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

Step	Step Description	Expected Result
Precondition	System is off
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
Postcondition	System is OFF

00002: WHOLE SYSTEM TEST

Step	Step Description	Expected Result
Precondition	System is off
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 GLOBLE VALVE on the nitrogen tank	One can see that there is nitrogen exit from the gas outlets
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
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

00003: KOH pipe system test

The lack have to be marked with 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 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.
Postcondition	System is off

00004: WHOLE SYSTEM 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 hydrogen is generated
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
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 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
Postcondition	Turn off the system	System is off

00005: WHOLE SYSTEM TEST 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 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

00006: WHOLE SYSTEM 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 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
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
Precondition	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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
Disconnect the Power Supply on the system	Click "Stop" on Power Supply bottom from the GUI	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
	Click "Stop" on the valves (V₁) & (V₂) from the GUI	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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
Precondition	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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
Disconnect the Power Supply on the system	Click "Stop" on Power Supply bottom from the GUI	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
	Click "Stop" on the valves (V₁) & (V₂) from the GUI	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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
Precondition	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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
Disconnect the Power Supply on the system	Click "Stop" on Power Supply bottom from the GUI	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
	Click "Stop" on the valves (V₁) & (V₂) from the GUI	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
	Open the bottle of Nitrogen gas 5 minutes @ 4 bars	The air bubbles appear (generate) in the Gas AutoSafety
	Turn Off the Nitrogen bottle by its gate valve manually	The Nitrogen bottle is closed
	Turn Off the Nitrogen bottle by its gate valve manually	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:

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