NMX‑HCTS‑3K5 / Rev 00 / Hydrogen · ISO 12619 / Noida · India 2026 · Product Page

NMX-HCTS-3K5 · UNDER CONTRACT — GOVERNMENT OF INDIA PROGRAMME

Hydrogen component test system. Fifteen families. Eleven proofs. One facility.

A turnkey hydrogen components testing facility, under contract for a Government of India automotive testing & certification centre: every mandatory test method of ISO 12619, UN ECE R134 and AIS 157 — hydrostatic strength and burst to 3500 bar, gaseous hydrogen from sub-atmospheric to 1050 bar, pre-cooled to −40 °C — across nine independently controlled, blast-rated test chambers with a closed-loop gas train. Engineered and being built at Noida. See all our hydrogen test equipment.

Enquire — hydrogen test systems Capability sheet (PDF)

Representative render — hydrogen components testing facility: a row of blast-rated stainless-steel test chambers with circular viewing ports, high-pressure gas panels and tubing runs, skid-mounted gas cylinders and a glazed control room in an industrial test hall

Fig · 01 The facility — representative render: test chambers, gas train and control room

Hydrostatic & Burst

3500bar · hydraulic intensifier

H₂ Service

1050bar · from sub-atmospheric

Pre-Cooled H₂

−40°C · fuelling protocol

Test Chambers

9multi-DUT · independent

Test Methods

11across 15 component families

ISO 9001 / 14001 Under contract — Government of India programme ISO 12619 · UN ECE R134 · AIS 157 ATEX/IECEx · NFPA 2 · PESO practice Noida · India

Overview

Hydrogen is the easy part. Proving the components is the work.

A hydrogen vehicle lives or dies by parts you can hold in one hand — regulators, valves, injectors, relief devices, lines and fittings. Before any of them is allowed near a road, a standard demands proof: tens of thousands of pressure cycles, burst margins, leak rates counted in cubic centimetres per hour, cold hydrogen, hot chambers, corrosion and time. This facility exists to produce that proof.

Representative render — inside a single blast-rated stainless-steel test chamber: small hydrogen fuel-system components fixtured to a manifold with high-pressure tubing and instrumentation lines, seen through the open chamber front

Fig · 02 The duty — components on test behind blast-rated steel (representative render)

The system is a complete certification workshop for compressed-hydrogen fuel-system components, under contract for a Government of India automotive testing & certification centre through an Indian heavy-engineering public-sector enterprise. Its scope is the full mandatory test matrix of ISO 12619 (Parts 1–16), UN ECE R134 and AIS 157 — eleven test methods applied across fifteen component families, from pressure regulators and cylinder valves to TPRDs, excess flow valves, hoses, rigid and flexible fuel lines, filters, fittings and HFCV (hydrogen fuel-cell vehicle) components.

The numbers set the architecture. Hydrostatic strength and burst proofs run to 3500 bar from a hydraulic intensifier; gaseous hydrogen service spans sub-atmospheric to 1050 bar from a compressor and booster station; hydrogen arrives at the device under test (DUT) at temperatures down to −40 °C, matching the fuelling protocol; and blends from 5% hydrogen in nitrogen or helium are mixed automatically to within 1% of full scale. Nine blast-rated chambers run their tests independently, so a 50,000-cycle endurance on one DUT never holds up a burst test on another.

A certification lab cannot argue with its own data. Everything this facility produces — every bar, every cycle, every leak rate — is signed, timestamped and traceable. That is the product.

Under Contract · In Execution

A won programme, being built

The facility is under contract following open national competition, with detailed engineering in progress at Neometrix Noida — test-requirement matrices at controlled revision, the electrical design basis issued, and long-lead gas-train packages in procurement.

Standards-Led · By Design

The standard is the specification

Every rig parameter traces to a clause: cycle counts, pressure ratios, temperature ladders and leak limits come straight from ISO 12619, UN ECE R134 and AIS 157 — and where documents differ, the contract resolves the gap in favour of the test standards.

Closed Loop · Gas Economics

Hydrogen is recovered, not vented

A closed-loop recovery and recycling train returns test gas to service instead of venting it, with three skid-mounted make-up cylinders (hydrogen and two certified blends) covering the balance — testing economics a working certification lab can sustain.

Architecture

A gas train, a test floor, and a paper trail that survives audit.

The diagram below is the facility’s process architecture as the engineering defines it — the closed-loop gas train, the nine-chamber test floor, the separate 3500-bar hydrostatic branch, and the safety and data systems wrapped around them.

