GB/T 45541-2025Testing method for proton exchange membrane electrolyzer performance (English PDF)

5.1 Strength Test

5.1.1 Principles

The strength test of the PEM electrolyzer generally adopts a hydrostatic test, with the test pressure being 1.25 times the design pressure. For PEM electrolyzers unsuitable for hydrostatic tests, a pneumatic strength test can be used, with the test pressure being 1.1 times the design pressure. Safety measures shall be formulated in accordance with safety production management regulations for the strength test, safety protection and monitoring devices shall be installed, and safety supervision and management shall be carried out throughout the process.

5.1.2 Hydrostatic test

The hydrostatic test shall use deionized water. The conductivity of the deionized water shall be less than or equal to 0.1 mS/m, and the water quality shall meet the requirements of GB/T 37562.

The hydrostatic test procedures are as follows.

a) Connect the gas outlets of the anode and cathode chambers of the PEM electrolyzer and install pressure sensors, pressure gauges, or other pressure monitoring devices.

Seal other inlets and outlets of the electrolyzer. During the test, the surface of the PEM electrolyzer shall be kept dry;

b) Introduce deionized water into the anode and cathode chambers, slowly raise the pressure to the design pressure. After confirming that there is no leakage, continue to raise the pressure to the specified test pressure. Hold the pressure for 30 minutes, during which time the pressure shall remain constant;

c) Observe the electrolyzer for any leakage, visible deformation, or abnormal sounds.

5.1.3 Pneumatic test

The pneumatic test uses high-purity nitrogen, which shall comply with the relevant provisions in GB/T 8979.The pneumatic test procedures are as follows.

a) Connect the outlets of the anode and cathode chambers of the PEM electrolyzer and install pressure sensors, pressure gauges, or other pressure monitoring devices. Seal all other inlets and outlets of the PEM electrolyzer;

b) Introduce high-purity nitrogen into the anode and cathode chambers, slowly raise the pressure to 10% of the specified test pressure and hold the pressure for 5 minutes. The method of applying leak detection liquid (or other leak detection tools) to perform an initial inspection of all joints, connecting components and the PEM electrolyzer. After confirming that there is no leakage, continue to raise the pressure to 50% of the specified test pressure. If no abnormalities are observed, gradually raise the pressure in increments of 10% of the specified test pressure, until the test pressure is reached, and hold the pressure for 10 minutes. Then, reduce the pressure to the design pressure and hold it for sufficient time for inspection. During the inspection, the pressure shall remain constant;

c) Observe the PEM electrolyzer for any abnormal noises. Use a special-purpose leak detection liquid to check for bubbles and visible deformation.

5.2 Airtightness Test

The test gas for the hydrogen side is one of hydrogen, helium, a hydrogen-nitrogen mixture, or a helium-nitrogen mixture. The test gas for the oxygen side is nitrogen or helium. The airtightness test procedures are as follows.

a) Connect the test device as shown in Figure 1;

b) Connect the outlets of the anode chamber (oxygen side) and cathode chamber (hydrogen side) of the PEM electrolyzer, and seal other inlets and outlets of the PEM T2---the gas temperature at the end of the test, expressed in (K);

p1---the absolute pressure of the PEM electrolyzer at the start of the test, expressed in (MPa);

p2---the absolute pressure of the PEM electrolyzer at the end of the test, expressed in (MPa).

5.4 Internal Crossflow Test

After the PEM electrolyzer passes the airtightness test, an internal crossflow test is conducted using high-purity nitrogen or helium as the test gas. For PEM electrolyzers with an isobaric structure, the pressure is maintained at a differential pressure of 0.2 MPa for 5 minutes; for PEM electrolyzers with a differential pressure structure, the pressure is maintained at the maximum permissible operating differential pressure for at least 5 minutes. The internal crossflow rate shall meet the manufacturer’s requirements in the technical documents. The internal crossflow test procedures are as follows.

a) Connect the internal crossflow test device as shown in Figure 2.Connect a pressure sensor to the inlet of the cathode chamber (the hydrogen side) and a gas flow meter to the outlet of the anode chamber (the oxygen side). Seal all inlets and outlets of other chambers of the PEM electrolyzer;

b) Introduce the test gas into the inlet on the hydrogen side and slowly adjust the pressure to the test pressure. During this process, maintain the pressure on both sides of the proton exchange membrane of the PEM electrolyzer in accordance with the test requirements;

c) During the test, the hydrogen side pressure shall remain stable. After maintaining this for 5 minutes, read and record the internal crossflow rate L of the test gas from the hydrogen side to the oxygen side on the flow meter.

Figure 2 -- Schematic Diagram of Internal Crossflow Test Device Connection The calculation method for the crossflow rate is given in Appendix A.

5.5 Power-on Test

After the PEM electrolyzer passes the airtightness, leakage rate, and internal crossflow tests, a power-on test is performed. The test procedures are as follows.

a) Connect the PEM electrolyzer’s water and gas pipelines, as well as the power supply cable, to the test system;

b) Start the circulating water pump and observe the temperature sensor at the PEM electrolyzer outlet. Wait until the PEM electrolyzer outlet water temperature reaches the set temperature and the water quality of the outlet water meets the requirements;

c) Start the test program. The applied current shall not be less than 10% of the rated current;

d) Adjust the PEM electrolyzer’s gas production pressure to the set value. After stable operation, check the electrolyzer’s operating parameters.

5.6 Temperature Test

Temperature sensors are installed at the inlet and outlet of the PEM electrolyzer. Test and record the inlet and outlet medium temperatures of the PEM electrolyzer.

6.1 Test Conditions

6.1.1 The test system shall be capable of providing water, electricity and gas management for the PEM electrolyzer. It should preferably be equipped with sensors such as temperature sensors, pressure sensors, current sensors, voltage sensors, voltage inspecting instruments, liquid flow meters, gas flow meters, oxygen-in-hydrogen analyzers, hydrogen-in-oxygen analyzers, hydrogen mass flow meters, and conductivity testers, etc. A schematic diagram of the test system flow is shown in Figure 3.

6.1.2 The operating ambient temperature should preferably be 5 C ~ 45 C, and the relative humidity should preferably be less than or equal to 75%. ......