Hydrogen Tank Validation Testing: Ensuring Safety and Durability

As the world transitions towards a more sustainable energy future, hydrogen is emerging as a key player in this transformation. With its potential as a clean energy carrier, hydrogen is being adopted in various industries, from automotive to aerospace and energy storage. However, with its growing use, the need for robust and reliable storage solutions has become more critical than ever. This is where hydrogen tank validation testing comes into play, ensuring that steel and composite tanks – as hydrogen storage solutions – are safe, durable, and able to withstand the challenging environments they encounter.

The Importance of Hydrogen Tank Testing

Hydrogen, while offering immense potential as a clean energy source, is a highly flammable and volatile gas. Any mishandling or failure in storage systems could lead to dangerous consequences, such as leaks, explosions, or fires. Hence, ensuring the structural integrity, durability, and reliability of hydrogen storage tanks is crucial to mitigate these risks.

Hydrogen storage tanks are therefore subject to tests that are designed to simulate real-world scenarios and potential hazards that these tanks may face during normal operation or in emergencies. These tests include rigorous assessments of pressure resistance, leak prevention, durability, and compatibility with various operating conditions. The primary objective is to verify that the tanks can perform safely under extreme conditions, providing assurance to end-users and manufacturers that they meet the highest safety standards.

Types of Hydrogen Tank Testing

In the hydrogen testing market we can differentiate between tank validation testing and component validation testing. Tank validation testing focuses on the performance of a tank during the R&D and production phase, while component validation testing ensures the functioning of all components used in hydrogen systems. The two employ various testing methods to ensure the safety and reliability of hydrogen tanks, each targeting specific aspects of performance and durability. The key methods for tank validation testing include:

• Life Cycle Testing: Hydro and Gas Cyclic Test

Hydro and gas cyclic testing simulates the life cycle of a hydrogen storage tank by repeatedly filling and emptying the tank with a fluid or gas under pressure. This process mimics real-world conditions, such as gas consumption in hydrogen-powered vehicles or refueling stations. During these tests, various parameters, including temperature, deformation, and possible leakage, are monitored to evaluate the tank’s long-term performance. These tests are performed thousands of times to ensure the tank can endure repeated use over its operational life. Both ambient or extreme temperatures are used during the tests.

• Burst Testing: Hydro Burst Test

Hydro burst tests are destructive tests designed to validate the calculated safety factor of the hydrogen storage tank. The tank is filled with water, and pressure is steadily increased until the tank bursts. This test ensures that the tank can withstand pressures significantly higher than what it would experience during normal use. Hydro burst tests are conducted during pre-production to meet safety standards and are performed on a small percentage (e.g., 0.5%) of tanks in a production batch.

• Leak Testing: Gas Leak Permeation Test

Leak testing is a critical component of hydrogen tank validation. Given hydrogen’s small molecular size and its propensity to leak through small openings, it is essential to ensure that tanks are leak-proof. This test involves filling the tank with hydrogen at a set pressure and monitoring for any leakage over a set period. To ensure safe and environmentally friendly testing, Resato offers hydrogen recycling configurations, which not only reduce operational expenses (OPEX) but also minimize the environmental footprint.

Pioneering Hydrogen Tank Testing Solutions for a Safer Future

At Resato, we understand the challenges associated with hydrogen storage and are dedicated to providing advanced testing solutions that comply with industry regulations, such as the R134. Our systems, from hydro cyclic tests to burst tests, are designed to ensure that every tank meets the highest standards of performance and safety.

By offering reliable tank testing solutions, we play a vital role in promoting the widespread adoption of hydrogen technology. With our commitment to quality, safety, and innovation, industries can confidently transition to hydrogen-based solutions.

Conclusion

As hydrogen’s role in the global energy transition continues to grow, hydrogen tank validation testing is essential for ensuring the safety, durability, and long-term performance of storage solutions. At Resato, we are proud to contribute to this hydrogen-powered future through our state-of-the-art testing solutions.

Do you want to learn more about how our hydrogen tank validation testing solutions can benefit your business? Contact our experts today!