and installed to allow for the operation of equipment needed to reduce
possible hazards.

3.7.4 Signage, Posting and Labelling

a. Each hydrogen system and control areas must have signage, placards, postings, and labels
displayed, so employees shall be aware of the potential hazards in the area. The location of
Hydrogen systems shall be permanently placarded as follows:
 HYDROGEN-FLAMMABLE GAS-NO SMOKING- NO OPEN FLAMES
 Each portable container shall be legibly marked with the name "HYDROGEN". Each manifold
hydrogen supply unit shall be marked with the name "HYDROGEN" such as: "This unit contains
hydrogen" (OHSACT; NFPA). Placards must be of sufficient size and colour that they are
readily visible to employees entering the work area.

b. All plant to be fitted with alpha-numeric labelling consistent with the power station plant codification
standards for unique identification.
c. Coding shall be used on all drawings, isometrics, schedules, documents and operating/
maintenance manuals.
d. The identification of contents of pipelines shall be in accordance with 240-114767031and shall be
submitted to Eskom for approval.
e. Identification shall include colour banding, code by stencilling or labelling and flow direction arrows.
Colour coding shall be in accordance with the requirements of SANS 10140 (parts 1 to 4).
f. All pipework shall be provided with markings, labels or colour coding indicating the contents thereof.

3.7.5 Layout
a. Separating the components into individual rooms may result in less stringent requirements (as per
SANS 10108) being applied to certain areas. Therefore, new plant design shall adopt the principle of
physically separating hydrogen generating areas from the control and switchgear i.e. rooms or
individual panels or segregated compartments in a container. The hydrogen production areas shall
be designed to prevent a confined explosion.
b. Building design shall take into account of separate compartments suitably laid out for the safe clean
storage and handling of potash. The design and layout shall take into account the safe mixing,
pumping and loading operations of electrolyte. (Storage may be separate from the Hydrogen plant if
preferred by individual stations.)
c. Doors and other openings shall provide a good seal against the ingress of rain and dirt.

d. All emergency exit doors shall open towards the outside and shall be lockable. Emergency exit door
"handles" shall be fitted on the inside of the doors fitted to open towards the outside for exiting from
the inside.

3.7.6 Safety Showers and Eye Washers

a. Safety shower and an eye washer shall be provided in the vicinity of the caustic-handling equipment.
An eye washer shall also be provided in the vicinity of the electrolyser. Further safety showers and
eye washers may be installed if required by power station specific requirements or designer
recommendations.
b. The design of the safety shower or eye washer shall be subject to approval by Eskom.

3.7.7 Ventilation
a. Ventilation shall be provided such that the requirements of SANS 10108 and SANS 10119 are met.
The principles contained in SANS 10119 allows for area classification to be downgraded (from Zone
0 to Zone 2 for example) through the implementation of ventilation systems.
b. For new generation containerised plant with protection based on the loss of vacuum in the container,
the allowable pressure rise (vacuum loss) shall be calculated such that a maximum hydrogen
concentration of 0,8 % is not exceeded. This is consistent with the principles contained in SANS
10119 and is 20 % of the explosive limit of oxygen in hydrogen.

3.7.8 Drains
Drain lines and pipes (e.g. condensate, oil and electrolyte) shall be provided. As these are likely to feed
to the common station drains, this will require an Environmental Impact Assessment.

3.8 FIRE PROTECTION

Preventive measures against fire shall include automatic or manual process shutdown systems,
sprinklers, deluge system, water spray system, dry -chemical and extinguishing systems. The fire safety
policy shall be in accordance with the AIA. The unitised hydrogen plant must provide appropriate
automatic fire detection and suppression systems for hydrogen systems containing significant hazards.
a. Portable fire extinguishers (PFE) shall be provided subject to an assessment of the risks with due
consideration to type, size, placarding, posting and labelling, physical positioning of PFE in relation
to the general arrangement of the plant".
b. The provision of fixed fire protection systems shall be determined by a suitably qualified /
experienced person by a documented Risk Assessment with due consideration as to exposure risks,
plant layout and general arrangement using both active and / or passive fire protection measures.
c. Fire protection may be achieved by passive or active means. Passive being elements of layout and
construction that affords a level of inherent protection against fire or exposure to fire (physical
barriers, walls, spatial separation). Active protection defined as a fixed fire protection, engineered
system usually water based to provide cooling to areas of exposed plant and equipment.
d. Standard practice for fixed fire protection of receivers and cylinders is a deluge water spray system
with medium velocity spray nozzles. The system should be designed to provide water flow rate of
10, 2 L/min/m2 each square meter of surface area of the storage vessels as detailed in SANS 10087.
All pipes and valves within 2m of the storage vessel should be protected.
e. There shall be provision to purge pipework with nitrogen or carbon dioxide. Carbon dioxide purging
on alkaline electrolyser hydrogen generating plant is not allowed.
f. For the installation of deluge system along the top of storage areas, the deluge systems should be
capable of being manually or automatically actuated. Fire extinguishing systems shall be used to
protect manifold piping, relief vents. Deluge system shall be actuated by temperature raised
detectors and remote, manual control. Enough hydrant outlets shall be located to enable use of
charged hoses at each operation involving equipment in hydrogen service.

3.9 PURGING
All piping equipment that was filled with hydrogen must be purged with an inert gas before work can
commence. The design of the plant must provide for a purging facility and the double block and bleed
principle must be applied. Points for administering an inert gas and venting to atmosphere must be
provided.
Depending on the application carbon dioxide is the most effective gas medium to reduce the flammability
limit. Following carbon dioxide is nitrogen, and is recommended to be used in applications where
moisture is present. Helium is a good alternative to nitrogen. The use of argon should be avoided due to
being the least effective in reducing the flammable range.
All hydrogen production plants shall be fitted with automated nitrogen purging systems. Nitrogen purging
shall be done following any safety trip. The availability of the nitrogen purging system to perform an
emergency purge must be monitored and alarmed and a facility to replenish the nitrogen without
interrupting the connected nitrogen supply must be provided.

3.9.1 Carbon dioxide purging and Cylinders

Carbon dioxide purging is required to degas the generator before maintenance activities or in the case of
an emergency. Carbon dioxide is used for generator purging as 60% carbon dioxide diluent of the
generator volume is required in order to dilute an equal concentration Hydrogen air mixture out of the
flammability region.

Figure 1: Hydrogen Concentration

The following are the purging requirements:

a. Sufficient carbon dioxide cylinder supply must be connected to each generator to replace the entire
volume of hydrogen inside the generator twice. Each carbon dioxide cylinder holds 22,6kg of gas in
liquid form, equivalent to 11,4m 3 at NTP, and is used for purging hydrogen and air from the
generator.
b. Carbon dioxide admission to the generator must be from the bottom of the generator and
displacement of hydrogen and air from the generator casing at the highest point on the generator
casing.
c. During displacement of carbon dioxide in the generator the hydrogen admission must be from the
highest point on the generator casing and venting of carbon dioxide from the lowest point on the
generator casing.

d. On-line gas analysing of hydrogen, carbon dioxide and oxygen.

e. Purging of the entire generator within 30 minutes.
f. Carbon dioxide purging station must be accessible and operable in the case of an emergency or fire.
As an alternative remote operation of vent valves and initiation of the carbon dioxide purge via a
control system.
g. All pipework, valve and fittings must be rated 1,5 times the MAWP.
h. Venting of all gasses through a water seal or flashback arrestor.
i. Siphon tube fitted carbon dioxide cylinder must be used and an evaporator must be utilised to
prevent freezing of the cylinder valves and piping, to ensure adequate purging rates with carbon
dioxide in an emergency. The evaporator shall ensure a minimum of 30 minutes of purging without
availability of power supply.

3.9.2 Nitrogen purging

a. Nitrogen is an effective medium to purge pipe lines and systems and does not create carbonic acid
in a moisture environment.
b. A nitrogen purging facility must be provided as an integral part of the Hydrogen Generating plant
and the control system must identify the requirement for a purge and monitored that such a critical
safety activity was done before the plant can start hydrogen production. It is preferred that this be
fully automated or require limited manual intervention. The nitrogen used for purging must have a
purity better than 99, 5% with the oxygen content less than 0,5%. The dew-point of the nitrogen gas
must be better than -50 °C at NTP. This is essential for the start-up of the hydrogen generating plant
from an inert gas purged state.
c. Nitrogen may be used as an alternative purging medium, provided it is approved by the generator
original manufacturer. The generator casing must be purged to 70 % dilution within 30 minutes and
an analyser to monitor 70 % diluent must be provided.

3.9.3 Air purging

a. Quality of air being used for purging the inert gas from the generator must be ensured and
monitored at the point of admission to the generator.
b. The quality of air that is introduced for purging of the generator must have a dew point of -20 °C at
normal pressure (700 kPa).

3.10 HYDROGEN AND HYDROGEN FIRE DETECTION

3.10.1 Hydrogen Detection

The system design must ensure that detection occurs instantaneously and operating personnel are
notified immediately, if hydrogen leaks into the atmosphere or a hydrogen fire occurs. A hydrogen
detection system must be compatible with other systems such as those for fire detection and fire
suppression. The detection units must be suitably rated, to prevent ignition of flammable mixtures. The
detection signal must actuate warning alarms and automatically effect shutdown whenever practicable.

