What Special Test Is Required For Thermal Generator Hydrogen Cooler

Aug 31, 2026

Thermal generator hydrogen cooler works with flammable hydrogen under positive working pressure. Strict tests are mandatory before delivery, to avoid gas leakage, water‑into‑hydrogen side leakage and structural failure during power‑plant operation.

Mandatory Special Tests

Helium Leak Test (Hydrogen‑gas side, most critical)

This is the most distinctive test for hydrogen coolers vs ordinary air coolers.

Pressurize the hydrogen (shell/gas) side with helium gas.

Use helium mass‑spectrometer detector to check micro‑leaks on tube‑to‑tube‑sheet joints, weld seams, flanges and housing.

Reject units with leak rate exceeding power‑plant acceptance threshold.

Purpose: Prevent tiny leakage of flammable hydrogen gas; avoid water seeping from tube side into generator cavity.

Hydrostatic Pressure Test (Water / tube side)

Apply higher test pressure on cooling‑water tube side, hold pressure for required duration.

Check tubes, tube sheet, water chamber for sweating, seepage or permanent deformation.

Purpose: Verify mechanical strength and tightness for cooling‑water circuit.

Air Tightness Test (Optional secondary check for gas side)

Pressurize gas side with dry compressed air, monitor pressure drop over holding time. Often used as pre‑test before helium leak detection.

Visual & Dimensional Inspection

Full visual check for weld quality, fin damage, coating.

Critical mounting dimension, flange hole position, overall footprint measurement.

Purpose: Guarantee interchangeability for 1:1 replacement during generator overhaul.

Vibration simulation test (project‑specific optional witness test)

For some new‑build large power‑plant projects, customer may request vibration test to validate anti‑vibration performance of tube bundle, simulating generator operating vibration condition.