BRAZIL

PARAGUAY

ITAIPU HYDROELECTRIC POWER PLANT

TECHNICAL SPECIFICATION
ESP 002/07

SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION

AND STORAGE OF HYDROGEN

2
1
No

DESCRIPTIONS
REVISIONS

Prepared: GBH/MM
Checked: ACF

22/01/07
29/01/07

APPROVED

Reviewed: CCC
Approved: WFJ

DATE
05/02/07
09/02/07

EN.DT Superintendence of Engineering

ENE.DT Department of Electronic and Electromechanical Engineering
TECHNICAL DIRECTORATE

3877-20-15200-I

R0

ESP 002/07 - SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION AND STORAGE OF H2

SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION

AND STORAGE OF HYDROGEN

NUMBER OF PAGES IN THIS DOCUMENT

RO This Specification comprises the following pages:
- Front Cover and Back Cover.............................................................................. 02
- Index ..................................................................................................................... 01
- Specification.. ........................................................................................................ 09
- Drawings and Documents of the Specification........................................................57
- Total Pages.. ...................................................................................................... 69

SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION

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AND STORAGE OF HYDROGEN

INDEX

1.
1.1

INTRODUCTION....................................................................................................... 1
General ..................................................................................................................... 1

2.
2.1
2.2
2.3

SCOPE OF THE SUPPLY........................................................................................

Equipment and Services Included in the Supply .....................................................
Services and Materials not Included in the Supply...................................................
Responsibility of the CONTRACTOR.......................................................................

3.

DOCUMENTS AND TECHNICAL INFORMATION FROM THE CONTRACTOR.... 2

4.

DRAWINGS AND TECHNICAL DOCUMENTS FOR APPROVAL........................... 3

5.

DEADLINE FOR DELIVERY..................................................................................... 4

6.

SPARE PARTS ........................................................................................................ 4

7.
7.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.3.1
7.3.2
7.3.3

TECHNICAL REQUIREMENTS ............................................................................... 4

General...................................................................................................................... 4
Description of the Electrolysis System ..................................................................... 4
Production Capacity of the Electrolysis Plant .......................................................... 4
Quality of the Gas Produced ................................................................................... 5
System for Purifying the Hydrogen .......................................................................... 5
Principal Characteristics ........................................................................................... 5
ITAIPU Hydroelectric Power Plant ........................................................................... 5
Climate Data and Local Conditions ......................................................................... 5
Characteristics of the Electrical Components .......................................................... 6

8.

PAINTWORK AND FINISH....................................................................................... 7

9.

TRANSPORTATION AND STORAGE ..................................................................... 8

10.

INSPECTIONS AND TESTS .................................................................................... 8

11.

TESTS AND CHECKS AFTER ERECTION IN THE CHI ....................................... 8

12.

GUARANTEES.......................................................................................................... 8

13.

SPECIFICATION DRAWINGS AND DOCUMENTS ................................................ 9

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1
2
2

SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION

AND STORAGE OF HYDROGEN
1.

INTRODUCTION

ESP 002/07 - SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION AND STORAGE OF H2

1.1

General
The objective of this Specification is to establish the minimum requirements that
must be met by the CONTRACTOR in the design and supply of a system for the
production, purification, compression and storage of hydrogen, in the tests to be
executed in the factory, in the complete erection of the system and in the
supervision of the placement in operation, for the ITAIPU Hydroelectric Power
Plant.

2.
2.1

SCOPE OF THE SUPPLY

Equipment and Services Included in the Supply
-

Detailed project involving the complete set of drawings and technical

documents as described in the Section 4 of this Specification.

Supply of all components of the systems of production, purification,

compression and storage of hydrogen.

Supply of the instruments of control, command and protection of the

system of production, purification, compression and storage of hydrogen.

Panel for the electrical power supply, protection and control of the
equipment, for internal installation as described in the Section 7.3.3 of this
Specification.

Auxiliary materials, such as, supports, clamps, tie-rods, screws and

complete anchor bolts and other devices for erection and attachment of
the system components.

