Image depicting high-performing hydrogen infrastructure
Hydrogen infrastructure is key to the future of clean energy.

The Top 5 Best Practices for Designing Hydrogen Fluid Systems

Hydrogen is one of the most promising sources of clean and sustainable energy, with applications ranging from transportation and material handling to stationary, portable, and emergency backup power. As industries around the world explore its potential, it's becoming clear that designing effective hydrogen fluid systems requires a unique approach. Unlike traditional oil and gas systems, which are often hidden from public view and managed by professionals, hydrogen infrastructure is increasingly being used in everyday settings—such as refueling stations for hydrogen fuel cell vehicles. This shift means that safety, reliability, and user experience must be at the forefront of system design. To help you navigate this evolving field, here are our **top five best practices** for designing safe and efficient hydrogen fluid systems:

#1. Consider the End User

Most industrial oil and gas systems are out of sight and handled by trained professionals. But hydrogen is different—it’s moving into the hands of everyday people. Whether it's a driver refueling a hydrogen-powered car or a technician working with a hydrogen storage unit, the design must account for real-world use cases. Icon for hydrogen design Hydrogen systems must be designed with specific use challenges in mind. From ease of operation to visibility and accessibility, every detail can impact performance and safety.

User operating a hydrogen dispenser, a key part of hydrogen infrastructure

For example, a hydrogen dispenser must be intuitive, easy to use, and built with safety features that protect both the user and the system. The goal is to make hydrogen as convenient and reliable as any other fuel source.

#2. Minimize Potential Leak Points

One of the biggest challenges in hydrogen systems is the risk of leaks. Hydrogen molecules are extremely small, making them more likely to escape through even the tiniest gaps in a system. Unlike larger hydrocarbon molecules, hydrogen can easily pass through seals, gaskets, and connections that would otherwise be sufficient for oil and gas applications. Hydrogen molecule icon This means that traditional oil and gas design practices may not be suitable for hydrogen. To reduce the risk of leaks, it’s important to minimize the number of connections and use advanced tube-bending techniques where possible. Your supplier can also provide guidance on best practices for leak-tight design.

#3: Utilize High-Quality Stainless Steel

Hydrogen can cause a phenomenon known as **hydrogen embrittlement**, which weakens metal over time and increases the risk of failure. This is especially true for materials that aren’t specifically designed for hydrogen environments. Diagram illustrating how hydrogen embrittlement occurs Choosing the right material is crucial. High-quality 316 stainless steel, particularly with at least 12% nickel content, is often recommended for hydrogen systems. Nickel helps stabilize the microstructure of the steel, making it more resistant to embrittlement and extending the life of the system.

#4: Optimize Your Tube Fittings

Not all fittings are created equal when it comes to hydrogen. Traditional cone-and-thread fittings, commonly used in oil and gas, may not be ideal for hydrogen due to their susceptibility to leakage. These older designs were developed in the late 1800s and may not meet modern performance standards. Icon for hydrogen design Modern alternatives like Swagelok’s FK series fittings are engineered specifically for hydrogen applications. They offer high-pressure ratings, excellent sealing performance, and long-term reliability. Choosing the right fitting can significantly improve the safety and efficiency of your system.

#5: Consult With the Experts

Hydrogen is still a relatively new area for many engineers and designers. While progress is being made, there are still many unanswered questions and evolving standards. Icon for hydrogen design training Working with experienced suppliers who specialize in hydrogen can make a big difference. They can provide not only the right products but also valuable insights, design support, and technical expertise tailored to your specific needs. Whether you're building hydrogen fueling stations, storage systems, or vehicle components, expert guidance can help you avoid common pitfalls and ensure your system meets the highest standards of safety and performance.

An engineer inspecting hydrogen infrastructure

If you're looking to learn more about hydrogen best practices, product options, and design strategies, continue exploring Swagelok Reference Point for the information you need to succeed in this growing industry.

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