3.10.2 Hydrogen Detection Specifications

a. Detection and alarm at 1 % by volume hydrogen concentrations in air, equivalent to 25 % of the low
flammable limit (LFL), is required for enclosed areas in which Hydrogen build-up is possible.
b. Detection and alarm at 0,4 % by volume hydrogen concentrations in air (equivalent to 10 % of the
LFL) is required for permit-required confined spaces (OHSACT).
c. A 1 % by volume hydrogen concentration at any point 1 m from the hydrogen equipment should
generate an alarm in areas around hydrogen facilities.
d. Specification for hydrogen sensors should include requirements for the following:

 Minimum gas concentration detection requirements

 Full-scale range of the detector system
 Level of concentration for which alarm detection is required
 Response time of the detector system
 Accuracy of sensors
 Drift of the analyser
 Reliability and recalibration frequency
 Interface to facility safety and shutdown systems
 Analyser principle of operation adequate for the application CGA G-5.3, Commodity Specification
for Hydrogen
Use gas chromatography, which has parts-per-billion-by-volume capability, for the detection of hydrogen
in purged lines and vessels through the use of samples collected in sample bottles.

3.10.3 Hydrogen fire detection systems

a. A fire detection system must be capable of detecting, at a minimum distance of 4,6 m the flame from
the combustion of 5,0 l/min of Hydrogen at NTP flowing through a 1,6 mm orifice to produce a 20 cm
high flame. For a potential release of a large volume of hydrogen, sensors with the ability to detect
flames at distances greater than 4,6m must be used to provide coverage over a large area.
b. The fire detection should not be susceptible to false alarms from the sun, lightning, welding, lighting
sources and background flare stacks.
c. The fire detection systems response time should meet the requirements for the specific application
for prevention of loss of facility, equipment and protection of personnel.
d. Fixed systems are required for continuous monitoring of remote operations, and portable systems
are required for field operations.
e. Special imaging systems are required for determining the size and location of a flame for
assessment of the hazard because hydrogen is not visible during daylight conditions. Use thermal
protect-o-wire, temperature sensors, and UV-only optical fire detectors for transfer systems.

3.11 PROTECTIVE MEASURES FOR SLIPRINGS AND COUPLED EXCITERS

a. If the exciter or slip rings are situated in a housing into which hydrogen may leak, the accumulation
of an explosive hydrogen-air mixture must be prevented, e.g. by maintaining a flow of air through the
enclosure.
b. The flow can usually be produced while the shaft rotates at normal speed, but additional means may
be needed when the machine contains hydrogen and the shaft is stationary or rotating slowly or if an
exhaust duct is not provided to vent hydrogen leakage through natural convection and buoyancy. If
local fans are used to ensure ventilation, their motors shall have a type of protection for flammable
gas atmospheres in accordance with IEC Publication 79.
c. Hydrogen leak and fire detection must be installed in the enclosure.

3.12 MECHANICAL PLANT

a. Key design requirements for the hydrogen generating plants are:
 Safe operation shall be assured at all times.
 Simplicity and reliability.
 Measuring equipment and analysers must be installed to identify the production of a potentially
explosive mixture and prevent it from being stored.
 Automatic, unattended operation, insensitive to power interruptions. In the event of a power
interruption, the plant shall revert to a safe condition and hydrogen vented.
 All components suitable for use with hydrogen, and classified accordingly.
b. The production facility shall preclude the possibility of the oxygen and hydrogen forming an
explosive mixture.

c. For electrolysers operating at atmospheric pressures, a water safety seal shall be provided and
installed between hydrogen production (electrolyser) and reticulation gas holder storage.
d. All vents shall be routed to the outside of the building and positioned such that free dispersion of
hydrogen is ensured.
e. All gas vent lines to atmosphere shall flow through a water seal or be fitted with a flashback arrestor
normally low pressure rated to maximum 500 kPa hydrogen gas.
f. All water seals shall be designed for the maximum flow possible, ensuring that a sudden release of
gas does not break the seal.
g. All water seals shall be installed with automatic level control (e.g. float valve) and monitoring. Where
level control is not automated, there shall be a continuous overflow with monitoring carried out.
h. Any equipment installed, that introduces a risk of air entrainment, must be fitted with on-line
monitoring equipment that will automatically react if an unsafe condition occurs.
i. If a gas holder is used:
 The gas holder's water seal shall be designed to fulfil the requirements of the output of the
plant.
 Precautions shall be taken to prevent corrosion of the gasholder.
 The gas holder shall be designed for unrestricted movement.
 The gas holder shall be fitted with low pressure monitoring.
 At least one low-level proximity switch shall be provided on the gasholder as a backup to the
fixed limit switches. The preferred proximity switches are the type where a magnet is fitted to the
gas holder bell and reed type switches for high-high, high, low and low-low are fitted to fixed
positions adjacent to the bell.
 The gas holder water safety seal shall be fitted with a low-level monitor that initiates a rectifier
trip or ensures that a safe plant condition is reverted to.

3.13 HYDROGEN STORAGE

3.13.1 Bulk storage

3.13.1.1 Vessels
a. Bulk storage vessels shall be provided for the specified capacity.
b. Pressure reduction, downstream of the storage vessels, shall be provided to reduce the pressure to
the required reticulation pressure.
c. The vessels shall be arranged and inter-connected in such a way that they may be taken out of
service individually for periodic statutory inspection and put back into service, with minimum loss of
hydrogen from the rest of the system. For pressure tests, vessels shall be completely isolated
(disconnected) from the rest of the system. The facility for purging the vessel prior to and following
pressure tests shall be provided.
d. Vessels shall be individually filled and individually used.
e. Isolating valves and non-return valves shall be fitted to the inlet and outlet of each vessel to ensure
individual vessel isolation and prevent pressure equalisation between vessels.
f. Valves shall allow for isolation without interfering with adjacent equipment and to prevent the
inadvertent cross contamination of hydrogen and air filled vessels by operators and maintenance
personnel.
g. Pressure regulators at the station main and at each generator shall be provided. Each pressure
regulator shall be followed by dual independent pressure relief devices.
h. Excess flow shut-off valves shall be provided at the bulk storage outlet that is required to protect
against the consequences of any possible pipe fracture or major leak. The excess flow shut-off
valves and system design as a whole shall be designed to allow the normal demand of gas flow
without shutting off the supply, but shall shut off the gas flow when demand exceeds the normal flow

by 20%. Or the excess flow shut off valve must be set at the dumping rate of the generator safety
valve.
i. Facilities for nitrogen or carbon dioxide purging shall be incorporated. Use of drain and vent valves
shall be acceptable for purging when no alternatives are in place.
j. Provision for the purging of vessels shall be as follows:
 Where there is a single inlet/outlet, purging shall be by means of evacuation and filling with an
inert gas.
 Where separate inlet and outlets are installed, purging shall be by means of positive
displacement.
k. The vessels shall be manufactured in accordance with BS EN 13445 and PD 5500. The design
temperature range is -10 °C to 50 °C.
l. All pipe connections to the pressure vessels shall be in accordance with ASME B16.5. Piping
between vessels shall be provided with manifolds and non-return valves so arranged that cross-
vessel transfer of hydrogen, including equalisation of receivers, cannot be achieved.
m. All manually operated valves that can lead to air contamination of hydrogen or hydrogen venting
directly into atmosphere shall have lockable handles and be fitted with locks under the control of the
"permit to work" system.
n. It is preferred that all new storage vessels shall be horizontally installed.
o. Hydrogen shall not be supplied to the bottom of the bulk storage vessels and nor shall hydrogen be
delivered to generators from the bottom of the bulk storage vessels. This is to prevent corrosion
particles and other impurities such as moisture accumulated over a long period of time from being
fed into the reticulation system.
p. Filling of the storage vessels will be automated, based on a filling philosophy to optimise cell stack
life and meeting the requirements of minimum hydrogen availability. The receiver filling and
hydrogen production philosophy must be based on the volume of hydrogen calculated from the
known volume of storage vessels and pressure measured.
q. A metering station after bulk storage must be fitted to reduce pressure to reticulation pressure and
measure pressure, dew point and mass flow into the reticulation system. The mass flow, pressure
and dew-point must be trended and data stored as a minimum for a moving 30 day period at a
sampling rate of at least once every minute.
r. The ambient temperature for the design of the bulk storage vessels, valves and equipment is -20ºC
to +50ºC.
s. All bulk storage vessels shall be fitted with a sun-shield. The sun shield design must be such that a
fire spray system can cool down the surface of the vessel.

3.13.2 Hydrogen cylinder supply

a. A hydrogen bottle bank of eight cylinders with a weight of 12.78kg each will be installed inside the
power plant for topping up the generator when the bulk supply system is unavailable. A maximum
number of two cylinders can be opened simultaneously to limit the hydrogen that can leak into the
vicinity. Connecting fittings shall be configured so that it is physically impossible to cross-connect
incompatible systems without malicious intent to do so.
b. The high pressure line from the cylinder feed must be protected with an automatic emergency
isolating valve, which is required to protect against the consequences of any possible pipe fracture
or major leak.
c. An inert gas purging and venting facility (block-and-bleed valve arrangement) must be provided
between two isolation points. This includes the connection between each cylinder to the reticulation
system. An isolation facility between each cylinder and the reticulation system must be provided to
ensure that each cylinder can be individually isolated and replaced.
d. The high pressure reticulation line must be protected with a non-return valve as well as each
cylinder connected to the reticulation system.
e. Line pressure indication must be provided on all lines between two isolation points.

f. The low pressure side, after pressure reduction, must be protected by a safety valve rated to dump
the maximum amount of hydrogen from the source, without allowing the generator casing pressure
to increase above the maximum allowable working pressure.
g. As a minimum all hydrogen cylinders must comply with the relevant ISO standards.

