Automation for your hydrogen applications
Automation in parts of the hydrogen value chain offers you numerous advantages that improve the efficiency, safety and cost-effectiveness of the plant. As control and monitoring is automated, and therefore precise, you not only reduce downtimes, but can also increase the safety of the entire plant as well as record and evaluate data in real time.
Where can I use automation?
Along the hydrogen value chain, there are systems and processes that can be automated to improve efficiency, safety and cost-effectiveness. These include the production, storage, distribution and use of hydrogen.
- Electrolysers: Automation of electrolysis processes (e.g. PEM, alkaline electrolysis, high-temperature electrolysis), including control of energy consumption, water flow and optimisation of operating parameters
- Hydrogen treatment: Automation of processes to remove impurities and increase the purity of hydrogen, for example through pressure swing adsorption (PSA).
- Compressors: Automated control and monitoring of the compression of hydrogen for storage or transport.
- Hydrogen storage: Automated monitoring of fill level, pressure and temperature in high-pressure tanks. Automated control of cooling and pressure management for liquefied hydrogen storage. Automation of loading and unloading processes as well as temperature and pressure control.
- Filling station infrastructure: Automation of refuelling processes, monitoring of fill levels and safety mechanisms in hydrogen filling stations for vehicles.
- Fuel cell systems: Automated monitoring and control of fuel cell operation, including regulation of the gas supply, temperature management and efficiency optimisation.
In all processes, sensor technology is used to measure process parameters such as conductivity, pressure, flow rate or temperature, and the process is controlled via actuator technology (e.g. valve technology, pumps). If this control and monitoring takes place via a communication interface and automation, this is referred to as process automation.
Which sensor and actuator technology is available and which types are used in hydrogen applications?
Sensor technology
Sensor technology in hydrogen applications detects physical quantities such as pressure, temperature, conductivity and flow rate, which are important for controlling processes. There are two different signal types: - Digital signals: output discrete values, such as an input/output signal. - Analogue signals: output continuous signals, e.g. 4–20 mA for finely tuned controllers.
Actuator technology
Actuator technology includes components that perform physical movements in processes such as opening and closing valves or controlling pumps. These actuators are controlled by electrical signals.
Which communication interfaces are suitable?
Future-proof hydrogen plants require intelligent networking and communication between controllers, sensors, actuators and monitoring systems. Various communication interfaces are needed to ensure efficient exchange of data, status information and commands.
Typical fieldbus systems used in such plants include:
- Ethernet: A versatile and widespread network protocol that enables high transmission speeds and seamless integration with IT systems.
- CAN bus: (Controller Area Network): A robust protocol for networking controllers and devices in real-time applications; ideal for demanding automation tasks.
- PROFIBUS: An established fieldbus system that offers fast and reliable communication between process devices and controllers.
These interfaces play a central role in the integration and automation of complex processes in hydrogen plants.
Which protocols can be used?
In modern hydrogen plants, reliable communication protocols are essential in order to effectively transmit all relevant measured variables, output values and diagnostic data to the control systems (PLCs). The use of suitable protocols minimises cabling work and ensures stable data transmission.
The most important protocols include:
- PROFINET, EtherCAT, Modbus TCP/IP, EtherNet/IP
- PROFIBUS DP, CANopen
- büS (proprietary CAN-based bus for efficient networking and combined communication of numerous devices with higher-level controllers, easier device replacement) / EDIP(application protocol)
These protocols ensure efficient and reliable communication between the various components of the hydrogen plant and contribute to effective process automation.
You can find more information on the protocols here.
What kind of automation is available to me?
Automation can be implemented in various ways: centralised (with and without control cabinet) or decentralised. Which concept is suitable for your hydrogen application? We present both concepts to you and help you find the best solution for your needs.
Centralised automation
How it works
Depending on your requirements, the distributed automation concept can be implemented in your plant with or without a control cabinet. When using control cabinets, automation can be achieved in an efficient and economical manner with AirLINE Quick, as valve islands can be placed directly on the control cabinet wall or floor. This results in a reduction of lines and cables, which in turn reduces the amount of compressed air required. If you choose a variant without a control cabinet, it is possible to use valve islands with a high degree of protection. The advantage in this case is that you are close to the process and require fewer additional cable trays, hoses and lines.
Advantages of centralised automation:
✓ Fast installation and reliable processes thanks to short distances and flexible, space-saving installation
✓ Reduced consumption of compressed air and energy makes your system faster, more economical and more efficient
✓ Simple monitoring and cleaning thanks to robust process units with a high concentration of valves
✓ Fewer hoses, lines and cable trays thanks to close proximity to the treatment process
A selection of the components that can be used
Learn more about centralised automation here:
Decentralised automation
How it works
Each process valve is controlled individually and supplied via its own smart control head. With the help of the control heads and the corresponding digital communication options, standard valves are turned into intelligent field devices. Process valves signal their switching status via LEDs, thus providing an excellent overview of the entire process.
