The Fuel Cell Challenge

A large-scale energy facility operated six fuel cell units to convert hydrogen and oxygen directly into electricity through chemical reactions. These fuel cells generate power continuously as long as fuel is supplied, with the added benefit of producing hot water and steam from waste heat recovery.

The facility had a reliable and cost-effective source for energy. However, the facility faced a critical operational challenge. Each fuel cell came equipped with a basic PLC (Programmable Logic Controller) panel, but these systems had limitations:

• No historical data storage: operators could only view real-time readings
• Site-based monitoring only: staff had to physically visit each fuel cell to check its status
• No remote access: centralized monitoring was impossible
• Limited data transmission: PLCs couldn’t communicate with other systems directly

This limited operators ability to track performance trends, anticipate maintenance needs, or monitor their assets from the control room.

The Dependency Dilemma

Making matters worse, the facility relied entirely on their fuel cell supplier’s long-term maintenance service. The supplier operated a centralized monitoring center that tracked fuel cells across multiple customer sites. When their analysis indicated a part needed replacement, they would ship components to the facility.

This arrangement created an uncomfortable dependency. Operators would receive replacement parts without understanding why they were needed or whether they were truly necessary. Without access to detailed monitoring data, they had no choice but to trust the supplier’s assessment completely; and no way to verify if maintenance was being performed efficiently or cost-effectively.

The Turning Point

The facility recognized they needed to take control of their own operations. The key challenges were clear:

• Limited visibility: Only basic, real-time data available through physical PLC panels
• No historical analysis: Impossible to identify trends or predict failures
• Remote monitoring gap: No way to oversee operations from the control room
• Maintenance dependency: Unable to make independent decisions about parts replacement and service timing
• Poor reporting capabilities: Difficulty communicating facility status to headquarters
• Basic process graphics: Low-quality visualization limited operational understanding

The Solution: Integrated Monitoring & Analysis

The customer chose HanPrism as their data management solution to transform how the facility managed its fuel cell operations:

Enhanced Data Collection & Storage

The new system continuously captures and stores data from all six fuel cells, creating a rich historical database. Operators can now review past performance, identify patterns, and make data-driven decisions.

Centralized Remote Monitoring

All fuel cells are now monitored from a single interface. Operators have complete visibility across the entire facility without leaving their desks.

Advanced Analytics & Calculations

The system goes beyond basic readings to provide calculated metrics. The site also uses advanced visualizations to quickly and easily understand the operating status.

Operational Independence

With comprehensive monitoring data at their fingertips, the facility can now:

• Analyze equipment performance independently
• Validate supplier recommendations with their own data
• Make cost-effective maintenance decisions

Improved Communication & Reporting

Enhanced process graphics and automated reporting tools make it easy to communicate facility status to headquarters, supporting better strategic decision-making at all levels.

The Results

With the addition of HanPrism, the site benefits from:

• Operational Efficiency: Operators have gained deep insight into their fuel cell systems, understanding performance characteristics and maintenance requirements more than before.
• Maintenance Control: Rather than passively receiving parts from suppliers, the facility now proactively manages maintenance based on actual equipment condition.
• Cost Optimization: With the ability to verify maintenance recommendations and schedule work efficiently, the facility has reduced unnecessary parts replacement and optimized service timing.
• Enhanced Decision-Making: Historical data analysis enables improved maintenance and operational strategies, helping protect and preserve their asset.
• Empowered Operations Team: Staff have evolved from reactive caretakers to proactive asset managers with enhanced operational awareness.

About Fuel Cell Technology

What is a Fuel Cell?

A fuel cell converts chemical energy from hydrogen and oxygen directly into electrical energy through chemical reactions. Unlike batteries, fuel cells generate electricity continuously as long as fuel is supplied, requiring no recharging. The heat produced during operation is captured and reused to generate hot water and steam, maximizing energy efficiency.

Key Components:

• Fuel Reformer: Converts fossil fuels (natural gas, LNG, methanol, coal, petroleum) into hydrogen fuel
• Stack: The power generation unit where hydrogen produces electricity
• Power Converter: Transforms DC electricity from fuel cells into usable AC electricity
• Waste Heat Recovery Device: Captures waste heat to supply hot water and steam

Ready to take control of your energy assets? Contact us to learn how integrated monitoring solutions can transform your operations.