Short cuts
Part 1 - Designing Hydrogen Systems
Part 2 - Building the Hydrogen System
Part 3 - Hydrogen System Operation
Appendix
Front Matter
Part 1 - Designing Hydrogen Systems
An introduction to hydrogen systems
Designing your hydrogen system
Functions within a basic hydrogen system
The system and its context
Effects of weather
Indoor systems
Electrical influences
The Design Process
System diagrams and lists
Collect information resources
The budget for your hydrogen system
Do it yourself or out-source
Working with the Materials
Hydrogen history and characteristics
Hydrogen safety
Oxygen
Oxygen and safety
Safety, Design and Operating Guidelines
Guidelines resources
Standards for hydrogen systems
Atmospheric hazard classifications
Process Control Safety in Hydrogen Systems
Safe housing of electrical and electronic process control devices
Pressurized electrical enclosures
Explosion-proof enclosures
Other isolation options
Code requirements
Basic electronic, electrical, andlaboratory safety
Electrical hazards
Out-sourcing circuit design
Pressurized Hydrogen Systems
Working with pressurized hydrogen systems
Protective clothing
MAWP and MOP
Settings for safety release valves
Housing the system
General design safety guidelines
Gas concentration monitoring
Gas concentration values
Hydrogen flammability
Hydrostatic testing
Fugitive emissions
Basic leak detection
Leak detection devices
Hydrogen detectors
General purpose pressure design considerations and formulas
Example 1
Example 2
Pressure regulation
Pressure measurement conventions
Pressure unit conversion constants
Material characteristics and compatibility
Stainless steel classifications
Brass in hydrogen systems
Experimental vs. long term use
Galvanic compatibility
Electromotive series table
Part 2 - Building the Hydrogen System
System Overview
Fittings and experimental systems
Primary subsystems
How this system works
Fittings
Component Overview
Tubing
Pressure tank and bubbler
Electrolyzer
Regulators
Storage tank
Gauges
Grades of accuracy for pressure gauges
Tools and Materials
NPT connections
Wrenches
Miscellaneous tools
Mill or drill press
Tube cutting
Common tools and construction materials for the project
Reservoir tank
Determining size of the electrolyte reservoir
Electrolyte Reservoir & Pump
Suitable materials for electrolyte reservoirs
Supporting the reservoir
Filter the electrolyte
Electrolyte reservoir cover
Keep the bugs out
Electrolyte pump
Pumping capacity
Pumps in hazardous environments
Check valves and the pump
Pump fittings should be flexible
Handling leaks
Test the pump sub-assembly
Setting up feed system valves
The electrolyte reservoir
Reservoir and pump parts list
Pressure Tank and Sight Glass
Pressure tank assembly
Assemble sight glass and connect to pressure tank
Pressure tank and sight glass parts
Electrolyzer and Electrolyte
How the electrolyte works
Obtaining potassium hydroxide
Potassium hydroxide (KOH) solution strength
Managing electrolyte strength
Handling KOH
Using KOH safely
Electrolyzer construction
Flanges
Alternative designs
Electrolyzer assembly
Flange ports
Positive electrode ports
Preparing the Teflon liner
Electrolyzer top
Positive electrode assembly
Make the silicone rubber washers
Make the nickel washers
Cut the electrode rods
Preparing the Teflon insulators
Fitting the positive electrode feed throughs
Positive mesh electrode
Positive electrode installation
Inserting the flange fittings
Negative electrode preparation
Negative electrode mesh
Fitting the negative electrode assembly
Installing the negative electrode assembly
Electrode separator
Fitting the separator
Assembling the separator
Electrolyzer final assembly
Attach the bottom blind flange
Bolt the flanges
If using 3/4" bolts
If using 5/8" bolts
Attach the top blind flange
Tools for building the electrolyzer
Materials for the electrolyzer
Bubbler Scrubber System
Purifying the hydrogen
Bubbler configurations
Bubble breakers
Bubbler liquids
Additional internal filters
Constructing the bubbler
Assemble the bubbler
Materials for the bubbler
Connections and Pressure Balancing
Hydrogen side fittings and tubing
Oxygen side fittings and tubing
Electrolyzer to pressure tank connections, bottom
Setting the adjustable check valve (oxygen outlet)
Gas migration and pressure differential
The accumulator
How accumulators balance pressure
Calculating the hydrogen side gas volume
Calculating the oxygen side gas volume
Fine tuning liquid levels for the accumulator
Other types of accumulators
Equalization valves
How the valve works
Equalization valves with bellows
Constructing a simple equalization valve
Other equalization options
Tools for connections & pressure balancing
Materials for connections & pressure balancing
Coalescers
Coalescers vs. filters
Moisture in the hydrogen gas stream
Storage Tank and Peripherals
Pressure switch
Pressure switch characteristics
Installing the storage tank peripherals
Pressure switch dead bands
Regulator installation
Storage tank and peripherals parts and materials
Storage tank connections to coalescer
Materials for storage tank connection
Catalytic and Sub-system
Building a catalytic recombiner
Materials for catalytic recombiner
Flashback arresters
Source for flashback arrestors
Filter
Catalytic subsystem assembly
Fittings for catalytic recombiner subsystem
Process Controller
Process controller subassemblies
Process controller enclosure
Explosion-proof enclosures
Pressurized enclosures
Purged and pressurized enclosures
Placement of electrical components
Specific electrical hazards
Parts description per legends
Tools for the process controller
Materials for the process controller
Process controller external wire assembly connections
Wire assembly 1 through port 2
Wire assembly 2 through port 3
Wire assembly 3 through port 4
Internal wire guide (process controller)
General wire connections
Wire assemblies
Port 2, Wire assembly 1
Port 3, Wire assembly 2
Port 4, Wire assembly 3
Process controller box fabrication
Preparing the ports
Pressure sensor
Installing the pressure sensor
Wire ports
Pressurize the box
Capacitive sensors
Sensors
Part 3 - Hydrogen System Operation
System Setup
Frame
Electrolyzer fluid level
Operating Procedure
Establish the routine
Initial startup
In process
Measuring gas output
Working with Commercial Hydrogen Cylinders
Purchase or rent the gas cylinder
Storing and moving hydrogen cylinders
Hydrogen regulators, cylinder valves and outlet connections
New or used regulators
Connect cylinder and regulator
Working with commercial nitrogen cylinders
Nitrogen Purging
Purging apparatus
Purging techniques
Nitrogen purging sequence
Hydrides for Hydrogen Storage
Hydrogen storage methods
Pros and cons of hydride storage
Types of hydrides
Hydride bottles
Charging the hydride bottle
Using the hydride bottle
Gas cylinder and hydride storage resources
Commercial Fuel Cell Units
Mass flow controllers
Purchasing new or used fuel cell units
Fuel cell unit options
Basic system inspection
Appendix
Suggested reading
Supplier and other resource links
Standards information resources
Other titles of interest
©Copyright 2006 Good Idea Creative Services, all rights reserved
