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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

  1. Make sure the circuit is closed (all valves are closed)
  2. Make sure the power is turned off
  3. Connect the Nitrogen tank to the system
  4. 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.

  1. Disconnect the nitrogen.

 Tank

  1. Make sure that the water tank has 60 liters of water
  2. 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 V 

 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    
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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System Test Specification

Test Specification

System Testing

Test Cases