When it comes to hydrogen, managing high-pressure gas is non-negotiable. The safety, efficiency, and reliability of every system depend on it. Yet, handling such extreme pressures isn’t straightforward—it demands precision and the right tools. At VES, we understand these challenges, and we’ve focused on designing systems that simplify high-pressure gas management while ensuring the highest safety standards. Here’s how smarter solutions are changing the game for hydrogen safety.
Breaking Down High-Pressure Gas Management
Managing high-pressure gas for hydrogen applications involves several interconnected processes: generation, storage, recovery, and testing. Each of these steps plays a vital role in ensuring that hydrogen pressure vessels meet safety standards while minimising waste and inefficiencies.
The High-Pressure Gas Generation Unit (HPGU) is at the centre of this approach, integrating gas storage and processing with advanced control systems to maintain precision and reliability. Housed in purpose-built, ISO-certified containers for easy transport and installation, the HPGU simplifies what has historically been a complex and costly process.
Advanced Storage Solutions for Safety and Efficiency
The HPGU’s gas storage container is a key innovation in managing high-pressure hydrogen systems. It divides storage into three areas: low-pressure recovery, intermediate storage, and high-pressure storage. This tiered design allows for more efficient gas handling, reducing energy use and optimising the flow of gas between different stages of the process.
The container also houses fueling and recovery panels, which direct gas between the storage units and the leak test module (LTM). These systems ensure that high-pressure gas is precisely delivered to where it’s needed while recovering unused gas for future cycles. By recapturing gas instead of venting it, operators can significantly reduce waste and operating costs—a critical factor as helium and other gases become increasingly expensive.
The Role of Gas Processing
Within the process container, the HPGU uses a combination of gas compressors, boosters, and chillers to generate and regulate pressure. This setup allows for precise control, which is essential when pressurising hydrogen vessels to test their integrity.
The primary chiller ensures that gas temperatures remain stable during compression, preventing thermal expansion or contraction that could compromise test accuracy. Additionally, an ultra-low chiller works in tandem with the fueling panel to cool gas before it enters the hydrogen vessels, further improving safety and system efficiency.
By maintaining stable pressure and temperature throughout the process, the HPGU minimises the risk of system failure and ensures consistent, reliable testing results.
Precision Leak Testing for Hydrogen Vessels
Safety is paramount in hydrogen applications, and nowhere is this more evident than in leak testing. The leak test module (LTM) is an integral part of the HPGU system, designed to identify even the smallest leaks in hydrogen pressure vessels.
Using advanced automation, each pressure vessel is loaded onto a gas test fixture (GTF) and transported to the LTM via an automated conveyor. The GTF, which holds up to four vessels at a time, ensures secure positioning within a vacuum test chamber.
The testing process begins with a gross leak check, followed by the injection of forming gas to pressurise the vessel. The system then holds the vessel at a predetermined pressure to assess its leak tightness. Once testing is complete, defueling occurs in stages, with recovered gas sent back to the storage container for reuse.
This method not only ensures that vessels meet stringent safety standards but also optimizes resource use by integrating recovery at every stage.
Smarter Systems for a Sustainable Future
The integration of SCADA (Supervisory Control and Data Acquisition) into the HPGU system takes high-pressure gas management to the next level. SCADA allows operators to monitor and control every aspect of the process in real time, from gas storage levels to chiller performance and leak test results. This centralised control enhances safety by identifying potential issues before they escalate, while also improving operational efficiency.
In addition, the modular design of the HPGU makes it highly adaptable. Whether testing a few vessels or scaling up for high-volume production, the system can be tailored to meet specific needs without unnecessary downtime or expense.
The VES Difference
At VES, we believe that smarter systems lead to safer outcomes. By combining advanced storage, processing, and testing technologies into a single, cohesive solution, we’re helping manufacturers meet the growing demands of the hydrogen economy. The HPGU system represents the future of high-pressure gas management, delivering safety, efficiency, and sustainability in equal measure.
