Hydrogen testing
- How do you ensure the safety and reliability of your hydrogen systems? As a powerful energy source, hydrogen requires strict high-pressure testing to prevent risks and validate tanks, components and hoses under extreme conditions. With over 30 years of experience, Resato develops advanced solutions that help manufacturers meet the highest safety requirements and comply with standards like R134 and GTR No.13-2.
Safety Compliance Custom-built
What is hydrogen testing?
Hydrogen testing ensures the safety and reliability of hydrogen systems. This verifies that components and systems meet strict safety and durability standards. Hydrogen, unlike other gases, requires controlled environments including extreme temperatures as low as -40°C. It is essential for industries using hydrogen as a sustainable fuel source, especially for heavy-duty vehicles. Testing guarantees that tanks, valves, and systems can handle high pressures safely. Hydrogen testing is crucial for advancing clean energy solutions while prioritizing safety.
How does hydrogen testing work?
It involves various tests where hydrogen, or other gases/liquids, is used as a medium to simulate real-world conditions. The testing process includes:
- Tank validation testing: determines temperature fluctuations, long-term use and if a hydrogen tank withstands pressure
- Component validation testing: ensures that valves and seals can handle the pressure without leaks
- Hose testing: evaluates whether hydrogen transfer systems maintain integrity under operational conditions
These tests must comply with strict standards like R134 to guarantee safe and efficient hydrogen applications.
Tank validation testing
Ensuring hydrogen storage tanks remain safe under real-world conditions.
Validation follows GTR No. 13-2 & R134 and is performed in three phases:
- Homologation testing
Certifies tanks before market entry via extreme-temperature & gas-cycle tests. - Batch testing
Random sample tanks undergo hydro-burst & ambient-temperature hydro-cycle tests. - End-of-line (EOL) testing
Verifies every unit meets functional standards with hydraulic & gas-proof pressure tests.
Component validation testing
Verifying valves, fittings and other parts under extreme hydrogen conditions.
Our programme covers three critical tests:
- Pressure cycling tests
Evaluate how parts handle repeated pressurisation without failure. - Leakage tests
Ensure connections stay gas-tight to prevent hazardous leaks. - Material compatibility tests
Assess resistance to hydrogen embrittlement and long-term integrity.
Hydrogen hose testing
Verifying durability, flexibility and leak-tightness under high-pressure hydrogen.
Our programme confirms compliance with strict industry regulations and long-term integrity through:
- Pressure & flex cycling
Proves hoses withstand repeated bending and full-pressure pulses without failure. - Leak & permeation tests
Detects micro-leaks and ensures gas-tight performance throughout service life. - Aging & compatibility tests
Assesses material resistance to hydrogen embrittlement and thermal aging effects.
What are the benefits of hydrogen testing?
Safety compliance
Ensures systems meet strict regulations that reduce risk.
Accident prevention
Component validation helps prevent failures and downtime.
Sustainable transition
Enables the shift from diesel to clean hydrogen fuel.
Environmental impact
Supports a greener future through safe hydrogen use.
Quality requirements
Hydrogen is highly flammable, so safety is our top priority and testing must be precise. By complying with the strictest international standards we minimise error and guarantee safe, reliable hydrogen systems.
We comply with the following standards:
- EC79
- EU406
- R134
- EN 17339
- GTR 13
- ISO 19887
- ISO 19880
High pressure challenges
Often overlooked are the challenges of working with hydrogen under high pressure. Here are the three biggest hurdles you need to overcome:
- 1
Unpredictable gas behaviour
Unlike liquids, gases are unpredictable and harder to control, increasing testing complexity.
- 2
Extreme temperature swings
Accurate results must account for –40 °C cold-soak to +85 °C heat-soak scenarios to avoid false pass/fail results.
- 3
Safety at stake
Neglecting precise temperature control can compromise safety and testing accuracy.
Resato’s solutions address these issues, offering reliable systems that ensure controlled and safe hydrogen testing processes.
Interested in hydrogen
testing solutions?
Hydrogen testing verifies system reliability, prevents leaks and keeps you compliant with international safety standards. From stationary tanks to on-board vehicle storage, Resato delivers the high-pressure expertise you need.