Smart electrolyzer design processes and clear documentation are essential to achieving consistent, reliable, and safe hydrogen production. We design, test, and evaluate every component of our electrolyzers based on new hypotheses, documenting each design decision along the way. We release actionable documentation and guidelines at every stage of our customer projects. This makes the use, maintenance, and support of our units safer and easier.
In this blog post, we delve into:
- the importance of a rigorous electrolyzer design process;
- why documenting discipline is essential to ensure comprehensive, actionable and up-to-date documentation.
We would greatly appreciate hearing your views and insights on these aspects and their significance.
A strict electrolyzer design process
Our R&D team draws on extensive industry experience to develop innovative products, free from the constraints of past design decisions or legacy systems. This approach enables fresh, safer designs, thoroughly documented and rigorously tested through simulations and laboratory experiments.
Our electrolyzer design process relies on simulations and laboratory experiments. For instance, we use 2D drawings and 3D models to visualize and refine our product designs, and extensive Piping and Instrumentation Diagrams (P&IDs) to describe the layout and operational process flows of our systems. This meticulous approach aids our manufacturing team in correctly assembling all components, and it provides a valuable resource for addressing any issues that may arise at a later stage.
Translating product design outcomes
An inherent aspect of our electrolyzer design process is ensuring that comprehensive safety protocols are defined. By conducting HAZOP and LOPA studies, we identify and mitigate hazards. This enables us to ensure the safety and compliance of our water electrolyzers with all relevant industry standards.
The disciplined approach we use to manage the underlying process of mapping and documenting outcomes is crucial. These deliberate efforts are intrinsically tied to our company’s DNA and underpin our commitment to designing, developing, and building a new generation of more robust, reliable, and safe water electrolyzers.
Functional product feature design
Developing robust control and automation capabilities for our electrolyzers requires a targeted process design and a deep understanding of each operational phase. Clear and consistent documentation plays a vital role in achieving this goal.
For instance, creating a process control narrative that outlines automatic states such as ‘ambient,’ ‘inerting,’ and ‘preparing’ to ensure smooth transitions between all operational phases of our systems requires a clear understanding of each phase. The same applies to the integration of PLCs and a Safety Instrumented System (SIS) to allow for real-time system monitoring, remote control to support faster troubleshooting, and outlining a Safety Requirements Specification (SRS) to always ensure a safe state.
Comprehensive project documentation
At Exion Hydrogen, we have established a standardized project timeline, from the signing of the commercial agreement to commissioning, with clear, time-bound project milestones and all the necessary documentation deliverables.
For instance, when a commercial agreement is signed, we issue a Product Reference Guide, all permitting documents, an Explosion Protection Concept, an Installation Manual, and a Data Policy document. And after a successful Factory Acceptance Test (FAT), we provide additional documents (e.g. Site Acceptance Test (SAT) documents) to ensure the flawless installation and commissioning of our systems. Our extensive list of document deliverables, from spare parts lists to the Declaration of Conformity, includes technical documentation, certificates, and actionable Operator and Service Manuals.
As the single point of contact, a dedicated Customer Success Manager coordinates and supports our customers throughout the entire project life cycle and beyond.
Documentation is not an afterthought
While documentation is often considered an afterthought, we see documentation as an essential part of our electrolyzer design process. By consistently recording all our design decisions and workflows, and providing comprehensive, up-to-date documentation at each phase of our customer project timelines, we significantly enhance the safety and user-friendliness of our water electrolyzers.
We are curious to learn what your observations and views are regarding the electrolyzer design process. Share your thoughts in the comments below!
Do you have any questions, want to reach out, or want to work together?
Alternatively, please get in touch through sales@exionhydrogen.com or +32 14 91 99 19.
