Situation
Tyne Pressure Testing has successfully completed gas function and leak testing on a prototype hydrogen fuel cell feed system. This system was developed as part of an initiative to advance engineering solutions for zero-emissions technologies.
Hydrogen is a promising sustainable alternative to fossil fuels, however its storage at high pressure within a fuel cell poses safety challenges, especially in the event of a leak. Tyne Pressure Testing was tasked with validating the functionality and integrity of the fuel cell feed system, through monitoring the required pressure changes within the system to ensure it was fit for purpose.
The hydrogen fuel cell feed system consisted of a series of interconnected stages designed to regulate pressure. The test reduced the extremely high storage pressure of 700 bar through multiple pressure reduction steps, ultimately delivering the low output pressure of 10 bar required to run the hydrogen fuelled engine.
Approach
As pressures changed within the system, Tyne Pressure Testing employed a robust testing methodology to replicate the hydrogen fuel cell feed system. The testing process involved gas testing using a mix of nitrogen and helium, as this is more searching and safer than using hydrogen when it comes to verifying the integrity of the system. Calibrated pressure transducers were used to monitor the internal pressures at various stages within the system. This type of test is typically conducted in our testing bays measuring up to 6 metres long.
The system was tested in stages, with each stage being individually pressure tested to ensure they held the required pressure and functioned correctly. Additionally, once all components were validated, the complete fuel cell feed system was assembled and tested to ensure it functioned as intended and produced the correct output pressure. A mass spectrometer was used to check each stage of the system for gas leaks.
Ensuring the safety and reliability of hydrogen fuel cell systems is crucial for advancing sustainable energy solutions. This project underscores Tyne Pressure Testing’s commitment to supporting innovation in the renewable energy sector, paving the way for a cleaner, greener future in the automotive and engineering industries.
Result
Tyne Pressure Testing helped successfully confirm that the system was fit for purpose.
This project reinforces Tyne Pressure Testing’s capabilities to support the renewable sector and the development of innovative technologies. By ensuring the safety and reliability of this hydrogen fuel cell feed system, Tyne Pressure Testing is helping pave the way for the adoption of sustainable energy solutions in the automotive and wider engineering industries.