hydrogen battery cell

Hydrogen testing: components, fuel cells & storage systems

How to get your hydrogen solutions safe, reliable, and compliant

How to get your hydrogen solutions safe, reliable, and compliant

As an innovative and flexible energy carrier, hydrogen is being used more frequently today across various sectors and industries, also offering a sustainable solution with environmental advantages. Hydrogen is for example utilised in the mobility sector, but also widely adopted in other energy-intense industrial sectors such as steel and metal processing, the electrical industry, and chemicals. These energy-intense sectors are heavily relying on low-carbon energy solutions and green hydrogen to reduce their impact on the climate and especially in mobility to achieve ambitious zero-emission targets.

However, no matter how hydrogen is used, the safety of all hydrogen components must be guaranteed.

HOW TÜV SÜD CAN SUPPORT HYDROGEN COMPONENT MANUFACTURERS

TÜV SÜD’s multidisciplinary team of experts possesses the knowledge and experience to provide quality and safety testing services for hydrogen components, fuel cells, and storage systems. Our testing scheme is set up according to global standards and regulations and specific safety requirements. In this way, we ensure the conformity of your hydrogen components so that your products can enter national or international markets without delay.

Within our state-of-the-art hydrogen testing laboratory, we conduct various tests for industrial & energy manufacturers and vehicle component manufacturers. 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 as well as users, this means a significant plus in safety by minimising operational, occupational, and safety risks.

Furthermore, we follow a customer-focused approach and can provide individual solutions for our customers in creating tailored test and certification setups for new, innovative systems, drawing on our experience and in compliance with existing standards. This enables us to deliver quality and security with long-term benefits for your company.

 

FIND OUT MORE ABOUT THE HYDROGEN TESTING APPROACH

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.

 

hydrogen testing approach

TÜV SÜD provides a holistic service approach, by testing, validating and certifying your hydrogen components to make them safe and compliant.

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EXAMPLES OF HYDROGEN COMPONENTS WE TEST AND CERTIFY

We offer hydrogen testing services for industrial & energy manufacturers for example:

  • Fuel cell systems
  • Hydrogen fuel stations
  • Fuel cell modules
  • Electrolyzers
  • Hydrogen storage systems

Our experts also provide hydrogen testing support specifically for vehicle component manufacturers and offer testing such as:

  • Tanks
  • Valves
  • Lines
  • Sensors
  • Pressure regulator
  • Fuel cells and fuel cell components

EXAMPLES OF HYDROGEN TESTS WE PROVIDE

Our hydrogen testing capabilities serve:

Get started with TÜV SÜD today!

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Frequently asked questions (FAQs) on hydrogen testing 

  • 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:

    hydrogen regulation hierarchy

  • Certification mark of conformity for fuel cell systems

    certification-mark-hydrogen-system-component

    • 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

     

     

    ts-pr-ps-certification-mark-fuel-cell-system

     

    • 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

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