NMX‑HCY‑30 / Rev 00 / hydrogen test systems / cycling · conditioning 2026 · Product Page

NMX-HCY-30 · ENGINEERED TO ORDER — HYDROGEN PRESSURE-CYCLING TEST FACILITIES

The whole life. Before the first fill.

Name: Hydrogen Pressure-Cycling Test Facility
Brand: Neometrix

A hydrogen tank lives by being filled and vented — thousands of times — and every cycle works the structure. Burst proves the margin once; leak proves it is tight; cycling proves it survives a lifetime. This facility runs that lifetime, compressed into weeks: intensifier-driven hydraulic cycling to the standards’ counts, real hydrogen gas cycling with pre-cooled −40 °C fills, and conditioned cycle blocks at the −40 / +85 °C extremes inside integrated climatic chambers — all in bunkered, remotely operated cells with hydrogen detection and nitrogen inertisation, because the facility assumes a tank will one day fail and makes that failure boring. It completes a family this site carries as delivered machines: the export-delivered burst chamber and leak rig, and the contracted component bench. Engineered to order — no delivered cycling facility is claimed.

Enquire — cycling facility Capability sheet (PDF)

Illustrative image, not a delivered facility — a hydrogen pressure-cycling test cell: a heavy concrete-and-steel cell with its thick shielded door open, a white composite cylinder mounted on a cradle connected to a stainless manifold with fine high-pressure tubing, an unlit warning-light mast, and a small control-room window in the far wall, no people and no text

Fig · 01 The cycling cell — a tank on its cradle, the manifold connected, and a lifetime of fills about to begin — illustrative, not a delivered facility

Cycles

tens of thousandsthe standards’ counts

Pressure

350 / 700 bar classramps · holds · profiles

Media

hydraulic + H2 gaspre-cooled fills to −40 °C

Conditioned

−40 / +85 °C classchamber-integrated

Built

to ordercells · plant · commissioning

ISO 9001 / 14001 Engineered to order GTR-13 · ISO 19881 pattern Hydrogen test house Noida · India

Overview

Every fill works the tank — so run them all first.

A composite hydrogen tank is not a passive vessel; it is a structure that breathes. Every fill stretches the overwrap, works the liner, loads the boss and the valve threads; every vent lets them relax. One cycle is nothing. Ten thousand are a life — and fatigue is precisely the kind of failure that hides from single proofs. So the type-approval rules split the burden across three machines: a burst test for margin, a leak test for tightness, and the cycling test — the long one, the honest one — for the lifetime itself.

Illustrative image, not a delivered facility — a hydraulic pressure-cycling intensifier skid: two cylindrical pressure intensifiers on a grey frame, a stainless valve manifold with fine high-pressure lines, blank round gauges, an accumulator bottle, and a floor-standing control cabinet with one blank dark screen, clean plant-room floor, no people and no text

Fig · 02 The cycling plant — intensifiers and profile control, driving fill after counted fill, around the clock — illustrative, not a delivered facility

Hydraulic cycling carries the count. The standards’ big numbers — tens of thousands of cycles — are driven hydraulically: intensifier and pump sets take each specimen from empty to test pressure and back under profile control, ramps and holds shaped to the rule, cycle after counted cycle, day and night. Multiple tanks share parallel manifolds; every profile is logged; and a pressure-decay trip watches each specimen so the moment one begins to fail — a weep, a leak, a crack — the plant catches it, isolates it, and preserves the evidence.

Gas cycling tells the thermal truth. A fast fill heats a tank — compression does work on the gas — and a fast vent chills it; hydraulic cycling cannot reproduce that. So the facility also cycles with real hydrogen: supply and compression, recovery or safe venting through the stack, and pre-cooled fills to the −40 °C refuelling pattern — the same protocol the dispenser will one day use — with in-tank temperatures recorded through every fill.

Conditioning moves the whole test to the extremes. Materials change with temperature — resins stiffen, liners harden, seals relax — so the rules demand cycle blocks at the −40 / +85 °C class extremes. The facility integrates climatic chambers from our delivered chamber line around the specimens, so the cycling continues while the environment holds at its worst — the same two-franchise pattern as our conditioned impact machines: the test rig and the chamber, engineered as one.

