**A modern hydrogen refueling station showcasing advanced fluid system design
The Top 5 Best Practices for Designing Hydrogen Fluid Systems
Hydrogen is one of the most promising sources of clean and sustainable energy in the world today. From transportation and material handling to stationary, portable, and emergency backup power, it has a wide range of applications—and industries across the globe are taking notice.
However, for hydrogen to reach its full potential, the fluid systems that handle, transport, store, and dispense the gas must be as safe and reliable as possible. Traditional industry knowledge from the oil and gas sector doesn’t always apply directly to hydrogen applications due to the unique properties of this fuel.
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Why? Because hydrogen behaves very differently than typical oil and gas media. It requires specialized design strategies to ensure system reliability and safety. With that in mind, here are our **top five system design considerations** for hydrogen infrastructure applications:
#1. Consider the End User
While most industrial oil and gas systems operate behind the scenes, hydrogen systems often interact directly with end users. Think about a hydrogen fuel cell vehicle being refueled at a public station—this is a consumer-facing process.
Hydrogen systems must be designed with specific use challenges in mind.
A well-designed hydrogen dispenser not only ensures convenience but also addresses critical safety concerns. Whether it's a refueling station or a portable unit, the user experience should be seamless, intuitive, and secure.
For instance, the design must account for high-pressure gas transfer, proper sealing, and ease of operation. These factors can significantly impact both safety and user satisfaction.
#2. Minimize Potential Leak Points
One of the biggest challenges in hydrogen systems is the risk of leaks. Hydrogen molecules are extremely small and can escape through even the tiniest crevice in a fluid system. Unlike larger molecules like crude oil, they can easily pass through gaps in seals, valves, and fittings.
Hydrogen molecules are extremely small and can escape through even the tiniest crevice in a fluid system.
This means that traditional oil and gas design practices may not be sufficient for hydrogen containment. Reducing the number of connections in the system and using proper tube-bending techniques instead of additional fittings can help minimize leak points. Working with an experienced supplier can provide valuable guidance on best practices.
#3: Utilize High-Quality Stainless Steel
Due to its small molecular size, hydrogen can cause a unique form of corrosion known as **hydrogen embrittlement**, which weakens metals over time. This can lead to cracks, fractures, and ultimately, system failure.
Selecting the right material can prevent hydrogen embrittlement.
To combat this, high-quality 316 stainless steel with elevated nickel content (at least 12%) is recommended. Nickel helps stabilize the microstructure of the metal, making it more resistant to embrittlement. This choice is crucial for long-term performance and system integrity.
#4: Optimize Your Tube Fittings
Not all components used in oil and gas systems are suitable for hydrogen applications. For example, traditional cone and thread fittings, while widely used, are more prone to leakage in hydrogen systems. Their design dates back to the late 1800s and may not meet the demands of modern hydrogen infrastructure.
Cone and thread fittings can be more prone to leaking in a system meant for hydrogen containment.
Instead, consider using advanced fittings like Swagelok’s FK series, which are specifically engineered for hydrogen. These fittings offer high pressure ratings (up to 1050 bar), proven reliability, and compatibility with hydrogen environments. They are ideal for hydrogen vehicles, refueling stations, and other critical applications.
Swagelok’s fittings are available in high-quality stainless steel and are designed to meet the unique needs of hydrogen systems. Choosing the right fitting can make a big difference in system performance and safety.
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#5: Consult With the Experts
Hydrogen is still a relatively new frontier in clean energy. As the industry evolves, so do the best practices for designing and maintaining hydrogen infrastructure.
When in doubt, work with a supplier that can offer hydrogen-specific knowledge, design expertise, and product recommendations.
Working with a supplier that specializes in hydrogen solutions can provide invaluable support. These experts understand the unique challenges of hydrogen systems and can guide you toward the best materials, components, and design approaches for your specific application.
Whether you're developing hydrogen infrastructure, manufacturing vehicles, or exploring new applications, expert guidance can help you avoid costly mistakes and ensure long-term success.
Want to learn more about hydrogen best practices, product choices, and design strategies? Continue to explore *Swagelok Reference Point* for the information you need to grow your success in this emerging hydrogen landscape.
For instance, the design must account for high-pressure gas transfer, proper sealing, and ease of operation. These factors can significantly impact both safety and user satisfaction.