FIG · 03PROCESS ARCHITECTURE · CLOSED-LOOP GAS TRAIN · NINE-CHAMBER FLOOR

Fig · 03 From make-up cylinders through blending, compression and pre-cooling to nine independent chambers — and back through recovery

Arc · 01

The Gas Train

Three skid-mounted make-up cylinders — hydrogen, hydrogen-nitrogen and hydrogen-helium blends, each ≥50 L at ≥200 bar with a certificate of analysis — feed an automatic blending skid that holds mixture accuracy within 1% of full scale at supply pressure, then a compressor and booster station that regulates gaseous test pressure from sub-atmospheric to 1050 bar. A pre-cooling stage delivers hydrogen at the DUT down to −40 °C; and a dedicated nitrogen purge system with its own lines, valves and vents inerts any circuit before hands touch it.

Arc · 02

The Test Floor

Nine chambers — blast-rated, gas-tight, stainless-steel — each with independent control and monitoring, so nine devices under test run nine different programmes at once. One of the nine is a dedicated burst bay on the hydraulic branch; around them sit the specialist rigs the matrix demands: a pneumatic-strength bench, a slow-strain-rate stress-corrosion-cracking rig in a hydrogen atmosphere, extreme-temperature pressure-cycling from −40 to +85 °C, and permeability measurement cells for hoses and lines.

Arc · 03

The 3500-Bar Branch

Burst and hydrostatic proofs are hydraulic, not pneumatic — a deliberate piece of physics, since liquid stores a fraction of the energy of gas at the same pressure. A hydraulic intensifier generates up to 3500 bar with programmable ramps (the standards ask for rates up to 1.4 MPa/s and holds of three minutes or more), drives components to 2.5× — and for flexible lines and fittings 4× — working pressure, and records the burst event at high speed for the certificate.

Arc · 04

Safety & Data

Electricals in classified zones are ATEX/IECEx; sixteen-point hydrogen detection, fan-proven dilution keeping any release below 25% of the lower explosive limit, blast-relief panels, vent stacks with flame arrestors, nitrogen purging and a hardwired emergency shutdown follow NFPA 2 and PESO practice under a HAZOP-led safety case. The PLC/SCADA layer runs every station through distributed I/O and produces timestamped, digitally signed records — archived for ten years.

Holding a hydrogen component, valve or fuel-system test requirement? Send it across — clause-by-clause response within two working days · [email protected]

Send tender spec

Specifications

Reference specification, as contracted.

The parameters below reflect the facility as engineered under the live contract. Chamber count, pressure classes and the method set are re-scoped against your specification.

