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Electrolyser System Test Specification
Pre-Starting
Please read these instructions thoroughly. This will make sure you obtain full safe use, Keep this instruction manual in a handy place for future reference.
Nitrogen purging
- Make sure the circuit is closed (all valves are closed)
- Make sure the power is turned off
- Connect the Nitrogen tank to the system
- Open Nitrogen tank valve
The amount of nitrogen needed for this process is based on how many times pressurized purges are needed to reduce the unwanted contaminant to the desired level.
- Disconnect the nitrogen.
Tank
- Make sure that the water tank has 60 liters of water
- Make sure that the KOH tank has 60 liters of KOH
Safety precaution
Storage of H2 is dangerous, for this reason, it should be burned using a fuel burner.
Electrolysis operation method
1- Ensure all sanitary connections
2- Fill the first tank with distilled water
3- Fill the second tank with KOH mixture with pH = 13.47
4- Ensure that all electrical connections are made, with no electricity connected to the device
5- Filling the device completely with nitrogen gas, starting with the entry of nitrogen gas at the electrodes and its exit from the hydrogen and oxygen vents, passing through the condensate
6- Operation of the distilled water pump
7- Operation of the KOH mixture pump
8- Connect electricity (continuous power) to the device
9- Wait a while and then start collecting the hydrogen and oxygen gases produced separately by connecting the outlets to specific tanks or connecting them directly to the burner.
For more information, please download the following files:
Electrolysis Test Specifications (.docx)
Electrolyser Operation Manuel (.docx)
Electrolyser Operation Manuel (.pdf)
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WE_Automation_Process
Step 1: Camera connections
1- Connect the camera Adapter
2- Connect the camera with PC
On PC, open “Internet explorer”, then enter the IP address “192.168.1.64“(written on the camera box), password: a1111111
Step 2: PLC
1- Connect wire of PLC.
2- Turn UP (Turn On) the PLC breaker.
GUI_Operation
1- Open file named “Electrolysis GUI” placed on the desktop of “Mediston Laptop”.
2- Through the GUI, we enter the solution.
3- When all valves are closed, turn on the power supply until burner is on.
If we find the voltage is up to 16V, the voltage must be reduced. (Working on updates)
System_test_cases
00001: The lack shall be detected when it exists
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Step |
Step Description |
Expected Result |
|
Precondition |
System is off |
|
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Switch ON the system |
Turn on the air compressor manually |
Air enters to the whole system |
|
Lack is detected |
Air exit from the pie system |
Lack position shall be detected with a marker |
|
Switch OFF the system |
Turn off the air compressor manually |
The air stops enter to the pipe system |
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Postcondition |
System is OFF |
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00002: WHOLE SYSTEM TEST
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Step |
Step Description |
Expected Result |
|
Precondition |
System is off |
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Open the valves V1 and V2 |
Open the valves V1 and V2 from the GUI |
The valve V1 and V2 are open and enable to let the nitrogen gas pass |
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WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE GLOBLE VALVE on the nitrogen tank |
One can see that there is nitrogen exit from the gas outlets |
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Switch ON the system |
Turn Off the globle nitrogen valve Turn Up (Turn On) the breaker (behind the Kelvinator refrigerator) Turn Up (Turn On) the two breakers (red & blue breakers in PLC box) Turn ON the system from the GUI |
THE SYSTEM IS GENERATING hydrogen and oxygen |
|
Burn the hydrogen |
Turn On the transformator |
The Hydrogen is burning |
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Switch Off the system |
Switch Off the system from the GUI Switch Off the transformator |
The system goes down |
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WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
All the hydrogen existing in the pipe system exit |
|
Postcondition |
Turn off the system |
System is off |
00003: KOH pipe system test
The lack have to be marked with a marker and fixed
|
Step |
Step Description |
Expected Result |
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Precondition |
System is off (No LIN signal) |
|
|
Switch on the KOH system |
Open the KOH valves Turn on the KOH pump |
The water passes through the KOH pump to the cell |