3.13.3 Hydrogen cylinder pallets

a. Unless fully compliant to the above for hydrogen cylinder supply, a hydrogen cylinder pallet cannot
be utilised inside the power generating plant.
b. The high pressure line from the hydrogen cylinder pallet feed must be protected with an automatic
emergency shut-off valve, which is required to protect against the consequences of any possible
pipe fracture or major leak.
c. An inert gas purging and venting facility must be provided between two isolation points. This
includes the connection between each hydrogen cylinder pallet to the reticulation system.
d. The high pressure reticulation line must be protected with a non-return valve as well as each
cylinder connected to the reticulation system.
e. Line pressure indication must be provided on all lines between two isolation points.
f. The low pressure side, after pressure reducing, must be protected by a safety valve rated to dump
the maximum amount of hydrogen from the source, without allowing the generator casing pressure
to increase above the maximum allowable working pressure.

3.13.4 Mobile hydrogen supply

a. Mobile hydrogen supply units shall be electrically bonded to the system before discharging
hydrogen.
b. All off loading facilities shall provide easily accessible grounding connections and be located outside
the immediate transfer area. Facility grounding connections should be less than 10 ohm resistance.
c. Transfer subsystem components should be grounded before subsystems are connected.
d. Electrical wiring and equipment located within 0,9 m of point at which connection are regularly made
and disconnected shall be in accordance with Zone 2 classified location.

3.14 PIPING SYSTEMS

3.14.1 Piping systems

a. Piping systems for hydrogen use shall be designed based on the most severe condition of
coincident pressure, temperature and loading. Special consideration shall be given for the unique
properties of hydrogen, such as hydrogen embrittlement. The most severe condition shall be the
requirement that results in the greatest required pipe thickness and highest flange range rating.
These include:
 pressure relief valves
 valves
 filters
 fittings
 gaskets
 Hydrogen pipe lines
It also includes hangers and supports and other equipment items necessary to prevent
overstressing and vibration of pressure-containing components. Safety reviews of piping systems
designs shall be in accordance with those detailed in Sections 4.1 and 4.2 in ANSI/AIAA G-095-
2004. Materials used in the designs of piping should be in accordance with BS EN 13480. Piping
and pressure-containing components shall be pressure tested.
b. Facility and transfer piping systems shall include safeguards in according with ASME B31.3 for
protection from accidental damage and for the protection of people and property against harmful
consequences of vessel, piping and equipment failures. Within a process area, hydrogen transport

piping shall be treated similar to hydrogen storage in that all such piping shall be isolated by an
exclusion zone in which access is restricted and certain types of operations are prohibited while
hydrogen is present in the piping system.
c. New piping for hydrogen shall not be buried. Piping shall be placed in open trenches with removable
grating if placed below ground. All piping shall be periodically pressure tested and recertified. The
piping and components shall be tagged and coded as described in ANSI/AIAA G-095-2004-Section
4.10.
d. Hydrogen piping that is installed in cable tunnels etc. must be monitored for hydrogen leakage and
fire detection. Alternatively they must be protected by an inert gas "blanket" at higher pressure than
the hydrogen.
e. Sufficient grounding connections should be provided to prevent any measurable static charge from
accumulating on any component. Each flange should have bonding straps in addition to metal
fasteners, which are primarily structural.
f. Joints in piping should be made by welding. Mechanical joints such as flanges should only be used
for ease of installation and maintenance. Provisions shall be made for the expansion and contraction
of piping connected to limit forces by providing substantial anchorage at suitable points, so there
shall be no undue strain to the piping.
g. All pipework, valve and fittings must be rated 1,5 times the maximum operating pressure.
h. Special consideration shall be given for the Joule-Thompson effect when the carbon dioxide
expands to prevent freezing of valves and piping.

3.14.2 Supports
The design of piping support members shall account for all concurrently acting loads transmitted into
such supports. All supports and restraints shall be fabricated from materials suitable for the service
conditions. Any attachments welded to the piping shall be compatible with the piping material and
service conditions.

3.14.3 Piping for hydrogen

a. Materials for hydrogen piping systems and components must be suitable for the stress, temperature,
pressure and exposure conditions. Conditions considered to characterise hydrogen embrittlement
failures include temperature, pressure and hydrogen purity.
b. High-pressure gas manifolds shall be constructed of suitable and of welded construction wherever
possible. Expansion or contraction should be looked at and adequate supports shall be provided.

3.14.4 Bending and forming piping

a. Pipe may be bent to any radius that will result in arc surfaces free of cracks and substantially free of
buckles. Flattening of a bend, as measured by the difference between the maximum and minimum
diameters at any cross section, shall not exceed 8% of the normal outside diameter for internal
pressure and 3% for external pressure.
b. Piping components may be formed by any suitable hot or cold working method, provided such
processes result in formed surfaces that are uniformed and free of cracks or other defects. The
various piping components should conform to the specified requirements of the engineering design.

3.14.5 Double block-and-bleed

A double block-and-bleed arrangement to isolate supplies from other parts of the system must be
implemented, including on inert gas purging and venting facility. A doubleblock-and-bleed arrangement
as shown in Figure 1 below is a positive way to ensure that hydrogen leaking through a shutoff valve
does not enter other parts of a system where it is not desired.

Figure 2: Double Block-and-Bleed Arrangement

3.15 COMPONENTS

3.15.1 Joints in piping and tubing

a. Welding is the first preference for all hydrogen systems and it shall be as the Eskom Welding
standard 240-56241933.
b. Joints in piping and tubing may be made for H2 by welding or brazing or using flanged, threaded,
socket or compression fittings. Brazing materials shall have a melting point above 538 °C (NFPA).
The fused joint is recommended in hydrogen systems because of its simplicity and high reliability.
Hard soldering and welding often can meet the bonding requirements, but the welded joint takes
preference for safety (OHSACT).
c. For every Eskom weld construction Project, the Eskom approved inspection authority (AIA) is tasked
to verify legislative compliance of the plant with regulations contained in the OHS-Act and PER. The
Contractors are responsible for welding done by their personnel. The contractor having authorisation
must also approve and accept a performance qualification made by a welder or welding operator for
another employer. If approval is given, acceptance is limited to performance qualification on piping
using the same or equivalent procedure wherein the essential variables are within the limits set forth
in ASME BPVC Section IX and ASME B31.3.
d. Tube fitting of flared or compression type may be used for tube sizes not exceeding 5.1 cm outside
diameter within the limitations of applicable standards.

3.15.2 Threaded joints

National pipe thread (NPT) and similar threaded joints with a suitable thread seal are acceptable for use
in hydrogen systems. Consideration should be given to back-welding threaded joints for hydrogen
systems inside buildings.

3.15.3 Flagged joints

a. In cases where welded joints are not desirable it can be replaced with flange connections. Flanged
joints with radially compressed seals, such as Grayloc, Reflange R-Con or E-Con type flanges and
seal rings are acceptable. Flanges with dual seals and inter-seal vent ports are recommended in
applications where leakage may be induced by system thermal expansions.
b. An earth loop connection of minimum 6mm2 must be fitted across the flanged connection.

3.15.4 Silver braze joints

The choice of braze composition is determined by ease of application to the material to be joined;
however, cadmium containing silver brazes shall not be used. Silver brazes are recommended for joining
copper-base materials and dissimilar metals such as copper and stainless steel. The melting point must
be greater than 538 °C.

3.15.5 Soft solder joints

Soft solder joints are not permissible in hydrogen systems.

3.15.6 Pipe connections

a. The designer shall determine that the type and the material of the fitting selected is adequate and
safe for the design conditions in the absence of standards, specifications or allowable values for the
material used to manufacture the fitting.
b. Greater flexibility should be provided in designs of small branches out of large and heavy runs, to
accommodate thermal expansion and other movements of the larger line. Branch connections
should be made in piping systems as followings:
 Fittings (tees, laterals and crosses) should be made in accordance with standards procedures.
 Outlet fittings should be welded.
 The branch pipe may be welded directly to the run pipe or without reinforcement.
 Extruded outlets in the run pipe, at the attachment of the branch pipe, should be butt-welded.

3.15.7 Flanges
Flanges should be designed and manufactured in accordance with ASME B16.5. Flanges using a soft
gasket should use a raised-face flange with a concentrically serrated face.

3.15.8 Flexible hoses

a. Flexible hoses pressurised to greater than 1,14 MPa should be restrained at intervals not to exceed
1,83 m and should have an approved restraint device such as the Kellems hose containment grips
attached across each union or hose splice and at each end of the hose. The restraint devices should
be secured to an object of adequate strength to restrain the hose if it breaks.
b. Hose containment methods and devices that differ from standard devices should be approved by the
AIA.
c. Only crimped clamps may be used on any hoses.
d. ISO standard gas cylinder connections must be fitted to the end of the flexible hose.
e. Flexible hoses shall have electrical continuity to earth through the length of the hose from both end
connections or shall have a bonding strap along the length of the hose.

3.15.9 Expansion joints

a. Bellows expansion joints used in hydrogen piping systems may be convoluted or toroidal and may or
may not be reinforced. Lap-welded tubing should not be used.
b. A fatigue life able to withstand the full thermal motion cycles is a design requirement, but the life of
the bellows should not be less than 1000 full thermal movement and pressure cycles in any case
(ASME B31.3).
c. Expansions joints shall be marked to show the direction of flow. Flow liners should be provided
when flow velocities exceed the following values:
 Expansion joint diameter less than or equal to 15,2 cm: gas flow velocity of 48 m/s per m of tube
diameter
 Expansion joint diameter greater than 15,2 cm: gas flow velocity of 300 m/s per m tube diameter

d. An expansion joint must be installed in a location that is accessible for scheduled inspection and
maintenance.
e. Pressure test of piping systems shall be performed with the bellows expansion joint installed in the
line with no additional restraints so the expansion joint cross connections or external main anchors
carry the full pressure load. Test should not be performed until all anchors and guides are securely
in place.

