Hydrogen Tanks

VES have developed the best in class leak detection machine to meet all the demands of testing high pressure hydrogen tanks, with R134A, AC19 and IP67 regulations all met with VES equipment. Using the knowledge and experience from over 30 years of manufacturing leak detection equipment, VES have developed a unique quantitative leak test for all high pressure tanks.

As the world moves away from internal combustion engines and traditional fuel tanks; high pressure hydrogen tanks are the new energy storage. VES have designed a number of machines for Hydrogen fuel tanks. As these tanks work at extremely high pressures and high volumes, leak testing comes with some very unique challenges that can be broken down into three different areas:

  • The potential energy can have catastrophic implications on the surrounding areas. Leak testing these Category 4 tanks creates great safety challenges for the industry moving forward.
  • With this high pressure and high-volume combination manufacturers are seeing increased costs in testing gases.
  • The gas composition changes over the course of the leak test with moisture and temperature changing dramatically under compression and venting.

Hydrogen

Vacuum Engineering Services have worked with their partners to create the new H2Safe solution. Combining all the history and experience in a leak test station with new high-pressure boosting/recovery systems and safety containment systems.

The H2Safe product range was developed by VES to accommodate 900 bar testing of hydrogen tanks to ensure no leakage occurs. H2Safe offers a 100% non-operator dependant qualitative test that is safe. Get in touch to find out more.

VES also noticed a poor MSA scoring on traditional pressure decay testing of fuel cells, costing manufacturers thousands of pounds in re-work and re-test fees. We implemented a tracer gas test system to minimise footprint and increase production throughput.

With everything we do at Vacuum Engineering Services, safety is our highest priority. Maintaining the highest of standards throughout our facilities. All pressure vessels included hydrogen tanks and fuel cells must meet the global regulations. Vacuum Engineering Services have experience in meeting all EU and global standards. Feel free to contact us to discuss further.

H2 Safe Solution

At VES we have designed a full package of machines to meet all the requirements for leak testing these high-pressure tanks. Starting with a vacuum drying station to meet stringent moisture content requirements. Moving on to a fully automated accumulation machine with built in point detection to meet the required leak rates and cycle times.

Accumulation machines work in atmospheric conditions using either forming gas or tracer gas; working without a vacuum chamber an accumulation tester provides accurate, repeatable and reliable results at relatively low cost. While VES have also introduced different testing gases, been able to provide a solution that is up to 94% cheaper per test piece than traditional 100% helium.

A unique design, developed in house at VES, specifically for high pressure applications (including Hydrogen and CNG tanks). The H2 Safe machines have been designed to incorporate three different elements:

  • A leak test
  • Pressure generation
  • Pressure containment


Fuel Cells

Fuel cells are made up of layers of material: An Anode, Cathode and Electrolyte. To ensure leak tightness of the cells and optimise performance, a helium leak test must take place. Legalisation and best practice require parts to be tested to a leak rate of 2 x 10-5mbar.l/sec. Vacuum Engineering Service have designed machines for both cells and modules for Hydrogen and Methane Fuel Cells.



As the world moves from internal combustion engines and fuel tanks to more renewable forms of energy; VES are at the forefront of design and manufacturing of leak detection equipment for Hydrogen Fuel tanks. Working at high pressures and high volumes, the potential energy can have catastrophic implications on the surrounding areas. Leak testing of hydrogen tanks create great challenges for the industry moving forward. Vacuum Engineering Services are the only provider of leak detection equipment who has the knowledge and experience of both leak detection systems and high-pressure applications. VES are powered by over 25 years of experience in leak detection and a drive to support all our customers with the most technical application.

With everything we do at Vacuum Engineering Services, safety is our highest priority. Maintaining the highest of standards throughout our facilities. All pressure vessels included battery coolers and fuel cells must meet the global regulations. Vacuum Engineering Services have experience in meeting all EU and global standards. Feel free to contact us to discuss further.

Methane fuel cells, along with any fuel cells, require leak testing and VES can recommend the best methods and technology to achieve efficience and reliably across your product range.

Hydrogen Fuel Cells

VES have developed the most efficient and effective methods for leak testing fuel cells. Using an aluminium chamber design with a volume optimised solution and state of the art tooling, all fuel cells can be leak tested to industry standards.

Hydrogen fuel cells are used in many modes of transport, including cars, buses, lorries and boats. Bespoke leak detection equipment from VES is tailored to your every need.

