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, 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
Do you have any questions? Take a look at our FAQ section or chat to our experts.
Integrated automation solutions for the hydrogen industry
Control systems for the entire value chain
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. More than 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. To achieve climate targets, hydrogen is also needed as a sustainable alternative to fossil raw materials in other industrial processes including methanation, ammonia synthesis, and the production of e-fuels, for example. 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 1,000 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
Our technologies for your hydrogen application
The control system for the hydrogen industry
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
- PC-based control technology is established worldwide across all industries
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:
- wide 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
Our product highlights for your hydrogen application
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
- compact design, large signal variety, and consistently high resolution
- certification according to ATEX, IECEx, and NEC/CEC
Elegant Ex panels: The CPX series in a robust aluminum design
With the CPX panel models, the tried-and-tested multi-touch technology of Beckhoff Control Panels and Panel PCs is available in a particularly robust design and meets the requirements for use in zone 2/22 hazardous areas. A high level of functionality combined with high-quality workmanship ensures the durability of the CPX panels even in harsh ambient conditions. The comprehensive CPX portfolio offers a wide choice of formats, sizes, mounting options, and performance features. The fanless panel PCs also offer reliable plant control.
Multi-touch panels for the hydrogen industry:
- capacitive touch technology for optimized operation
- high-quality design
- robust and durable
- flexible mounting
- up to 100 m distance between Ex panel and industrial PC with CP-Link 4
Measurement technology for voltage measurement in fuel cells
Precise measurement of single-cell voltages is key to the efficiency and service life of electrolyzers. While the overall voltage is specified on the stack, single cells can have different voltages during operation and drift over time. These deviations shift the respective operating point, which has a direct impact on efficiency. Continuous monitoring of the cell voltages creates transparency.
The EL3008-0003 and EL3008-0005 EtherCAT Terminals provide a compact solution that is designed specifically to meet these requirements. Eight voltage inputs with ±3 V or ±5 V, 16 bit resolution, 2 ksps, and high measuring accuracy capture the relevant parameters quickly and precisely. The cascaded measuring principle significantly reduces wiring work, while the high level of insulation enables use in stacks with total voltages of up to 1,500 V. Thanks to the modular EtherCAT concept, the terminal is suitable for flexible integration from test bench through to continuous long-term monitoring in series production.
Modular hydrogen systems with MTP
With modular automation, hydrogen applications can be flexibly implemented and adapted with little effort. Modularity is standardized by the Module Type Package (MTP). MTP describes individual modules based on various aspects, including their interfaces and the executable services. The information about the module is stored in an MTP file, which is imported into a higher-level control. This enables efficient commissioning and linking of modules from different manufacturers. The integration of the MTP concept into TwinCAT simplifies the guideline-compliant automation of a plant module through automatically generated source code and libraries for PLC programming.
The advantages of TwinCAT MTP:
- automatic generation and export of the MTP
- high degree of customization for optimum adaptation to existing processes
- guideline-compliant IEC 61131 function block library
- seamless integration into TwinCAT Engineering
End-to-end hydrogen automation from sensor to cloud
Hydrogen FAQs
Explosion protection is absolutely essential in the planning and operation of H2 plants due to the high volatility and explosion risk associated with hydrogen. This can be supported effectively by customized automation technology: Open-loop and closed-loop control hardware is placed outside Ex zones wherever possible; signals from hazardous areas are routed exclusively via Ex-certified or intrinsically safe I/O modules or signal isolators/barriers. The Beckhoff portfolio features ELX and EPX modules with intrinsically safe interfaces for this purpose.
Safety functions are implemented with deterministic SIL/PL-capable hardware (TwinSAFE, for example) and transmitted via safety-related protocols (Safety over EtherCAT, for example) so that rapid interlocks, emergency shutdowns, and short response times are guaranteed. High-availability sensors are integrated directly into the safety-related logic, with continuous diagnostics providing the necessary protection to reduce false alarms and reliably detect changes in status.
Hydrogen applications place high demands on automation technology, which is why powerful and flexible control systems are required. PC-based controllers are preferred because they provide high computing power for complex control algorithms, energy management strategies, and HMI functionality.
