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)

-----------------------------------------------------------

Systemtestcases

00001: The leck shall be detected when it exists

Step	Step Description	Expected Result
Precondition	System is off
Switch on the system	Turn on the air compressor	-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	The air stops enter to the pipe system
Postcondition	System is off

00002: WHOLE SYSTEME TEST

Step	Step Description	Expected Result
Precondition	System is off
open the valves V1 and V1	open the valves V1 and V1 from the GUI	the valve v1 anv d v2 are open and enable to let the nitrogene gas pass
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	-one can see that there is nitrogene exit from the gas outlets
Switch on the system	Turn off the nitrogene Turn on the systeme from the GUI	THE SYSTEM IS GENERATING hydrogene and oxygene
Burn the hydrogene	Turn on the transformator	The Hidrogene is burning
Switch off the system.	Switch off the system from thGUI Switch off the transformator	The system goes down.
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	All the hydrogene existing in the pipe systeme exeit
Postcondition	System off the systeme	systeme is off

00003: KOH pipe systeme test

The lack have to be marked wirh a marker and fixed

Step	Step Description	Expected Result
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
Lack is detected	Look at the KOH pump systeme and look if there is exiting of water from the systeme	There is extering 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.
Postcondition	System is off

00004: WHOLE SYSTEME TEST WITH ANOTHER POWER SUPPLY

Step	Step Description	Expected Result
Precondition	System is off
THE CHANGING F THE POWER SUPPLY WIT A POWER SUPPLY OF HIGHER VOLTAGE	Replacing the power supply with the welding machine	more hydrogene is generated
open the valves V1 and V1	open the valves V1 and V1 from the GUI	the valve v1 anv d v2 are open and enable to let the nitrogene gas pass
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	-one can see that there is nitrogene exit from the gas outlets
Switch on the system	Turn off the nitrogene Turn on the systeme from the GUI	THE SYSTEM IS GENERATING hydrogene and oxygene
Burn the hydrogene	Turn on the transformator	The Hidrogene is burning
Switch off the system.	Switch off the system from thGUI Switch off the transformator	The system goes down.
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	All the hydrogene existing in the pipe systeme exeit
Postcondition	System off the systeme	systeme is off

00005: WHOLE SYSTEME TEST WITH WITH ONLY ONE CELL CONNECTED

Step	Step Description	Expected Result
Precondition	System is off
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 V1	open the valves V1 and V1 from the GUI	the valve v1 anv d v2 are open and enable to let the nitrogene gas pass
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	-one can see that there is nitrogene exit from the gas outlets
Switch on the system	Turn off the nitrogene Turn on the systeme from the GUI	THE SYSTEM IS GENERATING hydrogene and oxygene
Burn the hydrogene	Turn on the transformator	The Hidrogene is burning
Switch off the system.	Switch off the system from thGUI Switch off the transformator	The system goes down.
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	All the hydrogene existing in the pipe systeme exeit
Postcondition	System off the systeme	systeme is off

00006: WHOLE SYSTEME TEST after increasing of the KOH concentration

Step	Step Description	Expected Result
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 te solution of the cells .	The solution flows into the containers.
Closing of the emptying valves.	closing the emptying valves after the whole sotution flowed from the cells into the containers .	the emptying valves are closed
Increase the koh concentration.	Pour 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 V1	open the valves V1 and V1 from the GUI	the valve v1 anv d v2 are open and enable to let the nitrogene gas pass
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	-one can see that there is nitrogene exit from the gas outlets
Switch on the system	Turn off the nitrogene Turn on the systeme from the GUI	THE SYSTEM IS GENERATING hydrogene and oxygene
Burn the hydrogene	Turn on the transformator	The Hidrogene is burning
Switch off the system.	Switch off the system from thGUI Switch off the transformator	The system goes down.
WASH THE SYSTEM WITH NITROGENE	Wash the system with Nitrogenen for few minutes BY TURNING ON THE VALVE on the nitrogene tank	All the hydrogene existing in the pipe systeme exeit
Postcondition	System off the systeme	systeme is off

00007: Test whether the membrane is ruptured

if there are air bubbles from the hydrogene half cells set the membrane have to be changed .

Step	Step Description	Expected Result
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 te solution of the cells .	The solution flows into the containers.
Closing of the emptying valves.	closing the emptying valves after the whole sotution 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 is connected
Stop the air	turn off the compressor	the compressor is off

Postcondition	System off the systeme	systeme is off

-----------------------------------------------------------

Related Sites/Items:

System Specification	ICPT - Electrolyser
Mechanical Design	Electrolyser Mechanical Design
Process Control System Spec./Design	PCS Design
Mechanical Realization	Electrolyser Mechanical Realization
Process Control System Realization (PLC+GUI)	PCS Realization
System Test Specification	Test Specification
System Testing	Test Cases