About Hydrogen System Design
When designing fluid systems for hydrogen, it required a different approach as compared to the traditional oil and gas systems.
The reason is simple: hydrogen behaves differently. As the smallest molecules in the universe, it can permeate materials, escape through the tiniest leaks, and react in ways that demand special design considerations—making its unique properties impossible to ignore.
To put it in perspective, if a hydrogen atom were the size of a golf ball, an oil molecule would be as large as the Earth. That’s how remarkably small hydrogen is—small enough to pass through microscopic gaps that oil molecules cannot. This is why precise sealing is not just important, but critical to safe, reliable system performance.
At Swagelok Malaysia, we recognize the unique challenges of hydrogen systems and deliver engineered solutions that meet the demands of this evolving energy landscape. Our tube fittings are specifically designed to mitigate hydrogen leaks, addressing the issue of continuous pore structures—microscopic pathways between metal surfaces that hydrogen can permeate. The FK Series fittings are precision-engineered to minimize these leak paths, helping you maintain system integrity and safety.
Line Sizing: Why Bigger Isn’t Always Better
Line sizing is another area where hydrogen requires a different approach. While engineers often rely on calculators to determine the correct size for managing velocity and pressure drop, hydrogen’s behavior is unique. Its density changes with pressure—which can lead to inaccurate results if not properly accounted for.
Oversizing components—a common habit among designers with oil and gas backgrounds—can significantly inflate costs. For instance, increasing from a ¾-inch to a 1-inch line can raise component costs by up to eight times. Right-sizing is not just efficient—it’s essential.
At Swagelok Malaysia, our team of field engineer can work with you to size your system correctly, balancing performance and cost without compromising safety.
Safety by Design: Keeping Hydrogen Secure
The estimated flammability limit of this substance in the presence of oxygen is approximately 4%. To ensure safety, we maintain concentrations well below that level—typically around 1%. Any leaks that could cause accumulation near or above this level are considered a serious concern and must be addressed immediately. Consistency in system design is critical. Mixing technologies from multiple vendors, a common cost-cutting approach in oil and gas, can lead to maintenance challenges, operational inefficiencies, and increased risk of failure.
Swagelok Malaysia offers a fully integrated portfolio of valves and fittings, ensuring compatibility, reliability, and long-term safety. Ready to optimize your hydrogen infrastructure? For more information, contact us at malaysiaenquiry@swagelok.com
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