Airbus required end-to-end development of a new hydrogen test facility to support the ZeroE programme, encompassing design, build, commissioning and operation of initial test rigs within a complex safety and regulatory environment.

KDC is acting as an integrated delivery partner under a fixed-price, task-driven model, defining facility requirements, leading multi-disciplinary design, managing suppliers and progressing through commissioning and acceptance.

Once complete, this will establish assured test capability, controlled technical and safety risk, and enabled readiness for hydrogen system verification.

Requirement

Airbus engaged KDC to develop their brand-new hydrogen test facility and design, commission and operate two initial test rigs within the facility. 

Skills & Tools

• Hydrogen test system architecture
• Entire facility 3D design in CATIA
• Rig management control system
• Safety & HAZOPS
• Electrical system design.
• CATIA
• DOORS
• AutoCAD Electrical
• FloMaster
• Stress Analysis – Pressure Vessel Design, Supplier Management.

Tasking

Full facility requirements definition, CFT and supplier management (green field site currently), Mechanical, Fluid mechanical, electronics/electrical, RMCS and GUI design. Commissioning test rigs including full requirements V&V. Operation of test rigs. 

Deliverables

• Detailed of entire facility in CATIA 

• Design acceptance for each test rig 

• ATEX final acceptance 

• Full safety analysis including HAZOPS 

• V&V report 

• Commissioning report – final acceptance 

• Rig operation SOPs by SQEPs. 

Outcome

Project in progress. Requirements all accepted. Facility under construction according to KDC specification. Down selection of suppliers complete. KDC currently managing the supply and the build phase. Preparations underway for the rig commissioning phase.