Airmatic Ltd was approached by Maximator UK to manufacture a series of bespoke stainless-steel vent pipe assemblies for use within a hydrogen-related application. Hydrogen systems demand extremely high levels of precision, cleanliness and integrity due to the volatile and permeable nature of the gas. As such, all components required careful fabrication in accordance with strict specifications and recognised standards.

The project involved producing multiple vent risers and hydrogen vent tips using both 316L and 304 stainless steel, based entirely on customer-supplied drawings and detailed part references. Each component had to meet exact dimensional tolerances and performance criteria to ensure safe venting and long-term reliability within a pressurised system.

Given the critical nature of hydrogen infrastructure, the project required not only high-quality fabrication but also comprehensive inspection and testing processes to validate the integrity of every weld and assembly.

The scope included:

Procurement of all 316L and 304 stainless-steel materials

Production of multiple vent risers in various sizes of Schedule 40 tube (1", 1.5", 2", and 2.5")

Fabrication of both top and bottom vent assemblies to drawing references OTM1.3.x

Manufacture of hydrogen vent tips to specific customer part numbers

All bends were supplied as butt-weld type, 1.5D 90° fittings to ensure smooth flow characteristics and structural integrity. Welding operations were completed by qualified and experienced welders using Airmatic’s internal procedures, developed in alignment with BS EN 15614 standards.

Particular care was taken to ensure weld consistency, penetration and cleanliness, as these are critical factors in hydrogen service where even minor defects can compromise safety.

Key Goals:

Manufacture high-quality stainless steel vent assemblies to precise customer drawings

Ensure all fabrication meets industry standards for hydrogen applications

Deliver a fully tested and compliant solution ready for installation

Maintain strict quality control throughout material procurement, fabrication, and testing

The solution and what we delivered:

Due to the safety-critical nature of hydrogen systems, a rigorous quality assurance process was implemented for every fabricated component.

Each pipe spool underwent:

Pickling and passivation to remove weld heat tint (HAZ discolouration) and restore corrosion resistance

External Liquid Penetrant Inspection (LPI) to detect any surface-breaking defects or cracks in welds

Hydrostatic pressure testing at 1.5 times the intended service pressure to confirm structural integrity and leak-tight performance

These processes ensured that all fabricated assemblies met stringent safety, durability, and performance requirements before delivery.

Technical hurdles we faced and the solutions we provided:

Material Requirements: Hydrogen applications require materials with excellent corrosion resistance and mechanical properties. The use of 316L stainless steel was essential, but careful handling and fabrication processes were needed to preserve its integrity.

Solution: Airmatic implemented strict material traceability and controlled fabrication procedures to ensure compliance with specifications and maintain material performance.

Weld Quality & Integrity: Hydrogen systems are highly sensitive to defects such as incomplete fusion in welds.

Solution: All welding was carried out by coded welders using qualified procedures, followed by LPI inspection and pressure testing to verify weld integrity.

Precision Manufacturing: Customer-supplied drawings required exact adherence to dimensions and configurations.

Solution: Our in-house fabrication capability allowed for tight control over tolerances, ensuring all components were manufactured accurately and consistently.

What long-term benefits can the client see:

Confidence in component integrity through comprehensive testing

Reliable performance in a demanding hydrogen environment

Reduced risk of leaks or failures due to high-quality fabrication

Compliance with industry standards and safety requirements

How this project has impacted Airmatic:

This project further strengthened Airmatic’s capabilities in manufacturing high-integrity stainless steel pipework for specialist and emerging sectors such as hydrogen energy.

Working on hydrogen-related systems required a heightened focus on precision, cleanliness and quality assurance. The project reinforced Airmatic’s internal standards and demonstrated the value of its in-house fabrication and testing capabilities when delivering safety-critical components.

It also highlighted Airmatic’s ability to support clients operating at the forefront of modern energy solutions, positioning the company as a trusted partner in high-specification engineering projects.

Ongoing support for the client:

Following successful delivery, Airmatic continues to support clients requiring bespoke stainless steel fabrication for critical applications. The expertise developed through this project enables Airmatic to respond efficiently to similar requirements in the hydrogen and high-pressure systems sector.

Conclusion

This project demonstrates Airmatic’s ability to deliver precision-engineered stainless-steel pipework for demanding and safety-critical applications. By combining skilled fabrication, rigorous testing and strict adherence to industry standards, Airmatic provided Maximator UK with a dependable solution tailored to the unique challenges of hydrogen systems.