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Lack is detected |
Look at the KOH pump system and look if there is exiting of water from the system |
There is entering of water from the pipe system |
|
Switch off the system. |
Switch off the the pump and then the 2 KOH vlves |
The system goes down. |
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Postcondition |
System is off |
|
00004: WHOLE SYSTEM TEST WITH ANOTHER POWER SUPPLY
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Step |
Step Description |
Expected Result |
|
Precondition |
System is off |
|
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THE CHANGING F THE POWER SUPPLY WIT A POWER SUPPLY OF HIGHER VOLTAGE |
Replacing the power supply with the welding machine |
More hydrogen is generated |
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Open the valves V1 and V2 |
Open the valves V1 and V2 from the GUI |
The valve V1 and V2 are open and enable to let the nitrogen gas pass |
|
WASH THE SYSTEM WITH NITROGENE |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
One can see that there is nitrogen exit from the gas outlets |
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Switch on the system |
Turn off the nitrogen Turn on the system from the GUI
|
THE SYSTEM IS GENERATING hydrogen and oxygen |
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Burn the hydrogen |
Turn on the transformator |
The Hydrogen is burning |
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Switch off the system. |
Switch off the system from the GUI Switch off the transformator
|
The system goes down. |
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WASH THE SYSTEM WITH NITROGENE |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
All the hydrogen existing in the pipe system exit |
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Postcondition |
Turn off the system |
System is off |
00005: WHOLE SYSTEM TEST WITH ONLY ONE CELL CONNECTED
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Step |
Step Description |
Expected Result |
|
Precondition |
System is off |
|
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CONNECTING THE COMPLETE VOLTAGE TO ONLY ONE CELL |
DISCONNECT THE POWER SUPPLY FROM TWO CELLS AND CONNECT IT TO ONLY ONE CELL. |
MORE CURRENT WILL DRIVE THROUGH THE CELL |
|
Open the valves V1 and V2 |
Open the valves V1 and V2 from the GUI |
The valve V1 and V2 are open and enable to let the nitrogen gas pass |
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WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
One can see that there is nitrogen exit from the gas outlets |
|
Switch on the system |
Turn off the nitrogen Turn on the system from the GUI |
THE SYSTEM IS GENERATING hydrogen and oxygen |
|
Burn the hydrogen |
Turn on the transformator |
The Hydrogen is burning |
|
Switch off the system |
Switch off the system from the GUI Switch off the transformator |
The system goes down. |
|
WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
All the hydrogen existing in the pipe system exit |
|
Postcondition |
Turn off the system |
System is off |
00006: WHOLE SYSTEM TEST after increasing of the KOH concentration
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Step |
Step Description |
Expected Result |
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Precondition |
System is off |
|
| Emptying the cells | Placing a container under the two emptying valves and open the two emptying valves so that the containers are filled with the solution of the cells. | The solution flows into the containers. |
| Closing of the emptying valves. | closing the emptying valves after the whole solution flowed from the cells into the containers. | The emptying valves are closed |
|
Increase the KOH concentration. |
For the solution from the cells into the KOH tank and increase the KOH concentration, by adding new KOH. |
The KOH concentration increase |
|
Open the valves V1 and V2 |
Open the valves V1 and V2 from the GUI |
The valve V1 and V2 are open and enable to let the nitrogen gas pass |
|
WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
One can see that there is nitrogen exit from the gas outlets |
|
Switch on the system |
Turn off the nitrogen Turn on the system from the GUI |
THE SYSTEM IS GENERATING hydrogen and oxygen |
|
Burn the hydrogen |
Turn on the transformator |
The Hydrogen is burning |
|
Switch off the system. |
Switch off the system from the GUI Switch off the transformator |
The system goes down. |
|
WASH THE SYSTEM WITH NITROGEN |
Wash the system with Nitrogen for few minutes BY TURNING ON THE VALVE on the nitrogen tank |
All the hydrogen existing in the pipe system exit |
|
Postcondition |
Turn off the system |
System is off |
00007: Test whether the membrane is ruptured
If there are air bubbles from the hydrogen half cells set the membrane have to be changed.
