Hydrogen testing: components, fuel cells & storage systems

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• What are the challenges for Hydrogen manufacturers and operators?

  One of the main challenges for hydrogen manufacturers and operators is to ensure the safe handling, storage, and transportation of hydrogen. Hydrogen is highly flammable and has a wide flammability range, posing safety risks if not managed properly. Therefore, rigorous testing and compliance with safety standards are critical to mitigate these risks. Developing and implementing effective safety protocols, conducting thorough testing of equipment and infrastructure confidence in hydrogen as a safe and viable energy carrier.
  
  Managing these challenges requires strategic planning, continuous innovation, adaptability, and collaboration with experienced hydrogen component testing experts like TÜV SÜD.

• Who should consider hydrogen testing services?

  Hydrogen testing is relevant for numerous stakeholders, such as:

  • Hydrogen component manufacturing companies
  • Hydrogen component operators, like fuel cell station operators
  • Organisations responsible for certifying hydrogen components

  The hydrogen testing services offered by independent third-party providers like TÜV SÜD ensure that hydrogen components meet relevant safety and quality standards and requirements, leading to reliable and high-performing hydrogen products.

• Why are hydrogen component testing services beneficial?

  Testing services are a strategic investment for hydrogen component manufacturers and operators that ensure the quality, safety, reliability, and performance of innovative hydrogen components.
  
  When choosing TÜV SÜD´s hydrogen testing services, you will get support from product development through material selection, qualification and design validation. Furthermore, with our comprehensive testing scheme, we ensure compliance of your hydrogen components with all relevant standards and directives and certify your products.
  
  Rigorous testing allows manufacturers to identify and fix defects before the products reach the market. This not only maintains the company's reputation for reliability but also prevents costly recalls and customer dissatisfaction. In addition, testing also optimises performance, streamlines certification and helps to gain access to national or international markets with your products without any delays.

• Which hydrogen tests for metallic and non-metallic materials are offered by TÜV SÜD?

  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
• Which specific tests are offered by TÜV SÜD for hydrogen systems and hydrogen fuel cells?

  Many hydrogen systems rely on a fuel cell. Since the hydrogen 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 a 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
• Which specific tests are offered by TÜV SÜD for hydrogen storage systems?

  TÜV SÜD's testing services for hydrogen storage solutions include specialised tests such as:

  • Leakage and permeation
  • Hydraulic pressure cycling
  • Accelerated Stress Rupture
  • Hydraulic overpressure and burst testing
  • H2 pressure cycling and refueling simulation
  • Liner Buckling and Blistering
  • Bonfire and gunfire testing
  • Environmental simulation (such as vibration/shock and impact)
  • Electromagnetic compatibility
  • Dynamic driving profile simulation
  • Norms for hydrogen vehicle fuel system components and containers
• According to which standards are hydrogen components tested and certified?

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

  Gaseous hydrogen

  Materials

  CSA ANSI CHMC 1
  CSA ANSI CHMC 2
  ISO 11114-X

  Vehicle components

  79/2009/EC in conjunction with 406/2010/EU
  UNECE R-134
  ANSI CSA HGV 3.1
  ISO 12619
  ISO 19882
  ISO 19887
  ISO 17268
  SAE J2600

   

  Vehicle fuel tanks

  79/2009/EC in conjunction with 406/2010/EU
  UNECE R-134
  ANSI HGV 2
  ISO 19881

  Stationary components & tanks

  ISO 19880-X
  CSA HGV 4.X
  ISO 19884
  EN 12245
  ISO 11119-X

   

  Liquid hydrogen

   

  Materials
  EN 1252-1

   

  Vehicle components
  79/2009/EC in conjunction with 406/2010/EU
  2021/535/EU

   

  Vehicle tanks
  79/2009/EC in conjunction with 406/2010/EU
  2021/535/EU

• Which legal requirements are relevant for the type of approval of hydrogens storage systems (HSS) in the EU?

  Please find below a graphic which highlights the hierarchy of the legal requirements for the type of approval of a hydrogen storge system in the EU:

  

• Certification mark of conformity for fuel cell systems

  

  • Subject of certification: Hydrogen-carrying components used at H2 refueling stations or vehicles
  • Normative basis: IEC 62282-2 and IEC 62282-4, ISO 19880-3 and ISO 19880-5, ISO 17268
  • Your benefits: You strengthen customer confidence in the safety and performance of your hydrogen components
  • Products: Vehicle, industrial and fuel cell components

   

   

  

   

  • 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 hydrogen systems
  • Products: Fuel cell systems, Electrolyzer systems