GMS TS 001

Test Capabilities

A wide range of tests can be performed to characterize and validate hydrogen recirculation components.

Performance Mapping

•         Blower and compressor curves, including pressure rise as a function of flow rate and speed

•         Entrainment ratio and operating range of an ejector or jet pump

•         Authority, linearity and hysteresis of a pressure control valve

•         Pressure drop and flow coefficient of gas-flow components

•        Thermal efficiency of a heat exchanger or preheater

•         Electrical efficiency and specific power

•         Turndown ratio and minimum stable operating point

System-Level Testing

•         Complete anode module or recirculation assembly under real closed-loop conditions

•        Component interaction between blower, valve and separator

•         Purge strategy adjustment and hydrogen consumption per purge

•        Validation of start-up and shutdown sequences

•         Transient loop response to a load step

•         Degraded operation with a deliberately detuned component

Water and Two-Phase Flow

•         Separation efficiency of a knockout or coalescer

•         Droplet carry-over as a function of gas velocity

•         Condensation mapping along the loop and dew-point monitoring

•        Controlled liquid water injection up to 300 mL/min

•         Validation of draining and level control

•         Flooding and drying limits

Gas Composition Effects

•         Hydrogen and nitrogen mixing with controlled ratio

•         Simulation of nitrogen accumulation caused by crossover

•        Performance sensitivity to gas density and molar mass

•         Operation with helium or argon, as an option

•         Methane and hydrogen mixtures, available as an option after requalification

Climate and Thermal Testing

•         Cold start from -25 °C and time to reach nominal operating conditions

•         Hot operation up to +85 °C ambient temperature

•         Freeze/thaw cycling with residual water inside the component

•         Thermal shock on the cooling circuit from -30 to +85 °C

•         Sensitivity to cooling flow rates from 2 to 18 L/min

Control and Electrical Testing

•         Control-loop dynamics captured at 1 ms

•         Validation of PWM, analog and CAN commands

•         High-voltage insulation behavior up to 1000 V DC

•         Current draw and inrush current

•         Verification of interlocks and fallback states

•         Behavior following loss of power, air, cooling or control signals

Endurance and Lifetime Testing

•         Continuous 24/7 operation without supervision

•         Start/stop cycling over several thousand events

•         Accelerated aging under combined humidity and temperature conditions

•         Performance drift monitoring throughout the test campaign

•         Testing to failure with data capture for root-cause analysis

•         Performance comparison before and after the test campaign

Leak Tightness and Integrity

•         Helium leak testing before and after the test campaign

•         Hydrogen sniff testing on each connection and interface

•         Leak evolution under thermal cycling and pressure

•         Verification of proof pressure and burst-pressure margin

•         Compatibility screening of seals and elastomers

Acoustics and Vibration

•         Noise level as a function of operating point, as an option

•         Tonal content and blade-passing frequency identification

•         Vibration signature and bearing health monitoring

•         Acoustic signature drift during endurance testing

Development and Qualification

•         Design of experiments and test protocol engineering

•         Supplier comparison using an identical test protocole

•         Incoming inspection and batch conformity testing

•         Model correlation and CFD validation datasets

•         Cross-comparison of sensors and instruments

•         Test data package for internal or customer design reviews