3.15.10 Valves
a. Valves for gas service in a hydrogen environment shall comply with the requirements of the
Compressed Gas Association (CGA) of America — CGAG-5.4 or equivalent such as
 European Industrial Gas Association; and
 British Company Gas Association.
 South African National Standards
b. Valves shall have factory certification of hydrostatic pressure tests and details of leak tests carried
out using hydrogen or helium as the leak test medium.
c. Test certificates stating compliance with the specification, for all valves, shall be available on site.
d. All valve and fittings must be rated 1,5 times the maximum operating pressure.
e. Valves identified by Eskom to form part of the permit to work system shall be lockable valves to
accommodate a 8mm padlock.

3.15.10.1 Excess Flow Valves (EFVs)

a. EFVs for gaseous hydrogen service must be self-actuated devices that shut-off flow when the built-
in sensing mechanism detects that the flow exceeds the pre-set flow value.
b. The normally actuated valve to open the hydrogen supply feed should not cause an operation of the
EFV and must be designed or selected as a gradually opening valve. EFV installed to provide an
immediate hydrogen supply shutoff in the event of gas line or component failure, must have a
manual reset facility.
c. EFV installed in-line with pressure gauges on hydrogen lines must have an automatic reset facility.
d. This is normally achieved via a small leakage that equalise pressure across the EFV.

3.15.10.2 Emergency Isolation Valves (EIVs)

a. Emergency isolation valves capable of full closure without leakage must be provided that are readily
accessible to stop hydrogen flow.
b. EIVs should be installed before branch or multiple distribution lines feed different facilities or to
isolate all hydrogen feeds to the generator. EIVs must have a metal-to-metal seat or a metal to metal
backup of a soft-seated valve for positive shut-off.
c. A block-and-bleed valve arrangement is acceptable as an emergency isolation point.
d. All EIVs shall have a fail-close operation and may be operated remotely or locally.

3.15.10.3 Isolating Valves

a. To allow for maintenance activities and emergency response, isolation valves are required. An
isolation valve shall be installed at an accessible location in the gas line so that flow can be shut off
when necessary.
b. The high pressure line from the cylinder feed must be protected with an automatic emergency
isolating valve, which is required to protect against the consequences of any possible pipe fracture
or major leak. A double-block-and-bleed arrangement is a positive way to ensure that
hydrogen/carbon dioxide leaking through a shutoff valve does not enter other parts of a system
where it is not desired.

3.15.10.4 Gas Cylinder Valves

a) The valves fitted to the individual gas cylinders must be of a screw down complying with the relevant
ISO standard.
b) The valve material must also comply with the relevant ISO standard compatible with the gaseous
medium.
c) Carbon dioxide cylinder valves shall be fitted with siphon tubes to facilitate rapid gas discharge.

3.15.10.5 Non Return Valves (NRVs)

a. The high pressure reticulation line must be protected with a non-return valve as well as each cylinder
connected to the reticulation system.
b. Each individual hydrogen cylinder connection to the manifold must be protected with a non-return
valve.
c. Swing-type and lift type NRVs are recommended for 2.54cm nominal and larger sizes. Poppet-type
NRVs are recommended for 2.22cm and smaller.

3.15.11 Gauges
a. The pressure gauges shall be the Bourdon type or intrinsically safe pressure transmitters for a
hydrogen environment application.
b. The gauge graduation shall be 50 kPa minimum for the storage vessels and 0,5 kPa minimum for
the atmospheric electrolyser.
c. The gauge pressure rating shall be 150 % to 200 % of the anticipated maximum allowable working
pressure (MAWP).
d. The gauge face shall be a minimum of 100 mm diameter for gauges not more than 2, 5 m above
ground and 150 mm diameter for gauges more than 2,5 m above ground level.
e. Each gauge shall be clearly marked on the face with a red line which indicates the relevant system
section maximum allowable working pressure level.
f. All gauges shall have blow-out protection and excess flow shut-off to minimise the release of
hydrogen should there be a rupture of the gauge. Gauges shall have pulsation compensators where
required.
g. All gauges will be fitted with safety glass.

3.15.12 Hydrogen venting

a. All vents shall be routed to the outside of the building at the highest point and positioned such that
free dispersion of hydrogen is ensured away from any possible ignition sources. The hydrogen and
the oxygen vent lines shall be at least 2m apart. All gas vent lines to atmosphere shall flow through
a water seal or be fitted with a flashback arrestor, normally low pressure rated to maximum 500 kPa
hydrogen gas.
b. The vent line must have a minimum diameter equal to the critical tube diameter. Critical tube
diameter (Dcrit): The maximum tube diameter, for a specific pressure, that will prevent hydrogen
flame propagation within the tube. Dcrit = 13 A, where A is the cell size and has a value of 1cm at
atmospheric pressure (i.e. Dcrit = 13 cm for atmospheric vent pipes).
c. All water seals shall be designed for the maximum flow possible, ensuring that a sudden release of
gas does not break the seal. Hydrogen venting from the generator casing down to 80kPa gauge,
must be achieved within 10 minutes when inert gas purging is initiated. The generator seal oil
minimum pressure requirements must be considered when this test is conducted.

3.15.13 Transfer connections

Interlocking between purging the generator with hydrogen or air must be incorporated in order to prevent
air being introduced to the generator while filled with hydrogen or vice versa.

3.15.14 Compressor machines

Where high pressure compression is required for bulk storage of the produced hydrogen gas:
a. Duplicate compressors shall be installed, with controls to select either one for operating or as
standby. Each compressor shall be rated to continuously handle the full capacity of the plant and
specifically designed to handle wet hydrogen containing traces of lye. (Note: when ordering spares
for compressor plant, it is essential to specify that the components are for hydrogen plant
compressors as they may be susceptible to degradation by wet hydrogen containing lye).
b. Compressors shall be single or multistage with inter-stage cooling, and after-cooling provided after
the final stage of compression.
c. Compressors shall be fitted with condensate blow down mechanisms between each stage to
prevent inter-stage build-up of condensate and damage to compressors. In all cases, this blow-down
shall be vented through a water seal. It is preferred that a condensate trap be installed and draining
of accumulated condensate will be done with level control, avoiding venting of hydrogen due to over-
draining. For automated blow-down, the condensate trap must be fitted with low-low level monitoring
which will disable compressor starting. For manual blow down, an appropriate works-instruction
shall be in place to avoid release of hydrogen.
d. Compressors shall be supplied with safety valves at each stage and on the final outlet which will be
piped to the outside of the building and away from oxygen vents. Safety valve settings shall be in
accordance with OHS Act requirements.
e. A condensate/oil drain line shall be fitted to the compressors leading to a recovery sump in an
accessible location in accordance with the power station's policy on effluent recovery and treatment.
f. The suction lines to the compressors shall be designed to avoid the pressure on the suction side of
the compressor to decrease below atmospheric pressure. It will be permitted for the design of the
suction line to incorporate a condensate trap to prevent pressure swings. If the volume of the supply
line is higher than the volume of gas that the compressor is able to take in during suction stoke this
will not occur.
g. An interlock must be installed to ensure that the selected compressor will not start if the appropriate
suction valve is closed so as to prevent any oxygen ingress to the receivers or storage facility.

3.15.15 Hydrogen dryers

a. A dryer system (a redundant dryer system applicable for atmospheric electrolysers) shall be
installed immediately after compression and before storage. These dryer systems should be
common for any one of the compressors.
b. Dryers shall be able to handle the quantity and quality of gas being produced and ensure safe plant
operation.
c. Desiccant dryers shall be acceptable subject to the requirements below.
 Dryers shall be fitted with filters to remove particles and oil.
 Oil and condensate off-loading will not be done directly to atmosphere. The block-and-bleed
principle shall be applicable to these systems. The drain outlet shall be fitted with liquid level
detectors.
 The liquid level shall be monitored and alarmed.
 The installed dryers are capable of continuous drying without the need to halt production for
regeneration of the drying medium and are compatible with the operating philosophy of the
compressors.
 Automated condensate off-loading systems shall be closed off from the main supply before the
condensate/oil is drained. Monitoring of a passing valve shall be provided.
 The installed dryers are capable of continuous drying without the need to halt production for
regeneration of the drying medium.
 Hydrogen velocity through the desiccant bed does not cause fluidization of the bed.

 The contact time between hydrogen and desiccant is sufficient to dry 100 % saturated inlet
hydrogen to the specified dew point.
 Sufficient desiccant is provided so as to negate the effects of desiccant ageing (normally a 30 %
loss of effectiveness).
 The desiccant must be compatible with the elements in the process for example KOH and oil, or
the process specifically designed to protect the desiccant from oil or KOH contamination.
 Dryer regen condensate must be drained into the drainage system and may not be recycled back
into the cell stack.
 Chamber blow downs shall be through a water seal or flashback arrestor.
 Ceramic or metallic cartridge type filters are installed to filter out impurities down to 1ppm or
better in the compressed hydrogen.
 All dryer chambers must be fitted with a heating element.
 In the case of regeneration, the heating cycle must be interlocked with minimum flow through the
chamber. The temperature of the heating element must not exceed 300 °C.
 A de-oxidiser must be fitted to remove oxygen as part of the gas drying unit. The gas must be
heated to a value which will ensure optimum operation of the catalyst. The catalyst must be
protected from moisture contamination. Sufficient catalyst must be provided to absorb 0,5 %
oxygen continuously for a minimum of one year at full production of the hydrogen generating
plant. Gas cooling and liquid separation must be provided after deoxidizer before gas drying. Gas
temperature at the inlet and outlet of the deoxidizer must be provided with alarming facility to unit
control desk.
 The dryer vessel design must be such that the desiccant and catalyst can be changed without
requiring replacement of the vessel or mechanical intervention that will require recertification
thereof. A specific access must be provided to remove and replace the desiccant or catalyst.