Full specification — expand

Product	Comprehensive hydrogen components test system — turnkey design, manufacture, installation, commissioning, training and documentation of a certification-grade testing facility
Standards	ISO 12619 (Parts 1–16) · UN ECE R134 · AIS 157 · specification gaps resolved in favour of the test standards · safety practice per NFPA 2, ATEX/IECEx directives and PESO guidelines · functional safety per IEC 61511
Component Families	Fifteen: pressure regulator · check valve · manual cylinder valve · automatic valve · gas injector · pressure indicator · pressure relief valve · PRD & thermally activated PRD (TPRD) · excess flow valve · housings & hoses · rigid fuel line · flexible fuel line · filter · fittings · HFCV components
Test Methods	Eleven mandatory: continued operation · hydrostatic strength & burst · leakage · pressure impulse · pre-cooled hydrogen exposure · pneumatic strength · accelerated life · injector bench durability with hot/cold static & thermocycle · permeability · extreme-temperature pressure cycling · stress corrosion cracking
Pressure Envelope	Hydrostatic strength & burst to 3500 bar (350 MPa), hydraulic intensifier, programmable ramps (≤1.4 MPa/s per standard), holds ≥3 min · gaseous hydrogen service sub-atmospheric to 1050 bar (105 MPa) via compressor + booster station
Endurance Duty	Cycle counts per component class — 50,000 (regulators, automatic valves) · 20,000 (check valves, TPRDs, filters) · 100,000 (fittings, low-pressure flexible lines) · TPRD split-temperature protocol 2,000 cycles at ≥82 °C + 18,000 at 57 °C · burst-strength retention ≥80% of virgin after cycling
Leak Measurement	Temperature ladder −40/−20 °C · +20 °C · +85/120 °C at pressure fractions of working pressure · limits <10 Ncm³/h hydrogen-equivalent (<2 Ncm³/h for PRDs) · helium-vacuum and immersion methods · blend results converted to 100% hydrogen equivalent per ISO 12619-2
Test Media	100% hydrogen · hydrogen-inert blends ≥5% H₂ balance N₂ and/or He · automatic blending ±1% of full scale (mass-flow-controller skid) or certified pre-mixed · pre-cooled hydrogen to −40 °C at the DUT
Test Chambers	Nine multi-DUT chambers/compartments · blast-rated · gas-tight · SS316 construction · independent control & monitoring per DUT · fabricated in-house at Neometrix Noida
Specialist Rigs	Dedicated burst bay (one of the nine chambers) · pneumatic-strength bench (ISO 12619-7/-14) · slow-strain-rate SCC rig in hydrogen atmosphere · extreme-temperature pressure-cycling chamber −40 to +85 °C · permeability measurement cells · accelerated-life stations holding pressure ±0.7 MPa and specimen temperature ±1 °C
Gas Economics	Closed-loop gas recovery / recycling system · three skid-mounted make-up cylinders ≥50 L at ≥200 bar (H₂ · H₂+N₂ · H₂+He) with certificates of analysis · dedicated nitrogen purge and inert-gas system
Control & Data	Centralised PLC + SCADA with distributed test-station I/O · DAQ of pressure, flow, cycles and temperature · recipe management · PDF/Excel/CSV reporting · all records timestamped and digitally signed · archive ≥10 years · role-based access · engineering workstation
Safety Systems	ATEX/IECEx-classified electricals · sixteen-point hydrogen detection · safety PLC / ESD chain with alarm panels · fan-proven dilution <25% LEL · blast-relief panels · vent stacks with flame arrestors · nitrogen purge interlocks · hydrogen-suitable fire suppression · HAZOP-led safety case with regulatory liaison
Electrical Basis	415 V 3-phase TN-S incomer · power-distribution, PLC/SCADA, safety (gas detection & ESD) and UPS panel line-up · IP54 indoor / IP65 outdoor enclosures · FRLS cabling · IEC/IS 60079 hazardous-area practice · seismic design basis per IS 1893 (site-specific) · IEC 60364 / 61010 / 61511 / 60204 / 62443 referenced
Calibration	All measuring instruments calibrated with NABL / ISO 17025-traceable certificates, included in the documentation pack
Acceptance Route	Factory acceptance testing at Neometrix works (customer-witnessed) → installation → site acceptance testing demonstrating all eleven methods · structured operator and maintenance training · O&M documentation in hard and soft copy
Support	24-month comprehensive warranty · 10-year spares and service support with an India-based service team · recommended consumables list per test method
Environment	Designed for 10–45 °C site temperature and 10–90% RH · indoor/outdoor packages as applicable
Status	Under contract — in execution · detailed engineering and long-lead procurement in progress at Neometrix Noida · configurable to customer specification

PDF · 1 page

Hydrogen Component Test System — Capability Sheet

Tender Response

Send your specification — method-by-method compliance matrix in two working days

Variants

One test discipline, scaled to the requirement.

Requirements call this a hydrogen component test system, a components qualification facility or an R134 test bench. The architecture scales to all of them.

Var · 01

The Contracted Facility

The configuration on this page — eleven methods, fifteen component families, nine chambers, 3500/1050 bar, −40 °C — engineered as a complete certification workshop for a national automotive test programme.

Var · 02

Single-Method Benches

The same engineering packaged as standalone rigs — a burst and hydrostatic stand, a leakage bench with temperature ladder, a pressure-cycling system or an SCC rig — for laboratories building capability method by method.

Var · 03

Other Gas Regimes

The component-testing discipline applied to other fuel gases and standards — CNG components to ISO 15500 and ECE R110, oxygen equipment, nitrogen and helium service — drawing on Neometrix’s existing gas-systems line.

Var · 04

R&D Configurations

Development-duty versions for OEM and research programmes — fewer chambers, wider parameter freedom, the same signed data chain — where the goal is design iteration before certification rather than the certificate itself.

Applications

Where it serves.

Wherever a hydrogen component needs a number someone will stand behind.

A · 01National test agencies — type-approval of hydrogen vehicle fuel-system components

A · 02Vehicle OEMs & Tier-1 suppliers — development and design-validation testing

A · 03Safety-device makers — TPRD, PRV and excess-flow-valve qualification programmes

A · 04Hose & line manufacturers — endurance, permeability and burst evidence

A · 05Materials & research institutes — hydrogen embrittlement and stress-corrosion studies

A · 06Production plants — batch acceptance and quality-assurance testing

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 How is this different from a hydrogen cylinder burst chamber or a leak test rig?

