The Background.

As part for the drive for net zero emissions, the Hydrogen Economy is a large part of technologies being developed to enable this to happen. Vehicles using hydrogen as a fuel instead of fossil-based fuels emit mainly water as a waste product and no carbon-based emissions. Hydrogen filling stations are required for both heavy goods vehicles and cars. To date there are no standards for these filling stations in the United Kingdom, unlike petrol and diesel filling stations. TÜV SÜD National Engineering Laboratory is therefore developing test standards to verify the quantity of hydrogen dispensed at hydrogen filling stations.

The Client: TÜV SÜD

TÜV SÜD National Engineering Laboratory is the world’s foremost authority on flow measurement technology, combining ground-breaking research and development with independent flow meter calibration and testing services.

The Solution.

TÜV SÜD contacted Booth Welsh (BW) to help develop a test/calibration rig design for Heavy-Duty Filling Stations (HGVs). There are differences in the process conditions for Light-Duty and Heavy-Duty hydrogen filling stations. For example, Light-Duty hydrogen filling stations have 700 bar nominal working pressure (NWP) while Heavy-Duty vehicles have 300 bar NWP. Also, the quantity of hydrogen dispensed at Heavy-Duty hydrogen filling stations is significantly larger which requires a test standard with an increased capacity.

BW carried out process design reviews, HAZOPs, a Risk Analysis, and a DSEAR (Dangerous Substances and Explosives Atmospheres Regulations) review. From this, our mechanical and piping team developed a piping model utilising thick-walled tubing, hosing and equipment to fit within a trailer of fixed dimensions. The final design was issued to TÜV SÜD who then issued it for tender and construction. BW then helped with contractor clarifications during the construction period. 

Client Testimonial

Revata Seneviratne, Consultant at TÜV SÜD said “we’ve been really pleased with the support from BW throughout the process. BW provided a fast and flexible solution which met our requirements”.
Find TÜV SÜD website here : Hydrogen Technology Services - Ensure your project is safe & efficient | TÜV SÜD (