Advantages of decentralised automation:
✓ Simple, on-site process monitoring on eliminates troubleshooting and guarantees availability of the water treatment plant
✓ Intelligent, fast-switching valve systems are particularly flexible, clearly arranged and reliable
✓ Easier start-up, maintenance and expansion due to individual solutions
✓ Proximity to the treatment process reduces the need for compressed air, energy, pneumatic hoses, lines and cable trays
A selection of the components that can be used
Want to learn more about decentralised automation? Click here:
Useful information about the automation of hydrogen applications
When is it worth considering decentralised automation over a centralised solution?
In hydrogen automation, designers and plant planners are often faced with the following question: Should control be centralised via a valve island or decentralised directly at the actuator? Both approaches have their specific strengths – and the choice is largely dependent on the requirements of the respective application.
Conclusion The decision regarding centralised and decentralised automation depends on factors such as air flow rate, installation effort, environmental conditions and costs. Both concepts have their place – and, when you opt for Bürkert, you will always receive the following: customised solutions for centralised and decentralised automation that are tailored to your specific hydrogen technology requirements.
How can functional safety be reliably implemented in hydrogen automation – and what role do valve islands and solenoid valves play in this?
Functional safety starts with the correct system architecture. Functional safety is a key element in safety-critical hydrogen applications – for example, when it comes to controlling ball valves or butterfly valves. The aim is to reliably execute defined safety functions such as the safe shut-off of processes in the event of a fault.
Typical application One example is the safeguarding of a hydrogen process in which a ball valve must be safely closed in an emergency. The combination of valve island and solenoid valves ensures that the shut-off takes place reliably even in the event of a power failure or system error.
Conclusion The functional safety of a hydrogen system (e.g. electrolyser) is largely determined by the system architecture of the safety functions. With Bürkert, you get a solution that satisfies your requirements regarding safety, integration and diagnostics. The combination of valve island and safety-rated solenoid valves enables flexible, scalable and standard-compliant implementation of your safety functions – tailored to hydrogen automation.
Solution using Bürkert components: Bürkert solutions enable the flexible, scalable and reliable implementation of functional safety functions in the automation of hydrogen systems. The selection of components and systems is based on the system architecture and the relevant SIL requirements.
Bürkert offers a carefully considered concept for implementing functional safety:
- TheType 8647 AirLINE SP valve island is a modular, electropneumatic automation system that has been specially developed for integration into the SIMATIC ET 200SP and PCS 7 systems from Siemens.
- In combination with Type 6518 and 6519solenoid valves, which are rated for functional safety, a safety-related shut-off of process valves can be achieved.
- The solution supports the achievement of defined performance levels (e.g. SIL2) in accordance with IEC 61508.
- Position feedback indicators on the pneumatic components enable diagnostics directly at the pilot valve, which simplifies start-up and maintenance.
- The valve island is ATEX and IECEx certified, meaning it can also be used in potentially explosive atmospheres.
Why is explosion protection so critical in hydrogen automation – and how can pneumatic systems be safely integrated into zones 1 and 2?
In hydrogen technology, explosion protection is of central importance. Due to the very low minimum ignition energy and the wide explosion limits of hydrogen, the use of electrical and electronic equipment in potentially explosive atmospheres is subject to particularly high safety requirements. In particular, automation technology must be designed in such a way that potential ignition sources are reliably ruled out. Plant planners are faced with the task of safely guiding electrical signals through suitable ignition protection concepts – such as intrinsic safety or flameproof enclosures – and correctly safeguarding critical interfaces to pneumatic systems without restricting plant availability unnecessarily.
Conclusion Safety in potentially explosive atmospheres cannot accept any compromises. With Bürkert, you rely on tested safety that goes hand in hand with high functionality. Whether it’s a centralised valve island in a certified control cabinet or decentralised Ex components directly at the process – Bürkert provides the right ATEX and IECEx-compliant solutions for a safe hydrogen future.
The Bürkert solution for explosion protection: Bürkert offers a comprehensive portfolio developed specially to meet the requirements of zones 1 and 2, as well as class/division markets.
- The Type 8650 AirLINE Ex valve island is specifically designed for use in zone 1 and offers maximum safety in a compact design.
- For zone 2, the Type 8647 valve island, in combination with the Siemens system, offers a highly efficient solution that can be installed directly in the Ex area.
- Certified solenoid valves (e.g. Type 6519 Ex): These valves are available in various types of protection and enable the safe control of process actuators directly on site.
- Systemhaus expertise: Bürkert supplies fully certified control cabinet solutions (Bürkert Systemhaus) that are tested and ready for connection, greatly simplifying the approval process for plant operators.
Do you need more information?
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