Consistent use of renewable energies with flexible metal hydride storage systems
Real-time control of hydrogen filling stations
Nel Hydrogen, Denmark
The production and use of green hydrogen from renewable energy sources is one of the key measures for reducing carbon emissions in the energy and transport sectors. Electricity generated from wind energy, hydropower, or solar energy can be converted into hydrogen by electrolysis and then stored in tanks, transported, and used anytime, anywhere. Hydrogen is used in carbon-neutral transport, such as in fuel cell vehicles, in the chemical industry, in steel production, and in power stations, where it is converted back into electricity.
Advantages of PC-based control for the hydrogen industry:
- innovative solutions thanks to open and flexible control technology
- seamless and secure communication from zone 0 to the cloud
- extensive portfolio of components for explosion protection
- PLC, motion control, HMI, safety, and measurement technology in a single system
- increased availability through cable and controller redundancy
Integrated automation solutions for the hydrogen industry
Extensive experience in relevant industries
As an experienced partner of the wind and solar industries, Beckhoff is already working at the very origin of the hydrogen value chain – renewable power generation. Over 125,000 wind turbines have already been automated with our open PC-based control technology. What’s more, a large proportion of the solar panels installed throughout the world are produced with the aid of Beckhoff technology. Beckhoff also has many years of experience in process technology, as well as in the automation of applications with explosion protection requirements.
When hydrogen is put to use – for example as a fuel for vehicles, in fuel cells, or in combined heat and power plants – Beckhoff technology has already achieved success in a whole host of applications. In the future, hydrogen will need to be used as a sustainable alternative to fossil fuels in further areas: in methanation and generation of ammonia, in the production of e-fuels, and in numerous other forms of technology that are currently still being researched. PC-based control is being deployed here, too, and is helping to reduce carbon emissions through the use of green hydrogen.
Efficient automation optimizes electrolyzers
Electrolysis involves the separation of water into the elements hydrogen and oxygen by means of electrical energy. Innovative and economical solutions for the electrolysis process are needed to meet the increasing demand for hydrogen from renewable energies. Our end-to-end control and monitoring solution contributes to high levels of efficiency and system safety.
PC-based control for electrolysis:
- high-performance embedded PCs for control cabinet installation
- control panels for operation and monitoring up to zone 2
- EtherCAT Terminals for detecting and processing all relevant signals
PC-based control for safe hydrogen storage and transport
Hydrogen is stored and transported in a liquid or gaseous state. In combination with oxygen, this highly flammable gas can form an explosive atmosphere. Beckhoff offers comprehensive solutions for safe automation up to zone 0, along with data acquisition and transmission to the cloud.
Safe control and monitoring:
- Intrinsically safe signal transmission and functional safety up to zone 0 thanks to ELX terminals with TwinSAFE SC
- Data pre-processing and transfer to the cloud via edge device
- Fiber-optic coupler for communication over distances of up to 20 km
Flexible automation and IoT solutions for hydrogen fueling stations
Hydrogen also plays a key role in the field of mobility. In logistics in particular, it has the potential to become the most important energy source for powering trucks, as well as in shipping and aviation. However, refueling with hydrogen is much more complex than with fossil fuels, as it needs to be compressed at a pressure of up to 1000 bar. In the context of functional safety, it is essential to monitor the pressure while filling and have the ability to shut the process down safely if necessary. The relevant explosion protection regulations must also be observed.
PC-based control for hydrogen refueling stations:
- individual plant visualization with TwinCAT HMI
- process data processing and evaluation with TwinCAT Analytics
- simple cloud integration with TwinCAT
Beckhoff technology highlights for the hydrogen industry
The control system for process automation
Beckhoff calls on a comprehensive modular range of components and deep-rooted, cross-sector expertise to create open automation systems using PC-based control technology. All control functions, such as PLC, visualization, cloud connection, safety technology, and measurement technology, are integrated on a universal platform. The system-integrated solution from Beckhoff offers an efficient alternative to conventional providers and is ideal for use across process industry markets, including in the hydrogen industry.
PC-based control for the hydrogen industry:
- universal platform for the automation of all processes and plants
- integration of all control functions into a single system
- high level of interoperability thanks to open interfaces in hardware and software
- control and cable redundancy for increased plant availability
- established worldwide across all industries
EtherCAT Terminals integrate all control functions
Beckhoff uses the principle of PC-based control technology to combine a wide range of I/O components in a single system. For example, EtherCAT Terminals used for integrating functional safety can be freely combined with EtherCAT measurement terminals and with I/O modules featuring an integrated safety barrier for connecting intrinsically safe field devices from the hazardous area. These elements can then be integrated into a holistic control system. This means that plant operators have an efficient complete solution at their disposal for all application-related requirements.
Flexible plant design with PC-based control:
- integration of all I/O components into a single system
- combination of safety, measurement technology, and explosion protection
- openness toward third-party systems
- high interoperability to simplify retrofits
- system openness for investment protection
Ideal for the hydrogen industry: The open EtherCAT fieldbus
As a universal and open high-speed fieldbus, EtherCAT is suitable for all areas of application, from PLC and drive technology to sensors, measurement and safety technology, and explosion protection. With EtherCAT, you only need one communication technology for your entire plant, and can also benefit from the safety and optimum performance of the comprehensive EtherCAT architecture. The EtherCAT-based control also facilitates the integration of third-party EtherCAT devices and other fieldbus systems.