3.15.16 Generator hydrogen dryers

a. The gas dryer must be dimensioned for a test pressure of 1000 kPa gauge. Valves shall be
interlocked, so that the gas dryer is associated either with the generator for drying operation, or with
the blower and the blow-off line for regeneration purposes. Dryer status indication must be provided.
b. All dryer chambers must be fitted with a heating element and a blower.
c. In the case of regeneration, the heating cycle and blower must be interlocked that the heating
cannot be operated without ventilation. The temperature of the heating element must not exceed
300 °C.
d. The interlock between the heating cycle and the blower of the gas dryer, and the limitation of the
heating element temperature, is to prevent the heating resistor from reaching the ignition
temperature of a hydrogen-air flammable mixture that can occur if the heater element was not
cooled by flow from the blower while switched on. The blower must be switched on before the heater
element.
e. Dryers shall be able to handle the quantity and quality of gas to ensure that the hydrogen dew point
is improved with 5 °C at NTP over a 24 hour cycle, taking into consideration hydrogen contamination
from the seal oil system to a value of -30 °C at NTP.
f. Dryers shall be fitted with filters to remove particles and oil down to 1ppm or better.
g. Block-and-bleed isolation arrangement must be supplied before and after hydrogen dryer, without
isolating gas quality measurement while generator is on load.
h. A de-oxidiser can be fitted to remove oxygen as part of the gas drying unit. The gas must be heated
to a value which will ensure optimum operation of the catalyst. The catalyst must be protected from
moisture contamination. Sufficient catalyst must be provided to absorb 0,5 % oxygen continuously
for a minimum of one year at full production of the hydrogen generating plant. Gas cooling and liquid
separation must be provided after deoxidizer before gas drying. Gas temperature at the inlet and
outlet of the deoxidizer must be provided with alarming facility to unit control desk.

i. Oil and liquid off-loading shall not be done directly to atmosphere. The block-and-bleed principle
shall be applicable to these systems.
j. The liquid level shall be monitored and alarmed.
k. The dryer vessel design must be such that the desiccant and catalyst can be changed without
requiring replacement of the vessel or mechanical intervention that will require recertification thereof.
A specific access must be provided to remove and replace the desiccant or catalyst.

3.15.17 Condensate traps

a. In addition to condensate off-loading on the compressors, condensate traps shall be installed on the
suction line of compressor.
b. Volume of condensate should not exceed the capacity of the trap. If necessary multiple traps should
be installed. Needs to act as a buffer and remove condensate from gas.
c. Discharging of condensate traps shall be as described in the section of condensate traps.
d. All traps and bypasses shall be piped to the respective power station drainage sumps via the local
pipeline.

3.15.18 Cooling water systems

a. Materials making up the cooling water system shall be suitable for the power station water quality.
Materials shall be corrosion-resistant and of low carbon content. The use of aluminium is not
permitted.
b. The cooling system on all electrolysers shall be a closed loop system preferably demineralised
system. A common sump accumulating electrolyte overflow, water-seal overflow and/or gasholder
overflow is not permitted as potassium hydroxide is introduced.
c. The cooling water piping to hydrogen generating plant will be part of a large closed loop system and
shall be designed to avoid electrolyte contamination at all times.

3.16 OVERPRESSURE PROTECTION OF STORAGE VESSELS AND PIPING SYSTEMS

3.16.1 Safety Valves

a. The relief or safety valves shall be set to limit the maximum pressure to not exceed the MAWP. The
low pressure side, after pressure reducing, must be protected by a safety valve rated to dump the
maximum amount of hydrogen from the source, without allowing the pressure to increase above the
maximum allowable pressure.
b. Safety and relief valves should be direct spring or deadweight loaded. Pilot valve control or other
indirect operation of safety valves is allowed if the design is such that the main unloading valve
automatically opens at the set pressure or less and is capable of discharge at its full rate capacity if
the pilot or auxiliary device should fail.
c. All safety valves must be fitted upright with the high pressure entry from the bottom.

3.17 PRESSURE REGULATOR

 Cylinders should have a regulator and pressure gauge. Regulators should be non-venting or have
the vents piped to atmosphere through a flashback arrestor to a safe location. All regulators shall be
fitted adequate in-line filters.
 Mechanical shielding should be provided for regulators to protect them from mechanical damage.
 The regulators shall be designed for the specific application.
 The regulator delivery gauge range should be approximately 2 times the operating pressure and at
least 1.5 times the MAWP.
 Following the installation of a pressure regulator the downstream system shall be protected with a
pressure safety valve as per CGA G-5.6, Hydrogen Pipeline Systems.

3.17.1 Supplemental pressure relief

Supplemental pressure-relief devices must be installed to protect against excessive pressure created by
exposure to fire or other unexpected sources of external heat. Relief devices installed in any section of
the vessel and piping systems limit the allowable working pressure. The supplemental relief device
should be capable of limiting the pressure to 121 % of the MAWP.

3.17.2 Failure modes

Failure modes that must be considered in the design and operation of protective pressure-relief systems
include the following:
a. The minimum capacity of the primary protective device should be determined by the heat leak rate.
The device should be located as near as possible to the highest point in the line section.
b. The overpressure potential associated with connection to a high-pressure source of any type —
pump, pressure-relief valve or direct connection through a flow-limiting orifice requires the existence
of a pressure switch to cut off the source of high pressure but does not eliminate the need for the
primary protective device. The primary protective device should be located as close as practical to
the high-pressure source.
c. Capacity consideration for the jacket should be based on a catastrophic failure.

3.18 ELECTRICAL CONSIDERATIONS

3.18.1 Electrical installation

a. All electrical equipment within the risk envelope of normally operated hydrogen equipment shall be
suitable for the approved classification in accordance with SANS 10108.
b. Stuffing boxes shall be used for electrical wiring taken from one explosion-proof enclosure to
another. All outdoor controls shall be weatherproof with at least an IP 65 rating.
c. Where equipment is pressurised, the air for the equipment shall be taken from an outside source
free of hydrogen contamination. Alternatively an inert gas may be used.

3.18.2 Bonding and grounding

a. Exposed metal shall be earthed.
b. All metallic services and structures around hydrogen containing plant shall be earthed and
electrically unified to preclude the existence of discrete electrical bodies and potential differences
between services and structures.
c. All components in contact with hydrogen shall be bonded to electrically unify them with one another
and the unified system shall be bonded to earth. Components requiring unification and bonding shall
not be limited to the obvious items of equipment. Items for earthing and bonding include valve
handles, rubber corrosion protected cooling elements in heat exchangers and internal parts of
equipment such as the balls and gates of valves and other elements capable of forming distinct
electrical entities.
d. All grounding connections should be less than 10 ohm resistance.

3.18.3 Electric motors

a. All main and ancillary drive motors shall conform to NWS 1551 or any applicable specification listed
in NWS 1551 clause 2.
All motors shall be arranged so that they can be removed and maintained without disturbing the
driven machine, piping or electrical items.

3.18.4 Transformer
a. The transformer shall be designed for indoor operation and be rated for continuous operation at
maximum rectifier output. Cable boxes shall be fitted with removable gland plates.
b. Over-current protection shall be installed.
c. Equipment shall be designed for the quality of supply provided by the power station.

3.18.5 Electrical controls

a. The operation of the plant shall be fully automatic and preferably arranged with step-less voltage
control to vary the hydrogen output between the manufacturers minimum recommended production
capacity and 100 % of capacity.
b. If liable to damage by short breaks in the electrical power supply, the plant shall be provided with an
automatic protection facility and an alarm initiating contact.

3.18.6 Electrical connections and cabling

a. All connections shall be rated to the full current rating of the associated equipment i.e. fused-switch,
contactor, circuit-breaker, etc. and not to the design current or fuse-link rating.
b. Neutral connections shall have the same rating as the phase connections.
c. Insulated wire shall comply with SANS 1507 and SANS 1574. Stranded conductor only shall be
used unless the solid type is approved by Eskom for the particular application.
d. Wiring at 50 V and below shall withstand a 500 V test voltage to earth for 1 min and wiring above 50
V shall withstand 1000 V to earth, for 1 min when installed.
e. Wiring shall be neatly fixed to avoid vibration and shall not obscure access to components. Wiring
across door hinges shall be subjected to torsion rather than bending when opening the door.
f. All leads shall be marked at both ends, using interlocking white ferrules with impressed black
characters. Not more than two leads shall be connected to one terminal.
g. An un-drilled, removable gland plate shall be provided at least 300 mm above floor level for each
cable entering the equipment. For cables of 185 mm 2 and above, the gland plate shall be at least 6
mm thick and drilled to suit the gland. For gland plate to terminal distances greater than 400 mm for
control cables, or 500 mm for power cables, a means of fixing or bracing cable tails shall be
provided.
h. Power supply and control cabling shall not share cable trays. Where control and instrument cables
have to cross other cables only right angle crossing will be allowed. The minimum spacing between
control and instrument cables and the nearest power cables shall be 1 m.
i. The insulation of all the electrical equipment shall be in accordance with the specification IEC 60071
j. Power conditioning equipment shall be designed for reliability and ease of maintenance, and shall
incorporate adequate redundancy to allow for fault repairs and routine maintenance without reducing
the plant availability
k. Individual harmonic currents shall not exceed the following: (these are measured at the electrical
supply boards):
 rms amplitude of 100/n percent, where n is the harmonic number.
 Sub-harmonic currents shall not exceed the RMS amplitude of 100n percent, where n is the
Fraction given by the sub-harmonic frequency divided by the fundamental frequency
l. All lighting and small power shall be designed and supplied in accordance with the Standard 200-
11764.The Occupational Health and Safety Act (OHS Act) specifies minimum illumination levels for
safety. At no time shall the illumination level fall below these recommendations, hence the lighting
installation of the construction phase lighting must be regularly maintained to ensure conformance to
the said act.
m. Any termination cubicle, junction box or distribution box utilized outdoors shall be IP65 rated and
IP55 for indoor in accordance with IEC 60529. Finishing colour of 230/400 V cubicles shall be light
grey G29 to SANS 1091.