Fuel cells are made up of multiple layers of material, including an Anode, Cathode and Electrolyte. Any leakage from these sealed layers can be detrimental to the performance of the cells. Common testing methods of fuel cells include pressure drop and pressure rise. Both these methods have significant disadvantages in production for repeatable and reliable results. Most cells have small volumes and thin walls, therefore sealing repeatability can be difficult. Using the pressure rise/drop method of leak testing has inconsistent results. With similar comparisons being drawn from the fuel systems and medical device industries many years ago, Vacuum Engineering Services have installed hard vacuum and accumulation machines to increase reliability and stay up to date with standards and regulations as production increases.

To ensure leak tightness of the cells and optimise performance, a helium leak test can be carried out. Legalisation and best practice require parts to be tested to 2 x 10-4mbar.l/sec.

Vacuum Engineering Services have designed machines for both cells and modules for Hydrogen and Methane Fuel Cells. Delivering optimum performance and preventing harmful gases escaping to the atmosphere. Feel free to contact us to discuss further.

Battery Cells

How does the industry leak test batteries and battery cells? The industry has many methods of leak testing batteries and cells with no common leak rate standards and regulations. As the automotive industry moves away from the conventional internal combustion engine to the battery electric vehicles. Battery cell production has increased with an approximate 10% CAGR. The need to leak test the battery cells has become more and more important. Vacuum Engineering Services are a world leader in leak testing technology that can guarantee leak tightness across the full range of battery products.

Leak testing battery cells is necessary to stop water and lithium mixing. Lithium reacts intensely with water, forming lithium hydroxide and highly flammable hydrogen. Stopping this water ingress is necessary to maintain product integrity, all parts should be tested to a leak rate of 2 x 10-5 mbar.l/sec. All battery cells must now comply with IP67 or IP68. This states there is no water ingress for 30 minutes in 1 metres of water and no water ingress for 30 minutes in 1.5 metres of water, respectively. This is the equivalent of a leak rate well below 1 sccm, therefore all battery cells must be helium leak tested. Pressure decay and bubble testing will not give battery manufacturers the required accuracy to comply with IP67 and IP68.

  • Methane cells
  • Hydrogen tanks

Vacuum Engineering Services can leak test all battery cells (pouch, cylinder and prismatic), modules and systems to meet customer specific leak rates and requirements.

Batteries

Battery testing to IP67 in avoidance of ingress is essential for safety and efficiency of the electric drivetrain. Literature suggests that IP67 can only be attained through tracer gas leak testing as other methods are unable to reach the required sensitivity. Not only are the battery cells and modules tracer gas tested, but the largest automotive suppliers tracer gas test the battery coolers also.

Battery Coolers

Vacuum Engineering Services have the experience and expertise to deal with any of your leak detection needs. At VES we work with all parties to provide the best possible solution for the application. With electric cars and vehicles seeking longer range; higher powered batteries are becoming necessary. Therefore, battery cooling is a must. Battery thermal management systems are essential to maintain the battery cells performance and prevent thermal runaway.



With the industry using a mix of water cooling and refringent cooling, VES have designed and manufactured a leak detection machine to test both water cooled and refringent cooled loops. Both need leak testing to prevent product failure. With water cooling circuits leak tested to a range of 1e-2 to 1e-3 mbar.l/sec and refringent cooling circuits tested down to approximately 1e-5 mbar.l/sec. All products need testing to comply with IP67. VES has experience in testing to all products to meet IP67, with our accumulation machines testing to 1e-3 mbar.l/sec.

VES are the only manufacturer of leak testing equipment to have designed and built a machine running multiple gases on different circuits simultaneously. Maintaining product reliability while continuing to achieve a short cycle time.

Vacuum Engineering Services can design and manufacture leak detection machines for all applications including cooling/heating plates and battery coolers of different sizes and shapes.

Depending on the leak rate, there are two main methods of testing battery thermal management systems…

The components placed inside a sealed enclosure and charged with a helium tracer gas. Without the use of a vacuum, an accumulation tester provides accurate and reliable testing results at a relatively low cost. A sensor located within the enclosure can measure the quantity of helium, thus detecting any additional amount due to a leak in the component.

For any refringent testing, a hard-vacuum leak detection machine must be implemented. Vacuum Engineering Services can provide expert experience in testing production components for all leak rates and vacuum conditions.

Battery thermal management systems are essential to maintain the battery cells performance and prevent thermal runaway. Thermal runaway is one of the largest causes of failure for lithium battery cells, however good thermal management stops failures and reduces harm. Vacuum Engineering Services work with many of the largest thermal management companies in the world to deliver optimum solutions for their every need.

With everything we do at Vacuum Engineering Services, safety is our highest priority. Maintaining the highest of standards throughout our facilities. All pressure vessels including battery coolers and fuel cells must meet the global regulations. Vacuum Engineering Services have experience in meeting all EU and global standards. Feel free to contact us to discuss further.