All the tests executed in the factory, the complete erection of the system
and all the supervision over the placement in operation, as described in
this Specification.

All the inspections and tests, as described in the Sections 10 and 11 of

this Specification.

Transportation of the equipment and materials up to the Power Plant in

Foz do Iguau.

Primer paint and finish paint for retouching at the Job Site.

Spare Parts as per the following list and in accordance with Section 6 of
this Specification:
One unit of each filter of the water purification system;
One unit of each diaphragm of the compressors;
Electrolyte required for one year of operation;
All other components with a service life of less than one year of
operation.
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2.2

Complete erection of the system for the production, purification,

compression and storage of hydrogen, including the interconnections with
the interfaces of water and electric power supplies and grounding points.

All the wiring and electrical conduit necessary for interconnections

between instruments, electrical panel and equipment.

Services and Materials not Included in the Supply

-

Materials and services relating to civil work that may be required;

Provision of scaffolding and provisional ladders for the Job;

Provision of points for the supply of water and electric power, as indicated
in the ANNEXES 4 and 5.

2.3 Responsibility of the CONTRACTOR

The CONTRACTOR shall be entirely responsible for the design and supply of
the system for the production, purification, compression and storage of
hydrogen, for the tests executed in the factory, for the complete erection of the
system and the supervision over the placement in operation, involving all the
equipment and accessories, even those not specifically mentioned herein, to
function correctly and safely to the satisfaction of ITAIPU, in accordance with
the present Specification.
3.

DOCUMENTS AND TECHNICAL INFORMATION FROM THE CONTRACTOR

The CONTRACTOR shall supply, within the time limits contemplated in the
Section 4 of this Specification, for the inspection and approval of ITAIPU, all the
technical documents, drawings and information necessary for verifying the
complete conformity of the supply to this Technical Specification.

The drawings and technical documents shall be complete, indicating dimensions,

materials employed, weights, adjustments, etc., and shall be prepared in
accordance with the basic conditions established in the ESC-101/96 (ANNEX 1),
where applicable.
The erection may only be commenced after the approval by ITAIPU of the
technical documents and drawings, unless authorised in writing by ITAIPU. The
non-compliance of this requirement shall be to the account and risk of the
CONTRACTOR.
4.

DRAWINGS AND TECHNICAL DOCUMENTS FOR APPROVAL

ESP 002/07 - SYSTEM FOR THE PRODUCTION, PURIFICATION, COMPRESSION AND STORAGE OF H2

At least the following drawings and technical documents shall be submitted for the
approval of ITAIPU 30 (thirty) consecutive days reckoned after the date of the
Order of Initiation to be issued by ITAIPU:
-

Calculation spreadsheet demonstrating the sizing of the system, in

accordance with the technical requirements of this Specification;

Drawings for the erection at the Site, including plan views for installation,
sections and details of the installation of the system for the production,
purification, compression and storage of hydrogen, containing details of
the attachment, layout of the installations, location of the equipment,
instruments and electrical panels;

Characteristic performance curves of the electrolyser, of the compressor

and other equipment that become necessary;

Layout drawing of the equipment of the system, containing longitudinal

and cross sections, weight, dimensions and drillings of the base, etc.

Data sheets of the equipment and instrumentation;

Electrical diagram of power supply and control connections;

Layout drawings of the command and control panels;

Lists of materials;

Drawings of the identification name-plates;

Manuals of operation and maintenance;

Inspection Routine (RI).

The drawings and technical documents submitted for approval by ITAIPU must
follow the procedures described in the Section 6 - Part III, of ESC-101/96 (ANNEX
1).

The CONTRACTOR shall declare his agreement with the system for the approval
of technical documents and drawings adopted by ITAIPU, i.e., with the meaning of
every seal of approval.
5. DEADLINE FOR DELIVERY
The total term established for the tests executed in the factory and for the supply
of the system for the production, purification, compression and storage of
hydrogen is 120 (one hundred and twenty) days.

