Hydrogen Component Validation
Under Extreme Conditions
Hydrogen components face pressure extremes that destroy conventional materials. On Tank valves, fuel cell manifolds, and other pressure vessels operate at pressures up to 700 bar while enduring millions of pressure cycles and temperature swings from -40°C to +85°C. Our hydrogen component pressure testing systems validate these components through their complete development cycle, from R&D prototypes to serial production quality control. We engineer test rigs around your specific component geometry, not catalog specifications.
In addition to standard operating pressures, hydrogen components are typically subjected to significantly higher pressures during validation testing. This includes proof and burst testing to verify structural integrity and safety margins. The exemplary table below provides a typical overview:
| Application | Nominal Pressure | Proof Pressure | Burst Pressure |
|---|---|---|---|
| 300 bar systems | 350 bar | 440–525 bar | 700–1,050 bar |
| 700 bar systems | 700 bar | 875–1,050 bar | 1,400–2,100 bar |
These elevated pressures, combined with the compressibility of gases such as hydrogen or nitrogen, result in high stored energy levels, making safety engineering a critical aspect of any test system. Factors such as internal test volume, media selection, and containment design directly influence the explosion risk assessment and overall system concept.
Our approach ensures that these aspects are addressed from the beginning. By integrating pressure control, temperature conditioning, and precise data acquisition, we deliver test rigs that provide reliable, repeatable results — even under the most demanding hydrogen testing conditions.
Whether you are developing next-generation fuel cell components or validating high-pressure hydrogen systems, we support you with engineered-to-order test solutions that combine safety, flexibility, and performance.
Autofrettage- & Pressure Proof for COPVs
Our test benches are specifically developed for Composite Overwrapped Pressure Vessels (COPVs) and other high-pressure containers. Using filtered water as the test medium, they enable precise autofrettage and pressure hold procedures to validate strength, increase durability, and extend vessel life. With pressure ranges up to 1050 bar, the systems are adaptable to different COPV sizes and volumes. A robust steel safety chamber ensures maximum protection in case of rupture, while the automated pre-filling process minimizes air entrapment for reproducible and safe testing. The integrated tilting device simplifies the handling of large and heavy vessels. Siemens PLC control, combined with an intuitive HMI, provides recipe management, complete data traceability, and reliable acquisition of key parameters, including pressure curves, hold times, expansion…
High-Pressure Burst Test Stand
Components are exposed to extremely high pressures during operation and must be tested for quality and material fatigue. Our high-pressure test bench for burst pressure tests up to 15,000 bar can put any component to the test.
Pressure Testing H2 Components
Our flagship H2 test bench is utilised in research & development. In addition, it is used for constant benchmarking of the manufacturing process to validate H2 component quality. The rig is qualified to test H2 components such as 0n-tank valves, sensors, hoses, fuel cell components and more.
Leak Test Rig up to 1050 bar with Gas (Helium, Nitrogen, H2)
Our state-of-the-art 1050 bar gas leak test stand is a first of its kind in the hydrogen testing industry. Consequentially, leak tests can be performed with 95/5 moulder gas / H2, helium or nitrogen. While a leak is detected by a sniffer unit such as e.g. Inficon P3000XL.
Pressure Pulsation Test Rig up to 600 bar
Our flagship pressure cycle test bench is a powerful and versatile pressure test bench that exposes pressure vessels to changing pressure loads. For example, cooling circuits, sensors, hoses and many others components are put to a lifetime test by applying pressure cycles. Further, a climate chamber and media heating and cooling unit enable real-life conditions. In addition, a controlled media flow can be generated up to 60 l/min.
Contact Us
Our experienced technical sales team will help you implement your project and find a solution tailored to your specifications and requirements. We are represented internationally and can support you and your company worldwide. Our team has completed hundreds of projects many of which involved supporting test facilities with identical equipment. P+P Maschinenbau is your internationally trusted partner.
For the development of H2 components, our sister company, Poppe + Potthoff Maschinenbau GmbH, developed a test bench that covers various test standards and supports us in the design and validation of new components.
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