The facility is designed backwards from one assumption: that some tank, some day, will fail inside it. Everything — the cells, the remote operation, the detection, the inertisation — exists so that when it happens, it is data, not drama.

The Third Leg

Burst, leak — and the lifetime

The burst chamber and leak rig of this family are delivered, export machines on this site. Cycling is the third proof — the one that takes weeks and tells the longest truth.

Assume Failure

Make it boring

Bunkered cells, remote operation, hydrogen detection, nitrogen inertisation, decay trips — a specimen failure is expected, contained and recorded, never an event.

A Lifetime In Weeks

Counted, logged, signed

Every cycle counted, every profile logged, every temperature kept — the certification agency’s evidence, produced by the machine as it runs.

Architecture

Mount, cycle, certify.

The schematic follows the test — mount and connect, cycle, condition, survive and certify — and shows the facility that runs it: the cycling plant, the gas loop, the conditioning, and the cell and safety case around everything.

FIG · 03HCY ARCHITECTURE · CYCLING PLANT / GAS LOOP / CONDITIONING · CELL & SAFETY

Fig · 03 A lifetime of fills compressed into weeks — run remotely, watched continuously, inside a cell that assumes the worst

Arc · 01

Cycling Plant

Intensifiers and pump sets under profile control — ramps, holds, counted cycles to the standards’ numbers — with parallel manifolds and pressure-decay trips.

Arc · 02

Gas Loop

Real hydrogen fill-vent cycles — supply, compression, recovery and safe venting — with pre-cooled inlets to −40 °C and in-tank temperatures recorded.

Arc · 03

Conditioning

Climatic chambers integrated around the specimens — cycle blocks at the −40 / +85 °C class extremes, from the delivered Neometrix chamber line.

Arc · 04

Cell & Safety

Bunkered cells rated for the stored energy — remote operation, hydrogen detection, nitrogen inertisation, interlocks and vent stacks.

Have a hydrogen cycling, conditioning or test-laboratory requirement? Send the specimens, the standards and the cycle counts — a clause-by-clause compliance matrix within two working days · [email protected]

Send tender spec

Specifications

Reference facility, built to the standard.

The parameters below describe a reference installation. The cell count, plant rating, gas loop and conditioning envelope all follow from three givens: the specimens, the standards they certify to, and the throughput the laboratory needs.

Illustrative image, not a delivered facility — conditioned hydrogen cycling: a white composite cylinder inside an open climatic test chamber, heavy frost on the stainless high-pressure line entering through a side gland, fine instrumentation tubing, the chamber interior walls finely perforated, cold vapour drifting at the sill, no people and no text

Fig · 04 Cycling at the extremes — the chamber holds the cold while the plant keeps counting — illustrative, not a delivered facility

Where cycling facilities go wrong

In the years and the seconds, not the pressure. A plant sized for the brochure rather than the duty slows until a certification campaign takes quarters instead of weeks; profiles that overshoot write invalid cycles the auditor strikes out; a facility that cycles only hydraulically misses the thermal story a real fill writes into the tank; a decay trip that reacts in minutes instead of seconds lets a failing specimen destroy its own evidence; and a cell designed as an afterthought turns the one failure the whole facility exists to catch into an emergency.

So the plant is sized to the campaign — cycle rate × specimen count × uptime — with profiles proven against the rule’s tolerances; gas cycling stands beside hydraulic cycling, each doing what only it can; the trip logic watches every specimen at the pressure scan rate, isolates in seconds and preserves the failure as data; and the cell is designed first, not last — rated for the stored energy, inertised, detected, remote — so the facility keeps its central promise: failure is boring here.

