Automation and Control of Hydrogen Filling Stations

Turck’s interface devices ensure reliable isolation of the Ex signals in Portugal’s first hydrogen filling station, and the safety controller from Banner ensures the safety of the overall system

PRF Hydrogen Solutions implemented the first hydrogen filling station for refueling H2 buses for the Portuguese municipality of Cascais in record time – despite difficult conditions due to supply chain problems caused by the pandemic. The system has a modular design and can therefore be transported at any time if required. Bresimar Automação, Turck’s representative in Portugal, supported PRF with the appropriate interface technology for safe processing of the Ex signals and safety controllers from Banner Engineering, which ensure the system safety of the H2 filling station.

The control cabinets house the hydrogen filling station’s control and communication technology
The interface technology isolates Ex signals, amplifies them & supplies connected devices with voltage
The first hydrogen filling station in Portugal was built by the municipality of Cascais
The Banner SC26 safety controllers process all safety-related signals
Hugo Antunes, PRF

The first hydrogen filling station in Portugal is operated by the municipality of Cascais in the Lisbon region, to refuel its hydrogen buses. This commitment is no coincidence, as two of the largest manufacturers of hydrogenpowered buses, CaetanoBus and Toyota, produce their hydrogen buses in Portugal.

The automation and control of hydrogen filling stations is considerably more complex and demanding than conventional filling stations for petrol and diesel fuels. During refueling, the vehicles communicate pressure values, temperatures and other data with the refueling system via an infrared interface to ensure a smooth and safe refueling process. In the event of a malfunction or emergency, the system is immediately put into a safe state.

Technological support from Bresimar and Turck

Turck’s interface devices are responsible for the isolation of the intrinsically safe signals and their pre-processing. For example, the IM33-22Ex-HI two-channel isolating transducers and the single-channel IM33-14EX-CDRI are used in the filling station. They and other variants process temperature and pressure signals and pass them on to the Siemens controller at the filling station. The XS26 safety controller from Turck’s strategic partner Banner Engineering is responsible for controlling all safety-related processes.

Flexible thanks to modular design

PRF’s hydrogen filling station is housed in a 20-foot container and can therefore be transported if necessary, as can the three high-pressure modules for hydrogen compression. “This modular structure enabled us to work flexibly and efficiently,” Hugo Antunes emphasizes. “We were able to complete the system on time because we already had many of the necessary components in stock.”

Success and expansion

The success of this first filling station led to the municipality of Cascais issuing a tender for a larger, permanently installed hydrogen filling station, which PRF also won. The new station will include four compressors and local hydrogen production with a capacity of one megawatt through electrolysis. “This plant will be one of the largest in Europe and will supply completely green hydrogen, provided the power supply comes from renewable energies,” the project manager explains.

Conclusion

The project shows how forward-looking planning, modular construction and the use of reliable technology partners such as Bresimar and Turck can create innovative and sustainable infrastructures that make an important contribution to sustainable mobility in Europe. “We are very proud of what we have achieved and look forward to the upcoming projects with excitement,” project manager Hugo Antunes sums up. “By working with Bresimar and Turck, we were able to ensure that our systems not only work safely and efficiently but are also future-proof.”

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