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The total term established for the complete erection of the system and for the
supervision over the placement in operation is 120 (one hundred and twenty)
days.
6. SPARE PARTS
The list of the spare parts not contained under the item 2.1 of this Specification
shall be proposed separately and with prices per unit.
All the spare parts shall be suitably packed for a long period of storage, with
due identification of each item, and the corresponding shipping list together with
the storage instructions.
7. TECHNICAL REQUIREMENTS
7.1

General
The design and the supply of the system for the production, purification,
compression and storage of hydrogen, the tests executed in the factory, the
complete erection of the system and the supervision of its placement in
operation, besides conforming to this Specification shall, first and foremost, to
the extent applicable, comply with the latest revisions of the technical standards
of the Associao Brasileira de Normas Tcnicas (ABNT-Brazil) and/or the
Instituto Nacional de Tecnologia e Normalizacin (INTN-Paraguay), except
where other organizations are explicitly indicated in this Specification. The
systems of supervision, control and measurement shall adhere to the IEC
standard 61850.

7.2

Description of the Electrolysis System

7.2.1

Production Capacity of the Electrolysis Plant

The rated production capacity was calculated on the basis of the expected
hydrogen consumption, and shall be equal to or greater than 10 Nm/h of
hydrogen.

7.2.2

Quality of the Gas Produced

The hydrogen to be utilized shall possess a high degree of purity and shall,
at the outlet of the storage plant, comply with the following specifications:
- Purity H2: > 99.95%
- Contamination with O2: < 10 ppm
- Contamination with H2O: < 250 ppm
- Contamination with N2: < 200 ppm
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7.2.3

Contamination with CO: < 10 ppm

Contamination with CO2: < 20 ppm
Hydrocarbides: < 10 ppm

Hydrogen Purification System

The hydrogen purification system shall comply with the specifications of the
item 7.2.2 in order for the gas produced to possess the necessary quality to
comply with the requirements for utilization in Fuel Cells.

7.3
7.3.1

Principal Characteristics
ITAIPU Hydroelectric Power Plant
The plant will be situated within the ITAIPU Hydroelectric Power Plant on the
frontier between Brazil and Paraguay, having as references the City of Foz
do Iguau in Brazil and the City of Ciudad del Este in Paraguay.

7.3.2

Climate Data and Local Conditions

The climate data corresponds to the hottest months, November to March,
pertaining to the summer period, and were recorded at the Meteorological
Station of the ITAIPU Hydroelectric Power Plant.
a) General Conditions
- Elevation above sea level (m) - 174.94
- Mean Effective Temperature - 22 a 27C
- Relative Humidity - 80%
b) Sources of Electric Power Supply
- Voltage - 380 Vac / 60Hz
- Power - 100 kVA

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pH

c) Water Supply
The water for the process and for cooling to be utilised by the system
possesses the following characteristics:
7.20

Alkalinity to methyl orange - mg/l

20

Alkalinity to phenolfthaline - mg/l

Carbonates - mg/l

Bicarbonates - mg/l

20

Hydroxides - mg/l

Free Carbonic Gas - mg/l

1.82

Oxygen consumed in the acid medium - mg/l

0.9

7.3.3

Characteristics of the electrical components

1 - Electric Panel
The electrical installations shall be insulated, grounded and comply with
the standard NBR 5418 or its ISO equivalent for electrical installation in
explosive environments.
All the internal wiring shall be executed in the factory, verified and tested
before shipment.
All the control wiring shall be of the 600V class, with thermoplastic
insulation, fireproof.
All the electric indicator instruments, meters, etc., shall be connected
using terminal blocks.
Not more than two conductors shall be connected to the same terminal.
For the conductors that interconnect fixed parts with moving parts, for
example doors, terminal blocks must be used on both parts.
The conductors shall be individually marked with plastic tags of light
colour or white for identification when connecting the terminals of the
equipment or terminal blocks.
2 - Electrolyser
The electrolyser shall have an electrical consumption lower than 4.5
kWh/m. It is necessary to keep in mind that this power only refers to the
electrical consumption of the stack for the production of hydrogen,
without compressing the gas.
3 - Compressor
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The gas pressure at the entrance to the compression system shall be