Full specification — expand

System	Hydrogen pressure-cycling test facility — hydraulic cycling plant, hydrogen gas loop, conditioned cycling, rated cells & controls; engineered, built, installed, commissioned & proven
Function	Runs a tank’s entire pressure life before its first real fill — the third proof of the type-approval triad, beside the delivered burst & leak machines
Cycling Plant	Intensifier & pump sets under profile control — ramps, holds & counted cycles to the standards’ numbers (tens of thousands); parallel specimen manifolds; water / glycol media
Pressure Classes	350 / 700 bar vehicle classes & industrial equivalents — test pressures per the GTR-13 / ISO 19881 pattern rules, publicly stated
Failure Watch	Pressure-decay trips at scan rate on every specimen — isolate in seconds, preserve the evidence; leak-before-break monitored throughout
Gas Cycling	Real hydrogen fill-vent cycles — supply, compression, recovery or safe venting via stack; pre-cooled fills to −40 °C; in-tank temperature recording
Conditioned Cycling	Cycle blocks at the −40 / +85 °C class extremes — climatic chambers from the delivered Neometrix line, integrated around the specimens
Specimens	Type III / IV cylinders & tanks, valves, regulators, hoses & on-tank components — each cycled to its own standard on the same plant
Cell & Safety	Bunkered cells rated for the stored energy; remote operation; hydrogen detection; nitrogen inertisation; interlocks; vent stacks — failure expected, contained, boring
Evidence	Cycle counts, pressure profiles, temperatures & decay events logged per specimen — the certification agency’s record, produced by the machine
Service	Commissioning & proving; calibration, seals & wear parts, plant AMC; capacity extensions as campaigns grow
Sourcing	Compressors, intensifier cores & proprietary sensors are bought-in certified items; Neometrix engineers the cells, cycling plant, gas loop, conditioning, controls & installation
Status	Engineered to order · quoted against a hydrogen pressure-cycling test-rig requirement · grounded in the delivered hydrogen-test, high-pressure & climatic-chamber franchises · no specific delivered cycling facility is claimed on this page

PDF · 1 page

Hydrogen Pressure-Cycling — Capability Sheet

Tender Response

Send specimens, standards & counts — compliance matrix in two working days

Variants

One discipline, the facility the campaign needs.

Requirements call it a cycling rig, a fatigue test bench, a life-test facility, or a certification laboratory. The discipline — a lifetime of counted cycles, safely contained — is common; the facility follows the specimens and the standards.

Var · 01

Hydraulic Cycling Cells

Intensifier-driven cells carrying the big counts — multiple tanks on parallel manifolds, profile-controlled, decay-tripped, running around the clock.

Var · 02

Hydrogen Gas-Cycling Systems

Real-fill cycling with supply, compression, recovery and venting — fast-fill heating captured, −40 °C pre-cooled inlets to the refuelling pattern.

Var · 03

Conditioned-Cycling Integration

Chamber-integrated cycling at the hot and cold extremes — the delivered climatic line wrapped around the pressure life, engineered as one machine.

Var · 04

Component-Cycling Benches

Valves, regulators, hoses and on-tank components cycled to their own standards — the small-specimen benches beside the tank cells, on the same plant.

Applications

Where the lifetime gets proven.

Wherever a hydrogen vessel or component must show its whole life before entering service.

A · 01Cylinder & tank manufacturers’ test laboratories

A · 02Automotive research & certification agencies

A · 03Fuel-cell vehicle & storage-system programmes

A · 04Refuelling-component & valve makers

A · 05Research institutes & national laboratories

A · 06Defence & aerospace hydrogen programmes

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 Why is cycling its own test — is burst not enough?

Because margin and lifetime are different truths. The burst test asks one magnificent question — how much more than working pressure can this tank take? — and a healthy answer proves the design has headroom. But fatigue does not care about headroom; it cares about repetition. A composite tank is a structure that breathes: every fill stretches the overwrap fibres, works the polymer liner, loads the metal boss and its threads; every vent relaxes them. Damage from one cycle is unmeasurable — and cumulative. Micro-cracking in the resin, liner creep, fretting at the boss interface: these grow over thousands of cycles and would never show in a single proof, however severe. That is why the type-approval rules — the GTR-13 / ISO 19881 pattern family — require the cycling test as its own discipline, with counts in the tens of thousands chosen to bound a vehicle’s refuelling life with margin, at ambient and at the temperature extremes. Burst proves the tank is strong. Cycling proves it stays strong for every fill it will ever take — and the facility exists to run that whole life, safely, before the first real one.

