Hydrogen Applications

Complex test requirements - systematic test solution

Hydrogen produced in a climate-neutral way is a central key to the energy turnaround. It can substitute fossil fuels and help to sustainably reduce CO2 emissions. Numerous innovative hydrogen and fuel cell applications are therefore being developed at present in a highly dynamic market. However, these must not only make ecological sense, but also be particularly safe for the user. As an experienced testing technology specialist, we have developed a unique, multifunctional and modular H2 safety concept together with TÜV-Rheinland Industrieservice GmbH.

Our simple solution for safe testing

Hydrogen is flammable and highly explosive. In order to optimally protect members of staff, test equipment and the test specimen, test facilities for H2 applications must therefore be designed to be particularly safe. Since there are still no generally applicable specifications for the planning and design of the systems, we have developed our own safety kit together with TÜV-Rheinland Industrieservice GmbH. This enables turnkey solutions for tests with hydrogen and is divided into three levels.

The basics: Analysing and understanding risks

First, we analysed and systematised risks and possible effects of H2 tests - from low-risk tests with small leakage to high-risk applications with huge levels of hydrogen leakage. We take this knowledge and the customer's specific requirements for the test and the test material, and we create an individual risk assessment. We use the result as the basis for planning a safe testing solution.

Safety concept: Defining and standardising measures

With the help of the safety concept, effective technical solutions can be derived to minimise the identified risks. Depending on the individual risk, we recommend safe individual measures or a coordinated combination of different measures. For the user, we provide clear answers and offer technical solutions to all questions about the risks of H2 testing.

Test solutions: Developing and realising test systems

Thanks to modularity, we have been able to implement safe H2 testing solutions for the customer simply, quickly and tailor-made: Whether it is a compact test chamber for individual components, chambers for assemblies, or large-volume test benches for hydrogen-powered vehicles such as vans and trucks.

A well-thought-out safety concept

Test solution for fuel cell vehicles and direct hydrogen burners

Heat, cold, humidity, wind and dust: Hydrogen-powered vehicles and their components have to pass the same environmental simulation tests as vehicles with combustion engines or electric drives. However, they require significantly higher testing equipment safety standards. The reason is, on the one hand, the high flammability and high explosiveness of hydrogen, which pose a danger to members of staff, the test specimen and the test facility. On the other hand, in the case of vehicles with hydrogen-powered fuel cells, three different sources of danger must be considered, both individually and in combination.

1. H2 tank 
The tank stores gaseous hydrogen under high pressure
Danger Uncontrolled H2 release
  Ignition of an explosive H2 atmosphere
2. Fuel cell stack
Conversion of the energy stored in the hydrogen into electrical energy

Uncontrolled H2 release

  Ignition of an explosive H2 atmosphere
3. Lithium-ion battery 
Buffer storage for the generated electrical energy
Danger Thermal runaway with uncontrollable consequences
  H2 release and ignition of an explosive H2 atmosphere

The complex hazards that arise during tests of fuel cell-powered vehicles, but also with direct combustion engines, require a safety concept that is optimally adapted to them. This includes organisational measures, measures to avoid hazards, and measures to remedy hazardous situations that have arisen. Weisstechnik offers you the appropriate combination of suitable measures, based on the standardised risk assessment and customer-specific specifications.


Prevention ot the emergence of hazards

Technical solutions that detect and prevent the emergence of hazards at an early stage.

Elimination of existing hazards

Measures to limit the hydrogen input so that critical situations that arise do not lead to fire or explosion.

Operator obligations

Specifications and guidelines for the safe planning and execution of tests with fuel cells.