Confidential Client
Northeast and Southern USA
Power & Energy
Nexus Provides Power Systems Expertise for New Hydrogen Production Facilities
Overview
As demand for cleaner energy sources continues to grow, hydrogen fuel cell technology is emerging as a practical, zero-emission alternative to traditional transportation fuels. Unlike battery-powered solutions, hydrogen can be produced, transported, and dispensed through infrastructure that supports many of the same operational needs as conventional fuels, making it a promising option for large-scale transportation and industrial applications. The continued advancement of green hydrogen production is helping accelerate the transition to a lower-carbon economy while supporting energy reliability and long-term sustainability goals.
To support this growing market, a developer of hydrogen production facilities initiated multiple projects focused on expanding regional hydrogen generation and distribution capabilities. The objective was to develop hydrogen production facilities and the electrical systems capable of supporting large-scale green liquid hydrogen production processes while also providing flexibility for future expansion and increased capacity demands.
Nexus Engineering Group was engaged to provide specialized electrical engineering and power systems analysis services for multiple facilities. The project scope included evaluating plant distribution systems, analyzing electrical system performance, supporting equipment sizing and design, and developing recommendations that would improve reliability, scalability, and long-term operational performance.
Challenge
Developing electrical infrastructure for emerging hydrogen production facilities presented several unique challenges. Because the projects incorporated evolving technologies and rapidly developing production methods, the electrical systems had to be designed with enough flexibility to accommodate changing requirements throughout project development.
The facilities required complex power systems capable of supporting large inverter-based loads and rotating equipment while maintaining system stability under varying operating conditions. Electrical configurations needed to be carefully evaluated to ensure reliable performance during startup, normal operation, and potential future expansion scenarios. This required detailed engineering analysis and a comprehensive understanding of how different equipment and operating conditions would impact overall system performance.
In addition, long-term growth was a key consideration. The client anticipated future increases in production capacity and additional facility development. As a result, the electrical infrastructure needed to be designed with scalability in mind, allowing systems to be expanded without significant redesign or disruption to ongoing operations. Coordinating these requirements across multiple stakeholders while supporting an evolving project scope required close collaboration and disciplined engineering execution.
Solution
Nexus applied its expertise in medium- and low-voltage power distribution systems to support the development of electrical infrastructure for several green hydrogen production facilities. Working alongside the project team and equipment suppliers, Nexus provided engineering support for prefabricated power distribution centers (PDCs) housing the facility's 7.2 kV switchgear, 480V motor control centers (MCCs), sync-transfer variable frequency drives (VFDs), UPS systems, controls, and auxiliary electrical equipment.
To verify system performance and establish a reliable electrical design basis, Nexus developed detailed ETAP power system models of the 7.2 kV and 480V distribution systems. The team performed comprehensive short circuit, protective device coordination, arc flash, motor starting, harmonic, and capacitor bank sizing studies to evaluate system performance under a variety of operating scenarios. Particular attention was given to large inverter-based process loads and critical compressor equipment connected to the 7.2 kV system, ensuring adequate voltage support, equipment protection, and operational reliability throughout plant startup and normal operation.
Beyond the analytical work, Nexus played a key role in the detailed integration of the electrical equipment within the PDCs. The team reviewed and completed medium- and low-voltage one-line diagrams, developed typical electrical schematics for 7.2 kV switchgear, feeder breakers, VFDs, MCC starters, capacitor bank feeders, transformer feeders, and UPS systems, and reviewed equipment submittals to confirm compliance with project requirements and study results. Nexus also developed relay protection settings, verified CT and PT ratios, and created configuration files for main and feeder protection relays to support factory acceptance testing and reliable field operation.
To further streamline project execution, Nexus prepared detailed interconnection cable schedules that enabled the 7.2 kV and 480V distribution equipment to be prewired within the prefabricated electrical buildings before shipment. This approach minimized field installation activities, reduced construction risk, and improved overall project efficiency while delivering a scalable electrical infrastructure capable of supporting both current hydrogen production demands and future facility expansion.
Outcome
A key differentiator of Nexus’ approach was the development of standardized engineering methodologies and design recommendations that could be applied across multiple hydrogen production facilities. By establishing repeatable design practices and leveraging lessons learned from each project, Nexus helped improve consistency, reduce engineering risk, and support long-term
maintainability across the client's growing portfolio of green hydrogen assets.
The resulting electrical infrastructure provides the reliability, scalability, and operational flexibility
required to support current production needs while positioning the facilities for future growth in hydrogen generation and distribution. The standardized designs and coordinated engineering
approach enabled efficient equipment integration, simplified project execution, and established a
framework that can be replicated across future facilities. Through comprehensive engineering analysis, thoughtful planning, and close collaboration, Nexus delivered solutions that help advance hydrogen fuel cell technology and support continued investment in green hydrogen infrastructure.
Services
- Short Circuit Studies
- Arc Flash Hazard Analysis
- Motor Starting Studies
- Protective Device Coordination
- Relay Application Engineering
- Harmonic Analysis
- Electrical System Modeling (ETAP)
- PDC Design Integration
- Relay Configuration & Settings Development
- Interconnection Cable Design
- Distribution System Planning
Project Director