3.19 CONTROLS AND INSTRUMENTATION

3.19.1 Plant operation and instrumentation

a. The operation of the plant shall be fully automatic, at the manually set hydrogen production rate, to
maintain the rated pressure in the storage vessels.
b. Indicating, recording and out-of-limits detecting instrumentation shall be provided as necessary for
all parameters affecting safe operation of the plant (e.g. purities, temperatures and cell levels).
c. Remote data monitoring for the plant is required so that the plant can be supported by the OEM.
d. The control system for controlling the automated receiver filling and the control of the Hydrogen
Generating Plant will be integrated to ensure safe plant operation. The control philosophy will revert
to plant to the safest state when an unsafe condition is detected.
e. The best operating philosophy for the integrated system i.e. hydrogen production and storage will be
implemented to optimise cell stack life and needs to be approved by Generation Technology
Department.
f. All new installations for generator hydrogen cooling system, carbon dioxide purging will be fully
automated supplied with a full human machine interface that can be operated from a local and
remote station, with the remote station located in the control room.
g. All manual operated display valves, monitoring and plant status indication will be mounted in a two
dimensional plane at a minimum height of 1 m and a maximum height of 1,8 m.
h. The source code for all programmable logic controllers must be supplied with no access limitation to
Eskom. Version control must be implemented.
i. A data recording, trending and data view facility shall be provided with the plant.
j. All instrumentation and C&I equipment shall have an IP rating of IP66. The Junction Box location
shall be outside the hazardous zone location.
k. The terminal block for the marshalling cabinet and junction box terminations shall comply with the
SANS 60947-7-1 and 60947-7-2.
l. Eskom does not utilise binary transmitters and switches, but analogue transmitters with software
levels. Binary transmitters and/or level switches will be accepted in areas where they are required for
statutory requirements or for protection and hardwired interlocking.
m. For level measurement and/or switch where differential pressure transducers are used, all low
pressure instrument tapping points and isolation valve connections shall be ½ inch BSP tapered.
n. For level measurement and/or switch where an ultrasonic or radar transmitter is used, all low
pressure instrument tapping points and isolation valve connections shall be 2 inch BSP tapered.
o. All temperature pockets/wells shall be fitted with a cap and chain. All pockets/wells shall have ½ inch
BSP parallel female thread for the instrument connection and ¾ inch BSP tapered male process
connection, if not welded. The tapping points for the process connection shall have ¾ inch BSP
tapered female connection. All other low pressure instrument tapping points and isolation valve
connections shall be ½ inch BSP tapered.
p. All temperature pockets/wells shall be fitted with a cap and chain. All pockets/wells shall have ½ inch
BSP parallel female thread for the instrument connection and ¾ inch BSP tapered male process
connection, if not welded. The tapping points for the process connection shall have ¾ inch BSP
tapered female connection. All other low pressure instrument tapping points and isolation valve
connections shall be ½ inch BSP tapered.
q. All transmitters shall be HART devices and shall provide measurements that are repeatable and
have no drift for a minimum of 10 years with an accuracy of 0.1 % of full scale or better. Each
transmitter shall have its own tapping point. Transmitters provided shall be mounted in suitable
transmitter racks, equipment cabinets or field panels. They shall be supplied as complete
r. Temperature transmitters shall either use 4 wire Pt 100 RTDs, or 6 mm type K thermocouples, with
calibration characteristics that comply with IEC 60751 and IEC 60584 standards.
s. All pipe work supplied by the Contractor shall be inclusive of supports, valves, fittings, condensing
chambers for closed vessel level transmitters, transition pieces to primary isolating valves and drains

to provide complete impulse and blow-down lines for all instruments. All pipe work designs shall be
submitted to the Engineer for approval prior to installation.
t. All cable racking, cable trays and conduits required for the installation of the equipment. All cables
provided must be secured with suitable cable glands, straps or clamps on racks, in cubicles and
equipment rooms.
u. Where transmitters cannot be mounted in transmitter racks, equipment cabinets or field panels, these
shall be mounted firmly on stands or brackets as close as possible to tapping point. The location
shall allow safe and easy access for maintenance and calibration.

3.19.2 Mass flow meter

a. A flow/mass meter, with a minimum accuracy of 5 %, shall be installed after the storage vessels and
at each generator supply point and must measure the volume of hydrogen gas into the generator
from all sources of hydrogen.
b. The meters shall be of the positive displacement type fitted with a suitable orifice plate to prevent
damage to the meter in the event of a sudden in-rush of hydrogen during commissioning.
c. A mass flow meter shall be installed at the hydrogen generating plant and arranged to meter the
total quantity of hydrogen drawn off by the station. The measurement will provide a reading of
volume in cubic meters NTP.

3.19.3 Analysing Apparatus (Indicating)

a. Gas analysing equipment shall be provided for testing the purity of the hydrogen on-line. It shall be
the continuously indicating and recording type, essential for the safe operation and control of the
plant fitted with an alarm contact arranged to operate between adjustable pre-set limits in the event
of a drop in hydrogen purity. The response time of the equipment shall be catered for in the
operating philosophy with periods within the instrument's "dead band" assumed to be unsafe.
b. Only gas analysing equipment that has a fail-safe failure mode shall be installed in the plant that is
not indicating purity better than actual and is failing in a slow response time mode. The operating
philosophy of the plant must cater for potential equipment failure modes.
c. Metering equipment shall cope with the high flows when filling the generators and with the low
make-up rate in normal operation.
d. All gas analysing equipment must be fitted with a minimum gas flow interlock, gas readings can only
be accepted when minimum gas flow through the analyser is ensured.
e. Conductivity type sensing equipment shall be installed for gas purity monitoring at the outlet of the
desiccant dryers as well as at the analogue dew point sensing equipment.
f. Catalytic oxygen sensors shall be installed on the line supplying the gas holder on atmospheric
electrolysers to provide protection against oxygen entrainment and must be fail safe.
g. Where instruments used make use of a "de-oxidiser", these must also be backed up with an
additional purity measurement using an inert gas, such as nitrogen, as a reference. "De-oxidiser"
instruments require oxygen and hydrogen in order to function and therefore will not provide a
reliable reading in the absence of hydrogen. Plant operating philosophies must cater for this to avoid
the possibility of plant safety being assumed on the basis of an erroneous reading.
h. Hydrogen specific analysers capable of tolerating wet hydrogen shall be installed where this
condition is possible.
i. Critical instrumentation to ensure safe plant operation must be installed with broken wire monitoring
or supply failure and the hydrogen production operation reverted to a safe state when such a
condition is detected.
j. Hydrogen purity, oxygen content and quality must be measured before being administered to the
generator casing.
k. All analysers shall have a local display and they shall have the following parameters for
configuration
• High and low measuring range

• High and low display range

• Engineering units
• Temperature at measurement cell (where applicable)
• Offset adjustment on temperature measurement (where applicable)
• Offset adjustment on measured value
• Indication of measurement device health

l. All analysers shall provide measurements that are repeatable and have no drift for a minimum of 10
years. The output signal of all the analysers shall be load independent direct current 4 to 20 mA
signal or by bus interface. The output signal is also a rising linear and falling linear signal. All gas
analysing equipment with a drift worse than specified must be accompanied with a risk assessment
proving that no unacceptable safety risk will arise from utilising the specific analyser in the
application.
m. The size of the controller cubicles shall be minimum (0.9m x 1m x 2.2m), they shall conform to the
following:
 Floor mounted with suitable dust and vermin proofing
 Bottom cabling access
 Earthing
 Front and rear access
 Temperature monitoring per cubicle
 Powder coated RAL 7035
n. All cabling shall be of blue-stripe type i.e. consist of flame-retardant, halogen-free PVC outer sheath

3.19.4 Alarms and tips

a. Visual alarms shall be provided to indicate any abnormal or dangerous conditions which might
develop on the plant.
b. Each alarm channel shall be provided with potential free alarm repeat contacts wired to external
terminals to initiate a remote alarm system. The number of alarms installed shall be determined in
line with the requirements of the safe operating philosophy.
c. Control Device monitoring and controlling of the critical processes. Where reliable controls already
exist, the controller can be configured to monitor those controls with alarm and delayed over ride
facilities to trip the plant for critical processes. For example, the controller would monitor the actions
of the mechanical switches on the gas holder but override the plant if the compressors were not
tripped on a low-low signal by existing controls or if the new proximity switches provided a signal not
provided by the mechanical switches.
d. Regular plant operator tests shall be carried out to test system monitoring and safety equipment by
simulating failure modes. These test facilities shall be incorporated at design stage if possible.

