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A glimpse into modern hydrogen infrastructure systems.
The Top 5 Best Practices for Designing Hydrogen Fluid Systems
Hydrogen stands as one of the most promising sources of clean and sustainable energy, finding applications across sectors like transportation, material handling, stationary power, portability, and emergency backup. As industries worldwide embrace hydrogen, ensuring the safety and reliability of the fluid systems that manage this gas becomes paramount.
Traditional knowledge from the oil and gas sector doesn’t always translate well to hydrogen systems due to the unique properties of hydrogen itself. Unlike conventional fuels, hydrogen poses distinct challenges, necessitating tailored design approaches. Here are our top five considerations for designing robust hydrogen infrastructure:
#1. Focus on the End User Experience
In many cases, industrial oil and gas systems operate behind the scenes, managed by professionals. However, hydrogen's potential as a clean energy source places these systems directly in the hands of everyday users. For instance, refueling a hydrogen-powered vehicle involves a direct interaction with the dispenser. Therefore, the design must prioritize user safety and convenience while addressing specific challenges like high-pressure handling and leakage risks.
Designing for end-user experience is critical in hydrogen systems.
#2. Reduce Potential Leak Points
Hydrogen molecules are incredibly small, making them highly susceptible to escaping through even minute cracks or imperfections in the system. This makes minimizing potential leak points essential. Traditional seals and connection methods used in oil and gas systems often fail to meet hydrogen containment standards. By reducing the number of fittings and optimizing bending techniques, designers can significantly decrease the risk of leaks. Engaging with suppliers who offer specialized design training can further enhance system integrity.
Minimizing leak points is vital for safe hydrogen containment.
#3. Select High-Quality Stainless Steel
Hydrogen embrittlement—a form of corrosion that weakens metals—is a major concern in hydrogen systems. To combat this, choosing the right material is crucial. High-quality 316 stainless steel tubing is widely regarded as an excellent choice due to its durability and long service life. Specifically, stainless steels with elevated nickel content (minimum 12%) exhibit superior performance in hydrogen environments. Nickel stabilizes the microstructure of the steel, enhancing its resistance to hydrogen embrittlement.
Nickel-enriched stainless steel offers enhanced protection against hydrogen embrittlement.
#4. Optimize Tube Fittings
While cone and thread fittings have historically been popular in oil and gas systems, they may not be suitable for hydrogen applications. These older designs are prone to leaks, especially under high-pressure conditions. Modern alternatives, like Swagelok’s FK series fittings, are engineered specifically for hydrogen systems. With pressure ratings up to 1050 bar, these fittings provide reliable performance across various industries, including hydrogen vehicles and infrastructure.
Optimized tube fittings ensure greater safety and reliability in hydrogen systems.
#5. Collaborate with Experts
As hydrogen moves toward mainstream adoption, collaboration with experts becomes increasingly important. Suppliers specializing in hydrogen systems can offer tailored insights, design expertise, and product recommendations. At Swagelok, we combine deep materials science knowledge with practical engineering support to help clients build efficient, safe, and scalable hydrogen infrastructure. Our comprehensive suite of products ensures seamless integration into any project.
Partnering with hydrogen specialists accelerates innovation and reliability.
For those eager to deepen their understanding of hydrogen best practices, product innovations, and design strategies, explore Swagelok Reference Point. It’s a valuable resource for staying ahead in this rapidly evolving field.
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