Future technology – EtherCAT for the hydrogen industry:
- large selection of EtherCAT-compatible sensors and actuators on the market
- fast troubleshooting through diagnostic functions
- no loss of performance in extended plants
- simple commissioning by scanning the devices
- lean system cabling through remote I/O
TwinCAT: The control platform for the hydrogen industry
With its TwinCAT automation software, Beckhoff offers a central platform for controlling process machines and systems. In addition to classic process control in the PLC program, algorithms written in C++, MATLAB® and Simulink® can also be executed in real time. The support for prevalent and industry-specific standards streamlines the utilization of PC-based control within the hydrogen industry.
TwinCAT highlights for the hydrogen industry:
- control-integrated Industry 4.0 and IoT applications
- comprehensive data evaluation with analytics functions
- standardized communication via OPC UA
- support for common standards such as NAMUR, HART, and FDT/DTM
- execution of MATLAB® and Simulink® models
Integrated controller redundancy increases plant availability
System availability plays a decisive role in the hydrogen industry. PC-based control offers various redundancy options, ranging from cable to control redundancy, to safeguard against failures. For redundant control operation, TwinCAT Controller Redundancy is available.
This system-integrated software solution allows two standard industrial PCs to be operated as redundant controllers that both run the same PLC program with minimal setup. An additional, high-performance network connection between the two controls provides the necessary data synchronization, and the fact that standard Ethernet is used means no dedicated hardware components are required. This ensures that only one of the two industrial PCs addresses the fieldbus components at any given time, and that the control programs are executed on both computers with the same database. If one control fails, the second control seamlessly takes over, preventing plant downtime and data loss.
Beckhoff product highlights for the hydrogen industry
Intrinsically safe signal acquisition in IP20 and IP67
The ELX terminals combine highly compact remote I/O modules with safety barriers for the direct connection of intrinsically safe field devices from zone 0/20 and 1/21. The resulting absence of intermediate external barriers not only leads to a significant reduction in the space needed in the control cabinet, but also offers cost-saving advantages.
The EtherCAT Box modules in the EPX series combine intrinsic safety with a protection rating of IP67 and an extended temperature range of -25 to +60°C. The modules in the robust housing enable reliable data acquisition in areas where a control cabinet cannot – or should not – be installed. This makes them suitable for implementing modular and control cabinet-free system concepts in harsh and hazardous environments.
Highly compact I/O modules with integrated barrier:
- for comprehensive control from zone 0 to the cloud
- cost advantages resulting from the elimination of separate safety barriers
- installation possible inside and outside the control cabinet
- compact design, large signal variety, and consistently high resolution
- certification according to ATEX, IECEx, and NEC/CEC
Controllers and remote I/Os allow flexible topologies
High-performance industrial PCs form the basis for a central control station for managing and monitoring processes across the entire plant. Sensors and actuators are integrated via remote I/Os, which transmit the data from the field to the control station via a fieldbus coupler.
If a plant component is to be controlled locally in the control cabinet, this can be achieved using the embedded controllers in the CX series, which are certified for use in zone 2/22 in accordance with ATEX, IECEx, and NEC/CEC. The direct connection option of I/O modules presents a space and cost-saving alternative to fieldbus couplers. These compact controllers reduce the space required in the control cabinet and enable a decentralized automation architecture for modularizing systems.
ELX terminals: Intrinsically safe signal transmission and functional safety
Beckhoff meets the requirements for process control technology in terms of functional safety by fully integrating safety technology into the automation system. Thanks to its compact form and modular structure, the TwinSAFE safety solution fits seamlessly into the control platform. This allows PC-based control to serve as a unified platform that meets the requirements of both functional safety and explosion protection. The ELX terminals extended with TwinSAFE-SC thus enable the direct connection of intrinsically safe field devices up to zone 0/20 for safety-related functions.
Functional safety and intrinsic safety in a single system:
- highly compact solution with up to four channels on 12 mm
- direct connection of intrinsically safe field devices up to zone 0/20
- functional safety
- significant cost benefits
From the sensor to the cloud: End-to-end solutions for system networking
The process industry has a growing need for automation solutions that facilitate cross-plant networking. This is where PC-based control technology ticks all the boxes, with the possibility to link decentralized systems while enabling centralized process evaluation and control. As a result, PC-based control provides the optimal basis for implementing networked systems in line with Industry 4.0 and IoT concepts, spanning from horizontal integration – even across company boundaries – to vertical integration with networked systems, and integrated engineering over the entire product lifecycle.
Beckhoff has developed the TwinCAT IoT software library for communication between the system controller and cloud-based services. It is designed to support the standardized OPC UA, AMQP, and MQTT protocols for communication with popular cloud systems such as Microsoft Azure™ and Amazon Web Services, as well as private cloud systems in the company’s own network.
Connection of Ethernet-APL field devices in the I/O system
The rise of digitalization, especially in the areas of plant diagnostics and monitoring, is currently one of the major topics in the hydrogen industry. Processing plants are generally very widespread and have particular requirements that are met by the specially developed standard Ethernet-APL, which offers a transmission rate of 10 Mbit/s and a cable length of up to 1,000 meters.
Beckhoff integrates the Ethernet-APL technology into the modular terminal portfolio. The compact ELX6233 EtherCAT Terminal can be mounted in the control cabinet in combination with other EtherCAT Terminals. Two Ethernet-APL field devices can be connected via each terminal. As with all terminals in the ELX series, the ELX6233 enables the direct connection of intrinsically safe field devices from zone 0.