3.20 PRODUCTIONS QUALITY AND QUANTITY MANAGEMENT

The principle of continuous hydrogen quality and quantity measurement shall be such that:
a. Purity is measured as soon after the electrolytic cells as possible and before compression and
drying. Removal of moisture (free water) may be done before this point.
b. Hydrogen purity, oxygen content must be measured before bulk storage or reticulation to
generators.
c. Dew point after storage and before reticulation to the generators.
d. Hydrogen contamination in the oxygen stream must be measured.
e. Continuous on-line pressure measurement of pressure in hydrogen system.
f. Hydrogen purity and oxygen content is measured before administered to the generators.
g. Continuous on-line generator hydrogen purity and quality measurement.

3.20.1 Electrolytic cells

a. Each cell shall be fitted with points for manual gas sampling. Proof shall be provided that adequate
flow of gas, electrolyte and cooling medium is achieved through-out the cell stack. A maximum of
5ºC between the minimum and maximum measured temperatures shall be accepted though the cell
stack.
b. Means to ensure adequate electrolyte and cooling water flow through the cell stack shall be
provided.
c. The life expectancy of the cell stack should be minimum 10 years at full production.

3.20.2 Before storage

a. Continuous hydrogen purity, oxygen content and dew point measurement shall be in place on the
downstream side of the dryers before delivery to the bulk storage vessels and shall be periodically
confirmed by an independent measurement (not necessarily on-line) so as to ensure the integrity
and accuracy of the measuring devices.
b. A dew point not meeting requirements shall cause an alarm. Atmospheric dew point shall be better
than -50 °C NTP.
c. Measurement of hydrogen purity (minimum 99,5 %) and also oxygen contamination (maximum 0,5
%) shall be done. If oxygen is not measured, any impurity detected by the hydrogen analysers shall
be assumed to be oxygen.
d. The plant shall be tripped when the oxygen contamination reaches the limit of 1 %.
e. When hydrogen purity is less than 99,5 % one of the following two actions is required:
 Where there is not automated vent facility, the entire plant shall be tripped with an alarm to the
control room. OR
 Where there is an automated vent facility, the out of specification condition shall be alarmed the
hydrogen vented through a water seal, and compressors disabled from starting, until the quality
returns to specification.
A relaxation of hydrogen purity to 97,5 % is permitted only where thorough investigation into the
underlying causes has been carried out and necessary corrective actions identified.

3.20.3 After storage

a. After storage and pressure reduction, a maximum dew point of -30 °C below the minimum system
temperature, and for the generator working pressure, shall be allowed.
b. Instrument specific gas flow through the analyser must be ensured and monitored to ensure that the
purity of the gas that is being produced is monitored.
c. The mass flow, pressure and dew-point must be trended and data stored as a minimum for a
moving 30 day period at a sampling rate of once every minute.

3.20.4 At the generator

a. Continuous hydrogen purity, oxygen content and dew point measurement.
b. Hydrogen purity is measured before being administered to the generators.
c. Continuous on-line generator hydrogen purity measurement.
d. Measurement of hydrogen purity (minimum 96 %) and preferably also oxygen contamination
(maximum 1 %) shall be done.
Note: If oxygen is not measured, any impurity detected by the hydrogen analysers shall be assumed
to be oxygen and the generator must be tripped if the hydrogen purity is than less than 96 %.
e. The plant shall be tripped when the oxygen contamination reaches the limit of 1 %.

3.20.5 Additional plant monitoring requirements

Additional parameters shall be monitored for the purposes of verifying correct operation of plant and/or
ensuring plant health.
a. An on-line hydrogen leak detection system shall be installed in the production plant linked to a plant
trip and alarm. These shall be fitted above equipment where leaks are most likely to occur (e.g.
water seals, compressors, gas holder, dryers). OR Leak detection by monitoring the pressure rise
within containerized hydrogen generating plant set to detect a pressure rise that indicates the
presence of 0.8% hydrogen.
b. Storage vessel pressure and reticulation monitoring, which shall be maintained at a minimum
pressure of 500 kPa gauge or 100 kPa above Generator pressure, whichever is the greater, at all
times.
c. The supply lines between the hydrogen production plant and the generators shall be fitted with on-
line monitoring and an alarm facility.
d. Correct operation of the ventilation fans, where installed.
e. Concentration of base electrolyte, routine manual measurement is acceptable.
f. Individual cell voltages (anode/cathode, anode/tank, cathode/tank), routine manual measurement is
acceptable.
g. Individual cell temperatures. (On-line).
h. Individual cell electrolyte levels. (On-line).
i. Rectifier voltage and current. (On-line).
j. AC Ripple, manual measurement is acceptable.
k. Rectifier temperature. (On-line).
l. Mass flow after storage. (On-line).
m. Compressor running hours, indication.
n. Compressor motor currents, indication.

3.21 CORROSION PROTECTION

a. All piping and steelwork, manufactured from low-carbon or mild-steel, including the pressure vessels
shall be coated to prevent corrosion and comply with the requirements of:
 SANS 10140 (parts 1 to 4), Identification colour markings,
 ESKSCABB8, Corrosion Protection for Mechanical items of Plant.
b. As available coatings change with time, outdated specifications shall not be used.

3.22 MAINTAINABILITY
Access to all parts of the plant for normal operating and maintenance requirements without removing
panels.

3.23 MATERIALS FOR HYDROGEN SERVICE

The appropriate data must be available for the selection of a material for particular use, see Annexure A
for material selection. The following must be considered when selecting suitable material for hydrogen
applications:
a. Properties suitable for design and operating conditions
b. Compatibility with the operating environment
c. Availability of selected material and appropriate test data for it
d. Corrosion resistance
e. Ease of fabrication, assembly and inspection
f. Consequences of a material failure
g. Toxicity
h. Hydrogen embrittlement

i. Potential for exposure to high temperature from a hydrogen fire

j. Thermal contraction

4. AUTHORISATION
This document has been seen and accepted by:
Name Designation
Manie Van Staden Senior Consultant PEIC
Mfundo Verby Discipline Manager LPS CoE
Mary Maunye Senior Technologist Engineer LPS CoE
Justin Varden Senior Engineer Chemical CoE
Marlize Andre Chief Engineer LPS CoE
Nemalen Chetty Senior Engineer LPS CoE
Bruce Tyson Chief Engineer LPS CoE
Nkosi Ndika Senior Engineer LPS CoE
Anasen Pillay Senior Engineer LPS CoE
Jan Strydom Senior Engineer LPS CoE
Ndoda Mazibuko Senior Engineer C&I CoE

5. REVISIONS
Date Rev. Compiler Remarks
November 2012 0 HJ van Staden Compiled the Document 36-803
August 2013 1 W.O. Erasmus Reviewed and approved, final document for Authorisation and
Publication
August 2016 1.1 M. Maunye Reviewed the document from Revision 1 to 1.1
October 2016 1.2 M. Maunye Final Draft Document for Comments Review
January 2017 1.3 M. Maunye Updated comments after the presentation to the LPS study
committee.
March 2017 2 M. Maunye Final Document for Authorisation and Publication

6. DEVELOPMENT TEAM
The following people were involved in the development of this document:
Name & Surname Designation
Dikeledi Zitha Engineer, Arnot Power Station
Manie Van Staden Senior Consultant PEIC
Thokozane Ntuli Senior Advisor, Majuba Power Station
Neil Anderson Engineer, Matla Power Station
Nkhumeleni Matakanya Engineer, LPS CoE
Karlien du Plessis Engineer, Lethabo Power Station
Nhlanhla Ngcobo Engineer, Duvha Power Station
Nhlanhla Rikhotso Engineer, Kendal Power Station
Aandil Silal Engineer, Lethabo Power Station

7. ACKNOWLEDGEMENTS
Manie Van Staden and the Hydrogen Forum/Care group

APPENDIX A

8.1 ANNEXURE A.1 MATERIAL DATA SPECIFICATION

A.1 Material selection criteria

Hydrogen components and hydrogen systems commonly involve a wide variety of material, both metals
and non-metals (such as polymers). Each material that is involved (for example, seats, seals, adhesives,
lubricants, electrical insulation, springs, bolts and piping) should be carefully evaluated for its use in the
design, operating, and emergency conditions to which it will be exposed.
The selection of a material that is suitable for use in a hydrogen system involves several factors. Some
considerations involved in the choice of a material to be used in a hydrogen system include the following:
a. Compatibility with hydrogen (with concerns such as hydrogen embrittlement, hydrogen attack,
hydriding, porosity, permeation and diffusion);
b. Compatibility with adjoining materials (matching properties under changes in temperature and
pressure, for example, and the effect of such changes on the material's shape and dimensions);
c. Compatibility with the conditions of use (effects of temperature and pressure, for example, on
ductility, and expansion/contraction; property changes associated with changes in operating
conditions);
d. Compatibility with the surrounding environment or exposure (for example, a corrosive environment
or high temperature from a hydrogen fire or fire from nearby materials);
e. Toxicity (the use of a material that is toxic in any way, such as during fabrication, should be
considered only when absolutely necessary);
f. Failure mode (for example, brittle rapid rupture versus ductile slow separation);
g. Ability to fabricate into the desired form (for example, machining, welding and bending);
h. Economics;
i. Availability
Most of these considerations are common for the selection of a material for any purpose. However, the
first one is unique to hydrogen, and the next two are important for liquid hydrogen applications, because
of the low temperature involved (20 K). A brief discussion of these first three considerations is given
below.