|
Step |
Step Description |
Expected Result |
|
Precondition |
System is off |
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| Emptying the cells | Placing a container under the two emptying valves and open the two emptying valves so that the containers are filled with the solution of the cells . | The solution flows into the containers. |
| Closing of the emptying valves. | Closing the emptying valves after the whole solution flowed from the cells into the containers. | The emptying valves are closed |
|
Let the air enter to the half-cell set of oxygen. |
Connect the air compressor to one set of the half cell sets and tur on the compressor. |
Air bubbles are seen only in the one set on which the air bubbles are connected |
|
Stop the air |
Turn off the compressor |
The compressor is off |
|
Postcondition |
Turn off the system |
System is off |
00008: A simple test of an Electrolysis system -Case add water manually-
| Steps | Steps description | Excepted result |
| Precondition | System is Off | |
| The cells are partially filled with NaOH solution | ||
| Run pump to fill the cells with the NaOH solution | Open the valves (V3) & (V4) from the GUI | (V3) & (V4) are opened and enable to let the electrolyte solution pass |
| Click "Start" on the Electrolyte bottom from the GUI | The cells enable to filled with electrolyte solution | |
| Wait 5 seconds, the pump (P1) run automatically | The pump (P1) is turned On | |
| Turn Off the pump when the cells are filled with NaOH solution | When (L3) & (L4) go from "Low" to "High", turn Off the pump from the GUI | The cells filled with electrolyte solution |
| Pump (P1) turned Off | ||
| Close the valves (V3) & (V4) | Turn Off the valves (V3) & (V4) from the GUI | The valves (V3) & (V4) are closed |
| Wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Turn ON the burner to burn the gas | Click "Start" on Fuel Burner from the GUI | The transformer is turned On |
| The burner is turned On | ||
| Redness of the metal strip of the burner | ||
| Connect the Power Supply on the system | Ensure that the pump (P1) is turned Off | Pump (P1) is closed |
| Click "Start" on the Power Supply bottom from the GUI | The Power Supply is On | |
| The system is generating Hydrogen and Oxygen | ||
| 5 minutes after turning On the burner, a flame appears | ||
| Add water to the system | Click "Start" on Water from the GUI | |
| Turn On the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the water pass through the cells | |
| Turn On the pump (P2) | Pump (P2) is turned On | |
| After few minutes, Click "Stop" on the valves (V1) & (V2) with the Command OFF "CMD OFF" from the GUI | The valves (V1) & (V2) are closed | |
| When (L3) & (L4) go from "Low" to "High", turn Off the pump (P2) from the GUI | The pump (P2) is turned Off | |
| When (L3) & (L4) go from "Low" to "High", Turn Off the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Disconnect the Power Supply on the system | Click "Stop" on Power Supply bottom from the GUI | The electricity is turned Off from the system |
| The generation of Hydrogen and Oxygen are stopped | ||
| Turn Off the fuel burner | Click "Stop" on the Fuel Burner bottom from the GUI | Burner (Transformer) is Off |
| Click "Stop" on the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Flame disappears (is Off) | ||
| Re-wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Post condition | Turn Off the system | System is Off |
| The cells are partially filled with NaOH solution | ||
| The cells are filled totally with NaOH solution |
00009: A simple test of an Electrolysis system -Case add water automatically-
| Steps | Steps description | Excepted result |
| Precondition | System is Off | |
| The cells are partially filled with NaOH solution | ||
| Run pump to fill the cells with the NaOH solution | Open the valves (V3) & (V4) from the GUI | (V3) & (V4) are opened and enable to let the electrolyte solution pass |
| Click "Start" on the Electrolyte bottom from the GUI | The cells enable to filled with electrolyte solution | |
| Wait 5 seconds, the pump (P1) run automatically | The pump (P1) is turned On | |
| Turn Off the pump when the cells are filled with NaOH solution | When (L3) & (L4) go from "Low" to "High", turn Off the pump from the GUI | The cells filled with electrolyte solution |
| Pump (P1) turned Off | ||
| Close the valves (V3) & (V4) | Turn Off the valves (V3) & (V4) from the GUI | The valves (V3) & (V4) are closed |
| Wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Turn ON the burner to burn the gas | Click "Start" on Fuel Burner from the GUI | The transformer is turned On |
| The burner is turned On | ||
| Redness of the metal strip of the burner | ||
| Connect the Power Supply on the system | Ensure that the pump (P1) is turned Off | Pump (P1) is closed |
