Gus Graham

Director of Products & Markets Africa & Asia

Environment One Corporation
 Why Hydrogen?
Hydrogen Properties
Hydrogen Hazards
Hazardous Areas
Hazardous Equipment Design
Hazardous Area Processes
Generator Purging Process
Hydrogen Purity Monitoring
Additional Monitoring Equipment
Leaks And Leak Detection
 In the late 1930s, increasing demand for larger
generators required alternate cooling methods to be
developed

Large generators require more efficient cooling

methods

Required a low density gas with good cooling

properties initially Helium (He) was used

Due to scarce supply and high cost of He, Hydrogen

(H2) became the gas of choice
 Less windage / frictional losses

At generator operating pressures, the relative density of H2 is

4 times less than Air

Better heat transfer characteristics

H2 is 14 times more efficient at removing heat than air

This equates to more megawatts per pound of iron

 H2 cooled generators are a sealed environment which prevents
contamination

H2 cooled generators are pressurized vessels

Increased pressure suppresses partial discharge and increases

the level of voltage required for component breakdown

A pure H2 environment prevents oxidation

Pure H2 will not support combustion

Currently >10,000 H2 cooled generators worldwide

 Colorless, odorless and tasteless undetectable by
human senses
Non-toxic, but can cause suffocation by reducing
oxygen content in a confined space (asphyxiant)
Not listed as a carcinogen
Lightest gas, diffuses readily in Air
Non-corrosive and considered non-reactive, but will
reduce mechanical properties of some metals -
embrittlement
Burns with an almost invisible bluish flame
Explosive limit: 4%-76% by vol in Air
Auto ignition temperature in air: 566C (1051F)
 Most are familiar with the
elements necessary for fire
Fire Triangle

Equipment + Processes +
People comprise a Safety
Triangle within your plant
FIRE

IGNITION

PEOPLE
 FIRE

IGNITION

Generator fleet is getting older

Hydrogen auxiliary equipment is getting older
Workforce is getting younger and leaner and training
programs are leaner
Time between outages is getting longer
 Hazardous Areas are places where concentrations of
flammable gases, vapors, or dusts can occur

Hazardous Areas are classified based on the risk of an

ignitable concentration forming in the area

Hazardous Areas are also referred to as Classified

Areas
 Area Classification refers to the rating applied to the
area based on the risk of a flammable concentration
occurring

Area Classifications are the responsibility of the

power station to define, typically during plant design
phase

Prior to the mid 20th century, power plants werent

required to define Area Classifications
Hazardous Area Classifications:

Zone 0: Flammable mixture is present at all times

Zone 1: Flammable mixture is sometimes present during normal

operation.

Zone 2: Flammable mixture is present during abnormal conditions.

Zone 2 is the applicable Area Classification for most

Hydrogen Auxiliary equipment
 Hazardous areas require specialized equipment

Equipment needs to be designed to operate in the

respective Area Classification of the installation

IIB+H2 or IIC for Hydrogen use

Equipment designed to a more strict Area

Classification can be installed in a lower classified area

Zone 0 Zone 1 Zone 2

Different Protection Principles are utilized to meet the
Hazardous Area requirements

Protection Principles will vary from OEM to OEM and

device to device:

No arcs, sparks, or hot surfaces:

e increased safety
nA non-sparking

Example of type e
protection principle
with type nA
equipment installed
 Contain the explosion & extinguish the flame:
d flameproof
q powder filled
nC enclosed break

Example of type d
protection principle
with associated
equipment marking
 Limit energy of sparks and surface temperature:
i intrinsic safety (a,b,c)
nL limited energy

Example of type i
protection principle
 Keep flammable gas out:
p pressurized (x,y,z)
nR restricted breathing
m encapsulation (a,b)
o oil immersion

Example of type m Example of type p

protection principle protection principle
 Risk of hazardous areas require precaution

Operator training is the most critical element of safe

plant operation

Adequate signage identifying the Hazardous Areas and

what safety precautions need to be followed

Adhere to OEM prescribed maintenance on all

equipment operating in a hazardous areas
 The use of qualified Ex certified maintenance
personnel for equipment in hazardous areas

Regular calibration of Hydrogen purity meters

Strict adherence to generator purge procedures

Use only spark-free tools in the hazardous area

 Updated and understood SOP
Current and accurate P&ID
Verify valves are properly labeled and agree with P&ID
Verify Hydrogen Purity meter is calibrated and
operating properly
Portable Gas Analyzer
Portable Hydrogen Sniffer
Liquid leak detector (snoop or soap)
 Personal LEL (Lower Explosive Limit) detectors
Non-Sparking Tools (Bronze)
Verify sufficient carbon dioxide is available to purge all
generators on site
Create signage in key areas to note Gas In Generator
Keyed lock-out for Air and Hydrogen supply
systems
Communicate, Communicate, Communicate

Operations and I&C Involvement

 Online Hydrogen Purity monitoring is mandatory on
all Hydrogen cooled generators
2 primary methods of measuring Hydrogen Purity:
Density meter

Thermal Conductivity meter

Generator OEMs integrate Hydrogen Purity meters

into Hydrogen Control Panels/Cabinets
Installations vary from OEM to OEM and plant type to plant type

Seal oil system style impacts Hydrogen Purity system:

Vacuum Seal Oil Closed Loop/Bleed & Feed

Scavenging Seal Oil Open Loop/Constant Venting & Make-up

EXAMPLE OF A VACUUM
SEAL OIL SYSTEM UTILIZING A
DENSITY BLOWER METHOD
OF HYDROGEN PURITY
MEASUREMENT
EXAMPLE OF A SCAVENGING
SEAL OIL SYSTEM UTILIZING A
THERMAL CONDUCTIVITY
METHOD OF HYDROGEN
PURITY MEASUREMENT
 Online monitoring devices are important tools to
assure reliability and optimum performance

As risk factors in the fleet increase, additional

monitoring becomes necessary

RISK FACTORS:

Age of Generator
Size of Generator
Criticality of Generator to
the fleet
Operator experience
Plant staffing level
 Additional Temperature Sensors

Rotor Flux Probe

Generator Condition Monitor

Additional Vibration Sensors

Dew Point Monitors and Hydrogen Gas Dryers

Rotor Shaft Voltage Monitoring

 Hydrogen Usage

Type of monitoring.Alarm Points

Leak Detection Methods

Snoop (Liquid Soap), Ultrasonic Leak Detection, Helium Leak

Detection, Hydrogen Sniffers, Infrared Leak Detection (SF6)
Location of Leaks

Hydrogen System P&ID.Any Generator Case Penetration

Bushings, Seals, Hydrogen Coolers, Liquid Level Detectors, Gas

Manifold, Hydrogen Supply System, Hydrogen Control Cabinet,
Core Monitor, Hydrogen Dryer

Enclosed Areas..Confined Space

Best Practices
 Hydrogen
Hazardous Areas
Purging
Purity Monitoring
Hydrogen Leaks
Gus Graham
Director of Products & Markets Africa & Asia
Office: 518-579-3200
Cell: 518-227-5774
Email: rgraham@eone.com
Web: www.eone.com/solutions