Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Leak Test Capacity at 99% leak tester uptime: a worked example in hydrogen electrolyzer & fuel cell manufacturing

This scenario runs the leak test capacity calculation on the strong side: 99% leak tester uptime, with every other input held at its documented default. Use it when a test engineer or production planner needs to know whether the existing leak test bench can absorb a higher build rate, or whether a second helium or pressure-decay station is needed before the next build.

The inputs for this scenario

  • Stacks per leak test cycle: 2 stacks / cycle (unchanged)
  • Planned leak test cycles in the period: 40 cycles (unchanged)
  • Leak tester uptime: 99 % (raised for this scenario; the documented default is 88)
  • Leak test first-pass rate at the target test pressure: 95 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross leak test capacity = stacks per cycle × planned cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 75.24 stacks for good leak-test stacks per period, the number this scenario is built around.
  • At this operating point the engine returns 80 stacks for gross leak-test stacks per period.
  • At this operating point the engine returns 0.8 stacks for leak tester downtime loss.
  • At this operating point the engine returns 3.96 stacks for leak-test rework loss.

How this compares with the baseline

  • Against the tool's baseline example, where leak tester uptime sits at 88% and the headline result is 66.88 stacks, this scenario comes in 12.5% above the baseline at 75.24 stacks.
  • Use it when planning leak-test capacity against build rate, justifying a second tester, or quantifying how uptime and first-pass losses erode throughput. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good leak-test stacks per period: 75.24 stacks (headline result)
  • Gross leak-test stacks per period: 80 stacks
  • Leak tester downtime loss: 0.8 stacks
  • Leak-test rework loss: 3.96 stacks

Run it with your numbers

  • Every input above is editable in the live Leak Test Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.