Tank validation testing
How do you guarantee that your hydrogen tanks can handle extreme pressure and challenging conditions? Hydrogen tank validation is a key step in ensuring the safety and performance of hydrogen storage systems. Whether your tanks are used for vehicles or stationary storage, they must meet strict international standards. Resato’s advanced testing systems allow you to validate each tank under controlled, repeatable test conditions. This ensures reliable results and supports safe integration into hydrogen applications.
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What is tank validation testing?
Tank validation testing is the process of verifying the performance and safety of hydrogen tanks. It confirms that tanks can handle pressure variations, long-term use and extreme environmental conditions. Testing includes simulation of real tank cycles and exposure to low temperatures. This helps ensure the tank’s structural integrity, leak resistance and overall durability. Tank validation is required to meet international standards such as R134 and GTR No. 13-2.
How does tank validation work?
Hydrogen tank validation testing consists of cycle tests, burst tests, and leak tests. Each test simulates real-world conditions to ensure reliable and safe performance in each application.
Cycle test
Cycle testing replicates the tank’s lifetime usage by simulating thousands of filling and emptying cycles,
either with fluids or gas. During these tests, the tank is exposed to fluctuating pressure while temperature
is carefully controlled. This underscores test accuracy and allows for the precise measuring of leakage and
pressure levels.
Burst test
A hydro burst test is a destructive test used to validate the tank’s calculated safety factor. The tests are
performed with a fluid, usually water. This test is performed as a R&D or batch test (0.5%) to meet safety and
quality standards. With a burst test the object will be filled with water, the pressure in the object is slowly
increased till the object bursts. Steady pressure build is required to ensure reliable analyzing. Resato’s systems
ensure complete control and safety throughout this destructive testing phase.
Leak test
Following burst testing, leak tests confirm whether the tank maintains stable test pressure without pressure
drop. By pressurizing the tank with gas and monitoring for pressure drops, even the smallest leaks are detected.
Stable temperature conditions ensure precise measurements without external interference or data distortion.
Graphical test data shows pressure behavior under extreme temperature conditions, revealing any structural
imperfections or faults. Leak testing is used in both the R&D and production phase. Resato provides hydrogen
recycling solutions to reduce operational costs and support a more sustainable testing process.
Why is tank validation testing so important?
Hydrogen is kept under high pressure and must be handled with the highest care. Tank validation testing prevents dangerous failures by detecting weaknesses before tanks are used in the field. Our systems help you demonstrate compliance and reduce operational risks, even in demanding environments. By simulating actual operating conditions, we ensure safe performance throughout the tank’s life cycle. Resato’s systems are trusted by leading certification bodies and hydrogen system integrators.
Interested in tank validation testing? Contact Resato
Are you looking for a reliable way to validate your hydrogen tanks? Resato provides high-pressure testing systems tailored to your application. Whether for Type 1 or Type 4 tanks, our experts will help you choose the right solution. Contact Resato for more information or request a free quote. Our team is ready to offer you advice customized to your needs.