8.2 ANNEXURE A.2 HYDROGEN EMBRITTLEMENT

Hydrogen embrittlement is a serious concern for metals exposed to hydrogen. Hydrogen embrittlement
can cause a significant deterioration in the mechanical properties of metals. Hydrogen embrittlement
involves a large number of variables such as the temperature and pressure of the environment; the
purity, concentration and exposure time of the hydrogen; and the stress state, physical and mechanical
properties, microstructure, surface conditions, and the nature of any crack front in the material. The
susceptibility to hydrogen embrittlement of some commonly used metals is summarized in Table A.1.
Although a material may be subject to hydrogen embrittlement (even extremely embrittled), the material
may still be used in hydrogen service. For example, compressed gas cylinders that have been used
successfully for many years for the storage and transport of compressed hydrogen gas are commonly
made of alloy steel 4130X.

Table 1: Hydrogen embrittlement susceptibility of some commonly used metals

Extremely Severely Slightly Negligibly

Metal embrittled embrittled
embrittled embrittled

Aluminum alloys

1100 X
6061-T6 X
7075-T73 X
Be-Cu alloy 25 X
Copper, OFHC X
Nickel 270 X
Steel

Alloy steel, 4140 X

Carbon steel
1020 X
1042 (normalized) X
1042 (quenched & tempered) X
MaragIng steel, 18Ni-250 X
Stainless steel
A286 X
17-7PH X
304 ELC X
305 X
310 X
316 X
410 X
440C X
Inconel 718 X
Titanium and titanium alloys
Titanium X
Ti-5AI-2.5SN (ELI) X
Ti-6AI-4V (annealed) X
Ti-6AI-4V (STA) X

8.2.1 Low Temperature Effects

8.2.1.1 General
The selection of a structural material for use in liquid hydrogen service is based primarily on the
mechanical properties of the material, such as yield and tensile strengths, ductility, impact strength and
notch insensitivity. The material should have certain minimum values for these properties over the entire
temperature range of operation, with appropriate consideration for emergency conditions such as a
hydrogen fire. The material should be metallurgically stable, so that phase changes in the crystalline

structure do not occur with time or repeated thermal cycling. The choice of a material for use at liquid
hydrogen temperature of 20 K involves material behaviour considerations such as the following:
a. Transition from ductile to brittle behaviour as a function of temperature;
b. Modes of plastic deformation, particularly certain unconventional modes encountered at very low
temperatures;
c. Effects of metallurgical instability and phase transformations in the crystalline structure on
mechanical and elastic properties.
Two of the primary considerations in the selection of a material for liquid hydrogen service are low
temperature ductility (low-temperature embrittlement) and thermal contraction.

8.2.2 Low-Temperature Embrittlement

Many materials change from ductile to brittle behaviour as their temperature is lowered. This change in
behaviour can occur at temperatures much higher than cryogenic temperatures.
The results of the Charpy impact test as a function of temperature can be used as an indication of the
ductile-to-brittle transition behaviour of a material. Another indication of the ductile-to-brittle behaviour of
a material can be obtained by the relationship of the yield and tensile strengths of a material as a
function of temperature. If the yield strength of a material approaches the tensile strength of the material
as the temperature decreases, then the material will become increasingly brittle.
Generally, a material that has a ductile-to-brittle transition temperature above 20 K should not be used
with liquid hydrogen, unless its use is given careful consideration and thorough analysis. Most polymers
become brittle at temperatures much higher than liquid hydrogen temperature, and consequently, their
use in liquid hydrogen systems is generally avoided.

8.2.3 Thermal contraction

Materials generally have a positive expansion coefficient, that is, the material will expand as its
temperature rises (however there are a few exceptions to this). The temperature span from ambient to
liquid hydrogen temperature is about 280 K. Such a large temperature decrease can result in significant
thermal contraction in most materials. It is necessary to account for this contraction in the use of a
material at liquid hydrogen temperature. The thermal expansion coefficient itself is a function of
temperature.
Typical values for thermal contraction for a temperature change from an ambient to a cryogenic
temperature are as follows:
a. About 0,3 % in iron-based alloys;
b. Slightly over 0,4 % in aluminium;
c. Well over 1 % in many plastics.
The use of a plastics material between two metal surfaces (for example, seals) would have to
accommodate the approximately 0, 6 % more contraction that the plastic would experience compared to
the metal.

8.2.4 Material Suitability for Hydrogen Service

A material should be evaluated carefully before it is used for hydrogen service. A material should not be
used for hydrogen service unless data are available to show that the material is suitable for the intended
service conditions. Materials that have been used successfully with hydrogen should be preferred over
materials with little or no history of use with hydrogen. The suitability of some commonly used materials
for use with hydrogen is shown in Table A.2, which is provided as a guideline and for informative
purposes only.

Table 2: Suitability of some selected materials for hydrogen service

Gaseous Liquid
hydrogen hydrogen
Material (GH2) (LH2) Remarks
service service
METALS
Aluminium and its alloys S S Negligibly susceptible to hydrogen
embrittlement.
Copper and its alloys (such as brass, bronze S S Negligibly susceptible to hydrogen
and copper-nickel) embrittlement.
Iron, cast, grey, ductile NS NS Not permitted by relevant codes and
standards.
Nickel and its alloys (such as Inconel and E E Evaluation needed. Susceptible to
Monel) hydrogen embrittlement.
S May make martensitic conversion if
Steel. austenitic stainless with > 7 % nickel
S stressed temperature.
(such as 304, 3041_ 308, 316, 321, 347)
above yield
point at low Evaluation needed. Susceptible to
Steel, carbon (such as 1020 and 1042) E NS hydrogen embrittlement. Too brittle for
cryogenic service.
Evaluation needed. Susceptible to
Steel, low alloy (such as 4140) E NS hydrogen embrittlement. Too brittle for
cryogenic service.
Steel. martensitic stainless (such as 410 E E Evaluation needed. Susceptible to
and440C) hydrogen embrittlement.
Steel, nickel (such as 2,25; 3,5: 5 and 9 % E NS Ductility lost at liquid hydrogen
Ni) temperature
Titanium and its alloys E E Evaluation needed. Susceptible to
hydrogen embrittlement.

Table 3: (Continued): Suitability of some selected materials for hydrogen service

NONMETALS
Avoid use because of
Asbestos impregnated with Teflon a S S carcinogenic hazard.
Chloroprene rubber (Neoprene a) S NS Too brittle for cryogenic service.
Polyester fibre (Dacron) S NS Too brittle for cryogenic service.
Fluorocarbon rubber (Viton a) E NS Too brittle for cryogenic service.
Polyester film (Mylar) a S NS Too brittle for cryogenic service.
Nitrile (Buna-N a) S NS Too brittle for cryogenic service.
Polyamides (nylon) S NS Too brittle for cryogenic service.
Polychlorotrifluoroethylene (Kel-F a) S S
Polytetrafluoroethylene (Teflon a) S S
NOTE 1 S: Suitable for use.
NOTE 2 NS: Not suitable for use.
NOTE 3 E: Evaluation needed to determine if the material is suitable for the use conditions.

A Teflon, Neoprene, Dacron, Mylar, Viton, Buna-N and Kel-F are examples of suitable products available
commercially. This information is given for the convenience of users of this Technical Report and does not
constitute an endorsement by ISO of these product(s).

APPENDIX B

9.1 HYDROGEN GENERATING PLANT FACTORY ACCEPTANCE TESTING GUIDELINE

Factory acceptance testing must be done on all hydrogen plants unless it is a plant and design that was
previously witnessed and approved by GTD.
As a minimum the following must be checked and verified during factory acceptance testing from an
Eskom perspective:
a. Factory acceptance testing must be done on all hydrogen plants unless it is a plant and design that
was previously witnessed and approved by GTD.
b. As a minimum the following must be checked and verified during factory acceptance testing from an
Eskom perspective:
c. The hydrogen plant must be in a basic operating state without external devices connected to the
control system. If the control system is password protected the unit must be in the lowest level
status.
d. The hydrogen purity and oxygen content must be monitored on the hydrogen production stream.
The hydrogen content of the oxygen gas stream must also be monitored. The analysers for
conducting this test must be able to measure PPM.
e. The unit must be cycled through varying the pressure and creating a maximum delta pressure
across the hydrogen and the oxygen within the cell stack and the current through the cell stack must
be taken from minimum to maximum and vice versa. At all times the gas contamination must be
maintained below 4%. For the execution of this test the gas analysing tripping values must be
altered.
f. During operation the power supply from all the safety devices individually must be removed and the
unit should revert to the safest state.
g. The design must be approved and accepted by Eskom prior to FAT.
h. All safety trips must be tested.
i. All safety devices must be calibrated prior to FAT and witnessed by Eskom.
j. The unit must be fully assembled and fully compliant to the requirements of 240-56227413.
k. A leakage test must be conducted prior to FAT with the unit being pressurised to operating pressure
all outlets isolated and zero percent leakage over a 24hour cycle. Temperature compensation must
be done.
l. The hydrogen generating plant must run continuously uninterrupted for 7 days at full capacity
without tripping. The average production must be more than the specified output.
m. All inputs and outputs to and from the control system must be checked and verified.
n. All final drawings, set points and operating instruction documentation must be available.
o. Detailed control and safe plant operating philosophy must be submitted prior to FAT.
p. The source code of all programmable logic controllers will be made available to Eskom prior to FAT
with no limitation on access.
q. The source code will be reloaded from the copy supplied to Eskom prior to FAT.
r. For the warrantee period no alterations to the source code will be done without the consent of the
OEM.
s. At minimum product rate maximum pressure after the hydrogen in oxygen and oxygen in hydrogen
directly after the cell stack has stabilized, the hydrogen vent valve and alternately the oxygen vent
file will be forced open. The system needs to trip and maintain the contamination levels within the
levels stipulated in ISO 22734-1, Hydrogen generators using water electrolysis process – Part 1:
Industrial and commercial applications.

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