equivalent to the hydrogen gas pressure at the outlet from the
electrolysis system.
The outlet pressure from the compression system shall be equal or
greater than 350 bar.
The compression system shall be capable of compressing all the gas
produced by the electrolyser, avoiding the necessity for storing large
quantities of hydrogen at low pressure and for the compression period
extending beyond the production period.
The minimum flow of the compression system shall be 10 Nm/h of
hydrogen.
4 Storage System
The storage tanks shall withstand the pressure at the compressor outlet,
that is, 350 bar.
The storage tanks shall be capable of holding a volume of 800 Nm of
hydrogen.
5 Other Requirements
The electrolyser, purifier and compressor must possess an automatic
system of monitoring and control through software, thereby increasing
the safety of the system.
The system shall possess an oxygen sensor in the hydrogen outlet of the
electrolyser and a hydrogen sensor in the oxygen outlet. The sensors
must disconnect the whole system in the case of the concentration of
oxygen in the hydrogen or the hydrogen in the oxygen surpassing 1%.
The system shall possess a sensor to indicate oxygen and humidity
immediately before the hydrogen compressor.
The compressors shall be free of oils or greases, in order to avoid the
contamination of the hydrogen produced.
8. PAINTWORK AND FINISH
All the sheet metal, metallic structure supporting tubes and equipment composing
the system of production, purification, compression and storage of hydrogen, shall
be cleaned for the removal of grease, oil and any other impurities, being
subsequently protected against oxidation and finally receiving the finish paint. The
exposed stretches and those attached to the building structure shall be painted a
natural aluminium matt colour.
9. TRANSPORTATION AND STORAGE
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The components to be supplied shall be delivered by the CONTRACTOR to the

Warehouse of the ITAIPU Hydroelectric Power Plant, which shall be responsible
for the storage at the Power Plant, following the guidelines for correct handling and
storage provided by the CONTRACTOR.
All the expenses and responsibilities of the transportation, from the point of
shipment to the Power Plant, shall be borne by the CONTRACTOR, who must
prepare for the shipment in packaging suited to the mode of transportation.
The CONTRACTOR shall prepare all the documents required for the dispatch,
providing a packing list, and each package must have a list of its contents placed
inside it.
The CONTRACTOR is responsible for the losses and damage that occur during
transportation or storage caused by inadequate of defective packaging.
10. INSPECTIONS AND TESTS
The CONTRACTOR shall be responsible for the execution of the Tests and
Inspections in accordance with the Inspection Routine (RI), previously approved
by ITAIPU, within the deadline indicated in Section 4 of these Technical
Specifications.
11. TESTS AND CHECKS AFTER ERECTION IN THE CHI
It is necessary to verify, in accordance with the applicable standards, all the
functional characteristics demanded in this Technical Specification and those
provided by the CONTRACTOR in the drawings and documents of the equipment
or of its components. The verification of conformity to the Specifications must be
accompanied by the technical staff designated by ITAIPU.
It should be verified if all the components (mechanical, electrical and electronic) of
the equipment work under normal conditions of operation, defined in those
documents or in the applicable technical standards, including all the devices of
command, protection, signalling and automation.
12. GUARANTEES
The CONTRACTOR shall guarantee the equipment, accessories and the
performance of the system object of the Supply Contract, during the period of 1
(one) year reckoned from the date of conclusion of the reception tests of the
system of production, purification, compression and storage of hydrogen.
The approval of the drawings and equipment by ITAIPU doesn't exonerate the
CONTRACTOR from his full responsibility in relation to the integral project of the
system of production, purification, compression and storage of hydrogen, to the
correct dimensioning of the assembly, without faults or omissions that might
impede, harm or retard the erection and entry into operation.
13. SPECIFICATION DRAWINGS AND DOCUMENTS
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The following annexed documents form an integral part of this Specification:

ANNEX 1 - ESC 101/96 - Basic Guidelines for the
Preparation/Revision and Presentation of
Technical Documents.
ANNEX 2 Civil Plan View - Basic Design

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