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The Top 5 Best Practices for Designing Hydrogen Fluid Systems
Hydrogen is one of the most promising sources of clean and sustainable energy. From transportation and material handling to stationary, portable, and emergency backup power, it has a wide range of applications—and industries around the world are taking notice.
But for hydrogen to truly reach its full potential, the fluid systems that handle, transport, store, and dispense the gas must be safe, reliable, and designed with the unique properties of hydrogen in mind. Traditional knowledge from the oil and gas industry doesn’t always apply here—hydrogen behaves differently and requires specialized design approaches.
Get the Facts on Hydrogen
Why? Because hydrogen is much smaller and more reactive than typical hydrocarbon-based media. This means that traditional designs and materials used in oil and gas systems may not be sufficient for hydrogen applications. With this in mind, here are our **top five system design considerations** for hydrogen infrastructure:
#1. Consider the End User
Most industrial oil and gas systems operate behind the scenes, handled by professionals. But hydrogen is changing that. As a clean energy source, it's becoming more accessible to everyday people—especially in transportation. A hydrogen fuel cell vehicle, for example, is refueled at a station where users interact directly with the system.
This shift means that hydrogen systems must be designed with user experience and safety in mind. Whether it's a dispenser at a refueling station or a storage tank in a home, the design should be intuitive, secure, and easy to use.
Hydrogen systems must be designed with specific use challenges in mind.
With more public interaction, the need for robust, leak-free, and user-friendly systems becomes even more critical.
#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. Unlike larger hydrocarbons, such as crude oil, hydrogen can easily penetrate seals, gaskets, and joints.
Traditional oil and gas design methods aren’t always suitable for hydrogen. To reduce the risk of leaks, it’s important to minimize the number of connections in the system. Instead of using multiple fittings, consider using proper tube-bending techniques in strategic locations.
Hydrogen molecules are extremely small and can escape through even the tiniest crevice in a fluid system.
By reducing leak points, you enhance both safety and system performance.
#3. Utilize High-Quality Stainless Steel
Hydrogen’s small size also makes it prone to causing a type of corrosion known as **hydrogen embrittlement**. This phenomenon weakens metal over time, making it brittle and more likely to fracture.
To prevent this, it's essential to use high-quality materials like **316 stainless steel**, which has proven to be durable and resistant to hydrogen embrittlement. For even better performance, choose materials with a nickel content of at least 12%, as higher nickel levels help stabilize the microstructure and improve resistance.
Selecting the right material can prevent hydrogen embrittlement.
Choosing the right material from the start can save costs, increase safety, and extend the life of your system.
#4. Optimize Your Tube Fittings
Not all fittings are created equal. While cone and thread fittings have been widely used in oil and gas systems, they’re not always the best choice for hydrogen. These older designs can be more prone to leaks, especially under high pressure.
Modern alternatives, like **Swagelok’s FK series fittings**, are specifically engineered for hydrogen applications. They offer high-pressure ratings (up to 1050 bar), excellent sealing performance, and long-term reliability.
These fittings are ideal for hydrogen vehicles, refueling stations, and other critical infrastructure.
Learn About Hydrogen Fittings
#5: Consult With the Experts
Hydrogen is still an emerging field, and the technology is evolving rapidly. That’s why it’s important to work with suppliers who understand the unique challenges of hydrogen systems.
A knowledgeable supplier can provide tailored advice, design support, and product recommendations based on your specific application needs. They can also help you stay up-to-date with the latest standards and best practices.
When in doubt, work with a supplier that can offer hydrogen-specific knowledge, design expertise, and product recommendations.
At Swagelok, we specialize in clean energy solutions and offer a complete range of products and services for hydrogen infrastructure. Our engineering team provides expert guidance, helping you build safer, more efficient, and more reliable systems.
Whether you're designing a refueling station, a storage system, or a vehicle component, we’re here to support your success in the growing hydrogen market.
Learn More About Clean Energy Solutions
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