Process Safety & Pressure Equipment Testing for Hydrogen Based Systems

TÜV SÜD offers highly professional process safety and hydrogen-based pressure equipment compatibility testing solutions. We are familiar with the standards and regulations that must be met when it comes to production, transportation, and usage of hydrogen. Our experts reliably determine whether all requirements are met, including making sure the systems are safe, and components that are tested with hydrogen meet the performance requirements.

What is hydrogen component testing?

As an innovative and flexible energy carrier, hydrogen is being used more frequently today: In mobility, stationary applications, but increasingly also in industrial sectors such as steel and metal processing, the electrical industry and chemicals, offering a sustainable solution with environmental advantages. But no matter how hydrogen is used, safety must be ensured.

Hydrogen component testing is relevant for various materials, processes, and infrastructure. Whether that is through electrolysis, refueling stations, fuel cells or pressure vessels and tanks (stationary as well as portable): All components used in a hydrogen lifecycle, must comply with specified material requirements and safety standards.

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WHY IS HYDROGEN COMPONENT TESTING IMPORTANT?

When using hydrogen components, we must ensure that the use of hydrogen is safe for the user and the product is performing safely and smoothly. Within our hydrogen testing laboratory, we can perform a wide variety of safety- and performance-related tests to determine whether your components are suitable for hydrogen use. By working together with an experienced partner like TÜV SÜD you will gain various support and benefits:

• Receive support from product development through material selection, qualification and design validation to certification and type approval to ensure all safety and performance aspects of your hydrogen component are covered.
• Ensure compliance of your hydrogen components with all relevant standards and directives.
• Gain access to national or international markets with your products without any delays.

As experienced partner TÜV SÜD supports you with all your PressuriSed Hydrogen Component Testing needs

TÜV SÜD has more than one hundred years’ experience in transportation and safety. We have a hydrogen testing laboratory at our disposal where we can conduct various tests according to your individual needs. Our vehicle component and material testing lab for hydrogen allows us to make reliable statements on general product safety. We can also forecast the performance of components over time. For manufacturers as well as users, this means a significant plus in safety.

With TÜV SÜD you have a neutral and independent third-party inspection at hand. Our pool of interdisciplinary experts follows a customer-focused approach and delivers quality and safety results with long-term value for your business. We minimise operational, occupational and safety risks and provide a wide range of services in the field of hydrogen component testing.

TÜV SÜD’s hydrogen testing services

Our hydrogen testing portfolio consists of all tests required to evaluate the suitability and safety of components and systems like the following:

• Tanks
• Valves
• Lines
• Sensors
• Pressure regulators
• Fuel cells and fuel cell components
• Complete hydrogen storage systems

Moreover, our testing capabilities serve:

• Pressure cycle, leakage, and tightness tests
• Overpressure, burst and flow tests
• Hydrogen permeation and compatibility testing

With our various TÜV SÜD laboratories we offer our customers a comprehensive service portfolio. We provide hydraulic tests, environmental simulation and tests for electromagnetic compatibility as well as vibration tests that are conducted in addition to tests with hydrogen.

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Hydrogen Tests on metallic and non-metallic materials

We regularly test materials (metallic and non-metallic) regarding the following criteria:

• H2 compatibility (SAE J2600, ISO 17268)
• Cyclic H2 resistance
• Weight and volume change
• Tensile strength and aging
• Permeation at sample level (CHMC 2)
• H2 embrittlement (ISO 11114-4)
• Corrosion and Sustainable Load Cracking (ISO 7866)
• Hardness change (ISO 6506-1)
• Liner blistering
• Explosive decompression

PressuriSed Hydrogen System tests and Hydrogen Fuel Cell tests

Many hydrogen systems rely on a fuel cell. Since the fuel cell is one of the most crucial elements in terms of application, quality and functionality it should be put through its paces. At TÜV SÜD we provide all testing and certification services, regarding fuel cell products.

More specifically, when it comes to hydrogen and fuel cell components, we offer tests with focus on:

• Leakage and Permeation
• Pressure cycling with hydrogen and nitrogen
• Hydraulic pressure cycling
• Hydraulic overpressure and burst testing
• Static and Cyclic H2 exposure
• Rapid decompression
• Hydrogen exposure at extreme temperatures
• Environmental simulation (such as vibration and salt spray)
• Electromagnetic compatibility
• Dynamic driving profile simulation

Tests of hydrogen storage systems

Special tests build part of TÜV SÜD’s offering when it comes to the testing of hydrogen storage solutions which includes:

• Leakage and permeation
• Hydraulic pressure cycling
• Accelerated Stress Rupture
• Hydraulic overpressure and burst testing
• H2 pressure cycling and refuelling simulation
• Liner Buckling and Blistering
• Bonfire and gunfire testing
• Environmental simulation (such as vibration/shock and impact)
• Electromagnetic compatibility
• Dynamic driving profile simulation

We test and certify hydrogen components according to various standards

At TÜV SÜD we test and certify materials, components, tanks, and systems according to the following standards (among others):

GASEOUS HYDROGEN

LIQUID HYDROGEN

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Our certification marks for fuel cell systems and H₂ System components

Certification Mark of conformity for fuel cell systems

• Subject of certification: Stationary fuel cell systems for the generation of electrical power

• Normative basis: IEC 62282-3
• Your benefits: You strengthen customer confidence in the safety and performance of your systems

CERTIFICATION MARK OF CONFORMITY FOR H₂ SYSTEM COMPONENTS

• Subject of certification: Hydrogen-carrying components used at H₂ refueling stations or vehicles (such as valves, tank nipples, refueling couplings or hoses)

• Normative basis: 
  • IEC 62282-2 and IEC 62282-4 (for fuel cell modules)
  • ISO 19880-3 and ISO 19880-5 (for hydrogen valves and refueling hoses)
  • ISO 17268 (for refueling nozzles and refueling receptacles)
• Your benefits: You strengthen customer confidence in the safety and performance of your H₂ components