Q · 02 Why both hydraulic and gas cycling?

Because each tells a truth the other cannot. Hydraulic cycling is the workhorse of the count: an incompressible medium stores very little energy, so driving tens of thousands of cycles with water or glycol is fast, efficient and dramatically safer — which is exactly why the standards let the big numbers run hydraulically. But a hydraulic cycle is thermally silent. A real hydrogen fill is not: compressing gas into the tank does work on it and heats it — a fast fill can push internal temperature toward the material limits, which is why real dispensers pre-cool their gas toward −40 °C — and a fast vent chills the same structure. Those thermal swings stress liner, resin and boss in ways pressure alone does not. So the standards require gas cycling too: real hydrogen fills on the facility’s gas loop — supply, compression, recovery or safe venting through the stack — with pre-cooled inlets replicating the refuelling pattern and in-tank temperatures recorded through every fill. The two plants stand side by side and split the work: hydraulics carry the lifetime’s count, gas carries the lifetime’s heat.

Q · 03 What does conditioned cycling add?

The service envelope’s honest corners. A hydrogen tank certified for the road must live anywhere the road goes — a winter high-altitude morning, a summer coastal afternoon — and its materials do not behave identically across that span: resins stiffen and micro-crack more readily in deep cold, polymer liners harden, seals and boss interfaces relax and creep in heat. A lifetime proven only at laboratory temperature is a lifetime proven only for laboratories. So the rules demand cycle blocks at the extremes — the −40 / +85 °C class — and the facility answers with integration rather than improvisation: climatic chambers from our delivered chamber line are engineered around the specimen stations, with the high-pressure lines entering through conditioned glands, so the cycling plant keeps counting while the environment holds at its worst for days at a stretch. It is the same two-franchise pattern as our conditioned impact machines — the test rig and the chamber designed as one instrument — and it is precisely the configuration current certification-agency requirements describe: not a rig near a chamber, but a lifetime run inside one.

Q · 04 What happens when a specimen fails mid-campaign?

The facility’s finest hour — conducted entirely by machinery. Failure during cycling is not a malfunction of the test; for specimens pushed to extended counts it is often the point of the test, and the facility is designed backwards from the moment it happens. Detection is first: a pressure-decay trip watches every specimen at the plant’s scan rate, and the signature of a weep, a leak or a crack — pressure falling faster than the profile explains — trips isolation in seconds: the failing specimen’s manifold valve closes, the plant sheds it, and its siblings keep cycling undisturbed. Containment is second: everything happens inside a bunkered cell rated for the stored energy, operated remotely, with hydrogen detection above and nitrogen inertisation available — on the gas-cycling side, the cell’s atmosphere management and vent stack are part of the safety case from the first drawing. Evidence is third: the trip preserves the failure rather than obliterating it — cycle count at failure, the decay trace, temperatures, the specimen’s state — because a failure whose history is lost teaches nothing and certifies less. The promise the whole facility keeps: failure is data, not drama.

Q · 05 How does this fit with the burst and leak machines?

As the third leg of one certification triad — and the other two legs are already delivered machines on this site. The burst chamber for hydrogen cylinder testing — an export delivery — carries the destructive proof: hydraulic pressure driven past every margin until the tank yields, inside a chamber built to contain it. The dynamic high-pressure hydrogen leak test rig — the same family, the same export programme — carries the tightness proof at up to the 1000-bar class. Between them they answer how strong and how tight; the cycling facility answers how long. A laboratory equipping for hydrogen type-approval needs all three, and they share more than a subject: the same high-pressure engineering, the same fine-bore stainless discipline, the same instrumentation house, the same safety philosophy. That is the honest shape of this page’s claim — the cycling facility itself is engineered to order and no delivered one is claimed, but it is not a first step into unknown territory: it is the completion of a family whose other members have been built, shipped and commissioned — alongside the hydrogen component-test bench delivered under contract to a public-sector customer.