| Click "Start" on the Power Supply bottom from the GUI | The Power Supply is On | |
| The system is generating Hydrogen and Oxygen | ||
| 5 minutes after turning On the burner, a flame appears | ||
| Add water to the system | Click "Start" on Water from the GUI | |
| Turn On the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the water pass through the cells | |
| Turn On the pump (P2) | Pump (P2) is turned On | |
| When (L3) & (L4) go from "Low" to "High", the pump (P2) is turned Off automatically from the GUI | Pump (P2) is turned Off | |
| When (L3) & (L4) go from "Low" to "High", the valves (V1) & (V2) are turned Off automatically from the GUI | The valves (V1) & (V2) are closed | |
| Click "Stop" on Water from the GUI | ||
| Disconnect the Power Supply on the system | Click "Stop" on Power Supply bottom from the GUI | The electricity is turned Off from the system |
| The generation of Hydrogen and Oxygen are stopped | ||
| Turn Off the fuel burner | Click "Stop" on the Fuel Burner bottom from the GUI | Burner (Transformer) is Off |
| Click "Stop" on the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Flame disappears (is Off) | ||
| Re-wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Post condition | Turn Off the system | System is Off |
| The cells are partially filled with NaOH solution | ||
| The cells are filled totally with NaOH solution |
00010: A simple test of an Electrolysis system -Case without add water-
| Steps | Steps description | Excepted result |
| Precondition | System is Off | |
| The cells are partially filled with NaOH solution | ||
| Run pump to fill the cells with the NaOH solution | Open the valves (V3) & (V4) from the GUI | (V3) & (V4) are opened and enable to let the electrolyte solution pass |
| Click "Start" on the Electrolyte bottom from the GUI | The cells enable to filled with electrolyte solution | |
| Wait 5 seconds, the pump (P1) run automatically | The pump (P1) is turned On | |
| Turn Off the pump when the cells are filled with NaOH solution | When (L3) & (L4) go from "Low" to "High", turn Off the pump from the GUI | The cells filled with electrolyte solution |
| Pump (P1) turned Off | ||
| Close the valves (V3) & (V4) | Turn Off the valves (V3) & (V4) from the GUI | The valves (V3) & (V4) are closed |
| Wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Turn ON the burner to burn the gas | Click "Start" on Fuel Burner from the GUI | The transformer is turned On |
| The burner is turned On | ||
| Redness of the metal strip of the burner | ||
| Connect the Power Supply on the system | Ensure that the pump (P1) is turned Off | Pump (P1) is closed |
| Click "Start" on the Power Supply bottom from the GUI | The Power Supply is On | |
| The system is generating Hydrogen and Oxygen | ||
| 5 minutes after turning On the burner, a flame appears | ||
| Disconnect the Power Supply on the system | Click "Stop" on Power Supply bottom from the GUI | The electricity is turned Off from the system |
| The generation of Hydrogen and Oxygen are stopped | ||
| Turn Off the fuel burner | Click "Stop" on the Fuel Burner bottom from the GUI | Burner (Transformer) is Off |
| Click "Stop" on the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Flame disappears (is Off) | ||
| Re-wash the system with Nitrogen gas | Open the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are open and enable to let the nitrogen gas pass |
| Close the blue ball valve of the water tank manually | The blue ball valve is closed | |
| Open the bottle of Nitrogen gas 5 minutes @ 4 bars | The Nitrogen gas pass through the system | |
| The air bubbles appear (generate) in the Gas AutoSafety | ||
| Turn Off the Nitrogen bottle by its gate valve manually | The Nitrogen bottle is closed | |
| The air bubbles disappear (doesn't generate) in the Gas AutoSafety | ||
| Open the blue ball valve of water tank manually | The blue ball valve is opened | |
| Close the valves (V1) & (V2) from the GUI | The valves (V1) & (V2) are closed | |
| Post condition | Turn Off the system | System is Off |
| The cells are partially filled with NaOH solution | ||
| The cells are filled totally with NaOH solution |
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Related Sites/Items:
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System Specification |
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Mechanical Design |
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Process Control System Spec./Design |
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Mechanical Realization |
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Process Control System Realization (PLC+GUI) |
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System Test Specification |
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System Testing |