Design & Engineering Integration With Balance of Plant for a Green Hydrogen Project

To advance its green energy mission, the client is establishing a 100 kW Hydrogen Manufacturing Unit capable of producing 20 Nm³/hr of green hydrogen with 99.99% purity at 12 kg/cm²g. While the hydrogen plant itself is a free-issue item, the client required an engineering partner to design and engineer the Balance of Plant (BOP) for seamless integration and operational efficiency. The Design and Engineering of Green Hydrogen BoP scope included auxiliary systems and utilities essential for the hydrogen facility’s safety, functionality, and reliability.

Rishabh Engineering was selected as the detailed engineering partner to support the successful commissioning and operation of the hydrogen manufacturing unit. Our multidisciplinary team performed design and engineering of green hydrogen balance of plant with extended basic and detailed engineering services across mechanical, piping, civil & structural, electrical, and instrumentation disciplines

Project Scope:

• Fire Protection System: Designed and engineered a comprehensive fire safety system to ensure compliance with hydrogen safety standards.
• Air Compressor: Engineered a reliable compressed air system to meet the plant’s operational requirements.
• N₂ Cylinder Bank: Integrated the nitrogen cylinder bank into the overall utility framework.

Green Hydrogen BoP Design Scope:

• Design Basis & P&ID
• Process Data Sheets for Packages (H₂ Compressor, O₂ Compressor, etc.)
• Control Operating Philosophy
• Master Planning
• Hazardous Area Classification (HAC)
• 3D Model of the Entire Facility
• Piping GAD & Isometrics
• Electrical Load List
• Single Line Diagram (SLD) & Electrical Datasheet
• Civil Design for Equipment Foundation
• Complete Instrumentation Design
• Bill of Quantities (BOQs)
• RFQ for All Packages
• Technical Queries (TQ) and Vendor Document Review (VDR) for Procured Packages

Green Hydrogen Balance of Plant Integration – Detail Engineering Focus

Mechanical:

• Developed Mechanical Datasheets & RFQs for buffer tanks and essential packages like cooling towers, DM plant, and compressors.

Piping:

• Developed a 3D Model for efficient spatial planning.
• Created plot plans while considering statutory requirements and engineering norms.
• Designed a comprehensive fire-fighting package for the entire facility.

Civil & Structural:

• Established civil design philosophy based on soil testing and contour survey data.
• Delivered complete civil designs for the Greenfield site, including BOQs and tender documents.

Electrical:

• Developed an electrical load list and completed the facility’s electrical design.
• Provided electrical BOQs and tender documents.

Instrumentation:

• Prepared an instrumentation index and I-O List.
• Defined control philosophy and its integration with the technology package.

Technology Package Integration & Compliance:

• Reviewed and integrated the Electrolyzer Unit received from the technology supplier.
• Developed the Operating & Control Philosophy, ensuring alignment with the client’s requirements.
• Utilized renewable hybrid power (Solar + Wind) for sustainable operations.
• Ensured hydrogen storage, filling, and statutory compliance through extensive offline support.

Through their multidisciplinary expertise in green hydrogen consulting, Rishabh Engineering delivered a robust engineering package that successfully facilitated Green Hydrogen BoP Integration, thus reinforcing the client’s commitment to renewable energy and sustainability.