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Home » High Pressure Applications » Hydrogen testing » Component validation testing

Component validation testing

Every component within a hydrogen system must operate safely, reliably, and consistently under demanding conditions. Resato offers component validation testing solutions to guarantee the continuous performance of your components such as valves, fittings or pressure regulators.
Hydrogen component validation testing is a critical step in the early development and commercial production of components. Depending on your requirements, our systems can be designed to perform a wide range of tests in compliance with standards such as EC79, R134, and the ISO 12619.
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Precision validation under real-world conditions

Component validation tests require accurate and reliable test conditions to guarantee components can withstand pressure cycles, temperature variations, and hydrogen exposure without compromising structural integrity or leak tightness. Our validation systems replicate real-world conditions to assess material compatibility, fatigue resistance and long-term performance, while providing precise testing data and certificates.
Depending on your application, we engineer systems capable of reaching test pressures of up to 1050 bar, or even higher if required.
Testing can be executed in accordance with standards such as EC79, R134 and ISO 12619, ensuring alignment with applicable regulatory requirements.
Professional component validation testing equipment

Resato’s testing methods

Our advanced validation systems are designed to control pressure and temperature with high precision, enabling safe and accurate component validation testing. Depending on your requirements, our team engineers systems tailored to specific controlled conditions. Both fluids and gases can be used as test media.
Our systems can reach pressures of up to 1050 bar for both pneumatic and hydrostatic testing and can be designed for even higher pressures if required. Based on the certification standards you apply, Resato software delivers reliable testing data and generates certificates for your components.

Cycle Test

Life cycle testing simulates long-term use by exposing a component to repeated pressure cycles. This helps assess fatigue behaviour and performance stability under continuous hydrogen conditions. This confirms the component continues to perform reliably over time.
  • -20°C up to 85 °C

Burst Test

A hydro burst test is a destructive test used to validate a component’s safety factor by gradually increasing pressure, typically using water, until failure occurs. This test is performed to meet safety standards, with controlled pressure build-up for reliable analysis and safe execution.
  • > 3000 bar

Proof test

Proof testing verifies whether a component can withstand the maximum specified test pressure without significant loss. By applying a controlled peak pressure and monitoring the response, the test confirms structural integrity.
  • > 1050 bar

Leak test

Leak testing focuses on detecting even small leak paths or sealing weaknesses under high-pressure hydrogen conditions. By validating leak tightness at operational and elevated pressures, the test ensures consistent sealing performance throughout use.
  • > 875 bar

How is safety guaranteed?

Hydrogen’s highly flammable nature and its low density increase the risk of leaks and malfunctions, making component validation testing essential before integration. Component validation testing identifies weaknesses early, verifying structural integrity, sealing performance and material compatibility under defined hydrogen conditions. Dedicated test cabinets ensure testing is performed in controlled and secured environments. Our systems comply with CE requirements and include advanced safety features such as thick wall designs and protected test setups to safeguard operators. By addressing potential failure modes in a contained environment, you reduce risk in real applications while supporting compliance and a predictable certification process.

Tailored solutions built around your application

1

Do you need a product or a solution?

Hydrogen systems rely on the performance of individual components. Whether you are developing new valve designs or improving efficiency in series production of fittings, Resato supports you in translating your needs into a solution.

2

Asking the right questions

What is your typical test pressure? What kind of testing do you plan to conduct: static pressure test, cycle test, burst test, or other? Do you need to test with hydraulic test fluids or with a specific test gas? By asking the right questions, we gather all the relevant input to ensure alignment from day one.

3

Identifying your technical challenges together

Together, we diagnose your key challenges in validating hydrogen components, such as pressure cycling, leak integrity, or safety margins. Finding a solution that perfectly tackles your challenges and allows for reliable and safe testing under demanding conditions.

4

Finding the right solution for you

A component validation solution specifically designed to meet your requirements and preferred test methods. With our integrated data acquisition software, testing data is recorded and certification documents are generated automatically.

5

Building your solution made to last

Your component validation system is efficiently engineered to integrate seamlessly into your workplace and to align with your safety requirements. With dedicated service, maintenance and hands-on training, we encourage long-term support to maximize the lifecycle of your testing system.

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Interested in component validation testing? Contact Resato

Are you looking for a safe and reliable solution to validate components for hydrogen systems? Resato’s team provides high-pressure testing systems that help you meet safety standards and operate with confidence. Please contact us for more information or request a custom solution.
Contact Resato for more information
Get custom solution

Our team is ready to offer you advice customized to your needs.