Q · 06 What do you build, and what is bought-in?

We build the facility as a system, from franchises we have delivered. What Neometrix does: the cells — bunkered, rated for the stored energy, with their doors, glands, viewing and access engineered to the safety case; the hydraulic cycling plant — intensifier and pump integration, profile control, parallel manifolds, decay-trip logic and cycle counting; the hydrogen gas loop — supply, compression integration, pre-cooling to the refuelling pattern, recovery and vent-stack engineering, on the discipline of our delivered hydrogen component-test bench and refuelling-station lines; the conditioning integration — climatic chambers from our delivered chamber line, engineered around the specimen stations; the instrumentation, controls and records — per-specimen logging, trip systems, hydrogen detection and inertisation sequencing; and the installation, commissioning and proving, then calibration, seals and plant AMC through the campaigns. What is bought-in certified: hydrogen compressors and intensifier cores, chamber refrigeration packages, proprietary transducers and gas-detection heads, and relief and safety devices with their certificates. Engineered to order; quoted against a hydrogen pressure-cycling test-rig requirement; grounded in the delivered hydrogen-test, high-pressure and climatic-chamber franchises; no specific delivered cycling facility is claimed on this page.

↗

The hydrogen test house from Neometrix.

The delivered burst and leak machines this facility completes, and the contracted component bench beside them — engineered at our Noida facility.

↗ Burst — Delivered Sibling

Burst Chamber for Hydrogen Cylinder Testing

The margin proof — an export-delivered chamber of this same family.

↗ Leak — Delivered Sibling

Dynamic High-Pressure Hydrogen Leak Test Rig

The tightness proof to the 1000-bar class — the family’s other export delivery.

↗ Component Test

Hydrogen Fuel-System Component Test System

The component bench delivered under contract — the fourth wall of the hydrogen test house.

Browse all Neometrix product lines.

Get a quotation

Send the specimens
and the standards.

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

Enquire — cycling facility Capability sheet (PDF) +91 7777 876 876

ISO 9001 / 14001 ENGINEERED TO ORDER — HYDROGEN PRESSURE-CYCLING TEST FACILITIES HYDRAULIC + GAS CYCLING · CONDITIONED TO −40 / +85 °C · RATED CELLS · GTR-13 / ISO 19881 PATTERN ENGINEERED IN NOIDA · INDIA

The whole life. Before the first fill.

Every fill works the tank — so run them all first.

Burst, leak — and the lifetime

Make it boring

Counted, logged, signed

Mount, cycle, certify.

Cycling Plant

Gas Loop

Conditioning

Cell & Safety

Reference facility, built to the standard.

Where cycling facilities go wrong

One discipline, the facility the campaign needs.

Hydraulic Cycling Cells

Hydrogen Gas-Cycling Systems

Conditioned-Cycling Integration

Component-Cycling Benches

Where the lifetime gets proven.

Common questions.

The hydrogen test house from Neometrix.

Burst Chamber for Hydrogen Cylinder Testing

Dynamic High-Pressure Hydrogen Leak Test Rig

Hydrogen Fuel-System Component Test System

Send the specimens
and the standards.

Similar Products

Share This Page

The whole life. Before the first fill.

Every fill works the tank — so run them all first.

Burst, leak — and the lifetime

Make it boring

Counted, logged, signed

Mount, cycle, certify.

Cycling Plant

Gas Loop

Conditioning

Cell & Safety

Reference facility, built to the standard.

Where cycling facilities go wrong

One discipline, the facility the campaign needs.

Hydraulic Cycling Cells

Hydrogen Gas-Cycling Systems

Conditioned-Cycling Integration

Component-Cycling Benches

Where the lifetime gets proven.

Common questions.

The hydrogen test house from Neometrix.

Burst Chamber for Hydrogen Cylinder Testing

Dynamic High-Pressure Hydrogen Leak Test Rig

Hydrogen Fuel-System Component Test System

Send the specimensand the standards.

Similar Products

Share This Page

Send the specimens
and the standards.