Dynamic high‑pressure hydrogen leak test rig. 1000 bar.

System architecture

The Dynamic High-Pressure Test Rig is built around a central pressure generation system compliant with the test module and compatible with instrumented testing on plates, coupons, films, gas cylinders, components, and assembled parts. The pressure generation monitoring system meets the requirements of a wide variety of pressurised applications from ambient to 1000 bar. The primary gas medium is hydrogen, making the system specifically suited for hydrogen storage testing applications.

Test module and component handling

Component range

The test module accommodates samples from small flat coupons through to large cylindrical pressure vessels with a minimum sample length of 2 metres. Instrument capacity is rated between 200 and 600 litres. Hydrogen pressure vessels and other test samples are loaded securely into the test module, filled, and pressurised to the desired test pressure using forming gas or a specified gas mix.

Protective enclosures

Protective transparent enclosures provide operator safety throughout the filling and pressurisation sequence, enabling visual monitoring of the test article without exposure to the pressurised environment.

Pressure generation and gas recovery

The pressure generation system provides targeted pressure build-up with full monitoring. Upon completion of each test cycle, pressurised gas is recovered from the test module and stored for reuse — reducing consumption and ensuring safe handling of test media. Gas storage and gas recovery operations are fully covered by safety protection in compliance with EC health and safety directives.

Leak detection methods

The rig supports two established leak detection methodologies:

• Hard Vacuum Method — the test chamber is evacuated to a defined vacuum level prior to pressurisation. Any leak from the test sample is detected against the background vacuum by the mass spectrometer.
• Accumulation Method — tracer gas that leaks from the pressurised sample accumulates within the sealed enclosure over a defined period and is subsequently measured by the mass spectrometer.

The integrated mass spectrometer provides effective, quantified detection of tracer gas under both methods, enabling accurate leak rate assessment of the test article.

Environmental testing capability

An environmental monitoring chamber is supplied as part of the system, enabling testing of components under combined pressure and temperature conditions. The chamber covers both low and high temperature ranges and comes with suitable fixtures and grips for environmental testing. This is relevant for qualification testing where components must demonstrate leak integrity across an operating temperature envelope.

Control, data acquisition, and reporting

The operator dashboard and data acquisition system is an all-in-one solution for test management, instrument control, and data acquisition. The system runs on a supplied PC with Windows 10 or 11 compatibility. Pre-configured test methods with smart defaults allow faster test preparation, while prompted test method sequences ensure consistent outcomes regardless of operator.

The report generator produces full test printouts including date, serial number, and all test data. Export templates are customisable and can be linked with test methods. Result export files are configurable for Laboratory Information Management Systems (LIMS) and include easy-to-configure graphs and control charts for straightforward analysis.

The calibrated gas detection and monitoring system is compatible with standard sensing systems, ensuring compatibility with existing laboratory infrastructure.

Safety and compliance

Safety protection is incorporated across all stages of operation — gas handling within the test module, secure vacuum chamber operation, targeted pressure generation, gas storage, and gas recovery. The system is supplied with CE certification and compliance with named testing standards. The user interface clearly displays system status and position to ensure operator safety throughout the test cycle. Full documentation is provided including a verification report, calibration certificate, quality certificate, operator manual, and spare parts directory.

Construction and service life

The rig is constructed throughout in stainless steel to ensure long service life in demanding laboratory and industrial environments. Where alternative materials are specified, longevity is evidenced through material qualification documentation. The stainless steel build provides resistance to corrosion from process gases and cleaning agents, ensuring consistent performance over the service life of the equipment.