Scope, and what the result is for. Our burst chamber for hydrogen cylinder testing destroys storage cylinders; our dynamic high-pressure hydrogen leak test rig answers one question — does it leak — about vessels and assemblies. This facility is a different class of machine: a complete certification workshop for the small components of the fuel system itself, running all eleven mandatory methods of ISO 12619, UN ECE R134 and AIS 157 — from endurance cycling and burst to permeability and stress corrosion — because a type-approval file needs every one of those numbers, not just one.

Q · 02 How do ISO 12619, UN ECE R134 and AIS 157 relate to each other?

They are three views of the same physics. ISO 12619 is the component standard — sixteen parts: general requirements and shared test methods up front, then a part per component family, each defining its own test set and limits. UN ECE R134 is the international vehicle regulation for hydrogen safety, which references component-level proofs from the vehicle side. AIS 157 is India’s automotive industry standard implementing those requirements nationally. A component headed for an Indian hydrogen vehicle must satisfy all three — which is why the facility’s method matrix maps every test to its clause in each document, and why the contract resolves any conflict in favour of the standards themselves.

Q · 03 Why 3500 bar hydraulic but 1050 bar gaseous?

Stored energy. A litre of water at 3500 bar holds a small fraction of the energy of a litre of gas at the same pressure, because liquids barely compress — so the standards deliberately prescribe hydraulic media for strength and burst proofs, and the facility generates its highest pressures with a hydraulic intensifier behind a blast-rated bay. Gas is reserved for the duties that need real hydrogen physics — leakage, permeation, embrittlement, cold-fuelling exposure — where 1050 bar covers the service and proof conditions of 700-bar-class vehicle systems. Same components, two disciplines, each doing the dangerous thing the safer way.

Q · 04 What does the hydrogen safety case involve?

Layers, each assuming the one before it fails. Electricals in classified zones are ATEX/IECEx-rated so equipment cannot become an ignition source. Sixteen hydrogen detection points watch for any release; ventilation is fan-proven and sized to dilute a release below 25% of the lower explosive limit before it matters. Blast-relief panels, vent stacks with flame arrestors and nitrogen purge systems manage energy and inerting; an emergency shutdown chain closes fail-safe valves on detection, fan failure or a pressed button. The whole arrangement follows NFPA 2 and PESO practice and is developed through a formal HAZOP into a safety case — with the more stringent requirement prevailing wherever documents differ.

Q · 05 Do nitrogen or helium blends substitute for testing with real hydrogen?

No — and honest measurement is exactly why the facility does both. Inert blends make many duties safer and cheaper to run, and ISO 12619-2 permits them for leak measurement provided the result is converted to a 100% hydrogen equivalent, which is how the facility reports every blend-based leak rate. But some questions only hydrogen answers: embrittlement, permeation through hose walls, cold-fuelling exposure at −40 °C. So the gas train supplies both — certified blends from 5% hydrogen upward, mixed to within 1% of full scale, and 100% hydrogen up to 1050 bar — and the test method, not convenience, decides which one flows.

Q · 06 What makes test data “certification-grade”?

Traceability at every link. Instruments are calibrated with NABL / ISO 17025-traceable certificates before a single reading counts. Every record the SCADA produces is timestamped and digitally signed at source, so a cycle count or burst pressure cannot be quietly edited afterwards; reports export to PDF, Excel and CSV with the raw data archived for at least ten years; and access is role-based, so who did what is part of the record. The facility’s acceptance route is built the same way — factory acceptance at our works, then site acceptance demonstrating all eleven methods — because a certificate is only as strong as the audit trail behind it.

↗

The hydrogen test line from Neometrix.

Engineered and manufactured at our Noida facility for hydrogen energy and mobility programmes.

↗ Hydrogen Powertrains

Hydrogen Piston Engine Test Bench

Containerised dual-fuel hydrogen engine test cell.

↗ Hydrogen Storage

Burst Chamber for Hydrogen Cylinders

Destructive burst testing of storage cylinders.

↗ Hydrogen Integrity

High-Pressure Hydrogen Leak Test Rig

Dynamic leak testing of vessels and assemblies.

Browse all Neometrix product lines.

Get a quotation

Send your hydrogen
test requirement.

The Projects desk replies within two working days with a clause-by-clause response and a budgetary quotation. Write to [email protected] or use the form.

Enquire — hydrogen test systems Capability sheet (PDF) +91 7777 876 876

ISO 9001 / 14001 UNDER CONTRACT — GOVT OF INDIA PROGRAMME ISO 12619 · UN ECE R134 · AIS 157 MADE IN NOIDA · INDIA