Manufacturing site evaluation.
Every HydroHub™ deployment begins with a documented manufacturing site evaluation — a plant survey, a fuel and duty profile, a historian baseline, a utilities review, and a HAZOP of the proposed hydrogen injection system against the existing combustion train. It closes with a sized configuration and commercial terms. No plant modification is proposed before that record exists.
Six stages, in order.
Plant survey and manufacturing site evaluation
A structured walkdown of the combustion plant: boiler, furnace or kiln duty, burner arrangement, combustion air path, control system, and available tie-in locations. The output is a documented picture of what the plant actually does, not what its nameplate says.
Fuel and duty profile
Fuel type, calorific value, annual consumption and unit cost, together with the real load profile across the operating year. This determines which generator frame is appropriate and what recoverable fuel value is realistically available.
Historian baseline
Read-only extraction of fuel flow, steam flow, stack O2, stack temperature and load from the site historian — PI / OSIsoft, Aveva, GE Proficy or equivalent. Twelve months of record is preferred. This baseline is what any later performance claim is measured against.
Utilities and location review
Three-phase electrical capacity, demineralised water availability, generator footprint and ambient conditions. Nothing about a hydrogen injection system is exotic here, but each item is a hard prerequisite rather than a preference.
HAZOP and hazardous-area review
The proposed injection arrangement is taken through HAZOP against the existing combustion train, with hazardous-area classification confirmed for the generator location. On-demand generation means no stored gas inventory, which materially simplifies the study — but the study is still done, and documented.
Sized configuration and commercial terms
The evaluation closes with a sized configuration, an injection arrangement drawing, a commissioning scope and commercial terms. No plant modification is proposed before the assessment record exists.
Site readiness checklist.
Completing this before the site visit typically removes a full round of correspondence from the evaluation. Nothing here is unusual for a plant that already runs a permit regime and a historian — but every item is needed before a configuration can be sized or a HAZOP scheduled.
Plant identification
- Plant type, make, model and year
- Rated duty in steam t/h or thermal MW
- Typical and minimum sustained operating load
- Annual operating hours and shift pattern
Fuel
- Primary fuel and any secondary or backup fuel
- Most recent calorific value and fuel analysis
- Annual consumption and unit cost
- Known seasonal or supplier-driven quality drift
Combustion train
- Burner count, manufacturer and turndown range
- Forced or induced draught, and duct access points
- Current excess-air setpoint and measured stack O2
- Control system make, model and spare I/O
Injection point
- Candidate tie-in location for the injection lance
- Physical access for installation and maintenance
- Available permissives and trip signals for interlock
Utilities
- Three-phase voltage, frequency and spare breaker capacity
- Demineralised or distilled water availability
- Indoor plant room or outdoor pad, with footprint
- Ambient temperature, humidity, dust and corrosive exposure
Measurement baseline
- Historian platform and access method
- Available tags: fuel flow, steam flow, stack O2, stack temperature, load
- At least twelve months of baseline record
- Most recent efficiency or emissions test report
Safety and compliance
- Hazardous-area classification drawings
- Previous HAZOP or LOPA studies on the combustion plant
- Permit-to-work regime for hot work and confined space
- Current permitted NOx, CO and particulate limits
Commercial
- Capital sign-off and plant-modification sign-off owners
- Target outcome: fuel cost, emissions compliance, or both
- Outage windows available for tie-in and commissioning
Site assessment — answered.
What is a manufacturing site evaluation for combustion enhancement?
A structured survey of an industrial combustion plant that establishes whether oxyhydrogen injection is technically viable and commercially worthwhile. It covers plant duty, fuel and load profile, historian baseline, utilities, injection tie-in location, and HAZOP and hazardous-area review, and closes with a sized configuration and commercial terms.
What does the site readiness checklist cover?
Eight sections: plant identification, fuel, combustion train, injection point, utilities, measurement baseline, safety and compliance, and commercial decision process. Completing it before the site visit typically removes one full round of correspondence from the evaluation.
Is a HAZOP required to install a hydrogen injection system?
Yes. The proposed injection arrangement is taken through HAZOP against the existing combustion train and the generator location is confirmed against hazardous-area classification. Because oxyhydrogen is generated on demand with no storage vessel, there is no stored gas inventory to assess, which materially narrows the study scope.
How much plant data is needed before an assessment can start?
Plant type, rated duty, primary fuel, annual fuel consumption and annual operating hours are enough to begin a first-pass evaluation. Historian data — ideally twelve months of fuel flow, steam flow, stack O2, stack temperature and load — is required before any measured performance baseline can be established.
Does the site assessment commit us to purchasing equipment?
No. The assessment is a technical and commercial evaluation. It may conclude that the plant is not a suitable candidate, and that conclusion is reported with the same evidence as a positive one.
Start with the plant, not the equipment.
Send the completed checklist, or simply the plant type, duty, fuel and annual operating hours. YBG Industrial returns a first-pass evaluation and, where the plant is a candidate, a sized configuration from the oxyhydrogen generator range.