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What is hydrogen component testing?
As an innovative and flexible energy carrier, hydrogen is used more frequently today across various sectors and industries. It offers a sustainable solution with environmental advantages. As a business that builds solutions in the field of hydrogen fuel, you need to test all your hydrogen solutions and components to guarantee their safety. TÜV SÜD provides comprehensive hydrogen component testing, storage systems testing, and hydrogen fuel cell testing services.
These services are particularly vital given the diverse uses of hydrogen fuel. Hydrogen finds applications in several sectors such as mobility, steel and metal processing, the electrical industry, and chemicals. These energy-intensive sectors rely heavily on low-carbon energy solutions and green hydrogen to reduce their climate impact and achieve zero-emission goals. This means that our hydrogen testing services are crucial to sustainability goals.
Why hydrogen component testing is important
Hydrogen is an opportunity for industries to increase business resilience and decrease the reliance on fossil fuels. To make the most of this opportunity, you need to ensure the safety, quality, reliability and performance of your hydrogen components and solutions. Hydrogen component testing supports hydrogen component manufacturers and operators to demonstrate all these, facilitating the adoption of innovative hydrogen components.
Rigorous testing allows you 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, hydrogen testing solutions also optimises performance, streamlines certification, and helps you gain access to national and international markets with your products without any delay. To this end, different hydrogen component tests such as hydrogen fuel cell testing support you to fulfil global standards and safety regulations.
How TÜV SÜD can help you with hydrogen component testing
TÜV SÜD’s multidisciplinary team of experts has the knowledge and experience for providing comprehensive hydrogen component, storage system and hydrogen fuel cell testing, inspection and certification services. When choosing TÜV SÜD´s hydrogen testing services, you will get support from product development through material selection, qualification and design validation. We set up our testing scheme according to global standards and regulations, and specific safety requirements. This way, we ensure the compliance of your hydrogen components and solutions so that your products can enter national and international markets without delay.
Our experts conduct various tests in our state-of-the-art hydrogen testing laboratory with advanced hydrogen testing equipment. Our 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 and users, this means a significant plus in safety by minimising operational, occupational, and safety risks. Furthermore, we follow a customer-focused approach and can draw on our experience to provide you with individual solutions such as tailored test and certification setups for new and innovative systems. This helps us deliver quality and security with long-term benefits for your company. To find out more about our hydrogen testing portfolio and how we can help you ensure the safety, reliability and compliance of your hydrogen components and solutions, watch the video below:
Elevate your hydrogen business with TÜV SÜD's expert support for safety, reliability and compliance.
What our hydrogen component testing services include
We can support you along the entire product lifecycle of your hydrogen components, fuel cells and storage systems. Our team can advise you from concept and development stage, to validation, as well as qualification and certification, installation, and operational support. 
Our hydrogen testing services for industrial and energy manufacturers include tests for:
- Fuel cell systems
- Hydrogen fuel stations
- Fuel cell modules
- Electrolysers
- Hydrogen storage systems
Our hydrogen testing services for vehicle component manufacturers include tests for:
- Tanks
- Valves
- Lines
- Sensors
- Pressure regulators
- Fuel cells and fuel cell components
Examples of hydrogen tests we provide include:
- ECE R134 homologation and related tests
- Pressure cycle, leakage, and tightness tests
- Overpressure, burst and flow tests
- Hydrogen permeation and compatibility testing
- Hydraulic tests
- Environmental simulation tests
- Electromagnetic compatibility tests
- Vibration tests
Frequently asked questions (FAQs)
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, and thoroughly testing equipment and infrastructure, are key for confidence in hydrogen as a safe and viable energy carrier.
Managing these challenges requires strategic planning, continuous innovation, adaptability, and collaboration with experienced hydrogen solutions testing experts such as TÜV SÜD.
Therefore, rigorous testing and compliance with safety standards are critical to mitigate these risks. Developing and implementing effective safety protocols, and thoroughly testing equipment and infrastructure, are key for confidence in hydrogen as a safe and viable energy carrier.
Managing these challenges requires strategic planning, continuous innovation, adaptability, and collaboration with experienced hydrogen solutions testing experts such as 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 these components
Hydrogen testing services offered by independent third-party providers such as TÜV SÜD ensure that hydrogen components meet relevant safety and quality standards and requirements. This leads to reliable and high-performing hydrogen products
Which hydrogen tests for metallic and non-metallic materials do TÜV SÜD offer?
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 do TÜV SÜD offer 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 do TÜV SÜD offer 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 refuelling 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
What are the standards for hydrogen component testing and certification?
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 types of approval of hydrogen storage systems in the EU?
Hierarchy of the legal requirements for the types of approval of hydrogen storage systems in the EU.
What are the certification marks of conformity for hydrogen fuel cell testing?
Certification mark for hydrogen system components
We can provide a certification mark for hydrogen system components:
- Subject of certification: Hydrogen-carrying components used at H2 refuelling 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.
Certification mark for fuel cell systems
We can also provide a certification mark 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 hydrogen systems
- Products: Fuel cell systems, Electrolyser systems