Open interfaces such as OPC UA and the integration of MTP enable manufacturer-neutral skid integration as well as accelerating both plug-and-produce scenarios and the scaling of systems. Thanks to real-time capability and deterministic I/Os, time-critical control and safety functions can be implemented with short response times. Integrated diagnostics and redundancy mechanisms increase availability, while the simple integration of safety-related components (e.g., SIL/PL-capable solutions) supports an end-to-end safety architecture.
Overall, the combination of performance, openness, and deterministic behavior helps to improve the efficiency, operational safety, and maintainability of hydrogen plants on a sustainable basis.
The efficiency, service life, and safety of an electrolyzer depend directly on the quality of the measured values recorded in the process. The optimization of efficiency and energy consumption, early detection of degradation, stable control, and thus the safe operation of the electrolysis process all rely on high-resolution, synchronous measured values. Beckhoff supplies high-resolution EtherCAT-based measurement terminals that record cell voltages, currents, and temperatures deterministically and in real time.
Continuous condition monitoring increases the availability and safety of electrolyzers, compressors, and storage systems. Measured values such as cell or stack voltages and current densities, temperatures, pressures, and flow rates, as well as leakage signals, are considered critical in this context. In addition, vibration and motor data as well as network and power parameters can be captured and used to assess the condition of a plant.
These parameters can be captured easily in the Beckhoff system via EtherCAT Terminals. The specific terminals required to capture the measured values to be monitored can be selected from the large I/O portfolio and combined on a modular basis. The data is recorded and analyzed in TwinCAT and, in connection with TwinCAT condition monitoring, deviations are detected at an early stage and unplanned downtimes are reduced.
Cloud analysis is used as an important building block for remote monitoring and predictive maintenance of hydrogen systems. Process data is typically pre-processed and filtered via an edge device. A C60xx series Industrial PC from the Beckhoff portfolio can be used for this purpose, for example. The data is then transferred to the cloud via standardized interfaces such as OPC UA or MQTT, where analytics and machine learning models are used for dashboards, alarms, and predictive maintenance. Corresponding interfaces are available in TwinCAT. The data can be evaluated with little effort, e.g., via TwinCAT Analytics.
MTP (Module Type Package) offers decisive advantages for the construction and operation of the modules from which hydrogen plants are built – including electrolyzers, PSA units, compressors, storage tanks, and dispensers. The standardized description of the module interfaces supports manufacturer-neutral data exchange via OPC UA. This accelerates the implementation of plug-and-produce approaches, simplifies HMI generation, and facilitates both scaling and the replacement or expansion of individual skids.
Typical application scenarios range from electrolysis parks under flexible control to hydrogen filling stations and power-to-X pilot plants. It should be noted that although MTP enables orchestration at control level, it does not support hard real time. Control and safety-related (SIL) functions remain in the local module controller, and the requirements of the IEC 62443 standard with regard to IT security should be observed.
Beckhoff supports the implementation of MTP both for individual modules and for integration at process orchestration layer (POL) level via TwinCAT MTP.
OPC UA companion specifications are of central importance for interoperability and standardized data availability in modular hydrogen plants. Proven OPC UA modules such as PA-DIM, ADI, OPC UA for Machinery, VDMA profiles, publisher-subscriber model mechanisms, and AAS mapping are currently available and ready for use in the modeling and interoperable networking of electrolyzers, compressors, storage systems, and HRS. A hydrogen-specific companion specification has not yet been finalized; the OPC Foundation and the VDMA are working on corresponding developments. For a project-specific recommendation, an actual use case is required so that the appropriate combination of existing models can be proposed for the respective system.
More information
Information media
You can find our brochures, videos and webinars on the process industry here.
Digitalization for the process industry
Implement future-proof automation of process plants with Ethernet-APL, NOA, and MTP.
Module Type Package (MTP)
TwinCAT MTP integrates the Module Type Package concept into the engineering environment and enables efficient development of modular plants.
Energy industry
Future-proof solutions for the energy sector: from biogas plants to smart cities