SAFETY
PREVENTING HYDROGEN LEAKAGE
How pressure relief valves with rupture discs can stem hydrogen leakage
H
ydrogen is rapidly gaining traction as a clean, efficient, and versatile energy source, making it a key player in the
global transition toward sustainable energy. However, its unique properties present specific challenges, particularly its tendency to leak. In hydrogen systems, even minor leakage can pose serious safety, environmental, and economic concerns. One critical area of focus is the prevention of leakage through safety devices such as pressure relief valves (PRVs).
WHY HYDROGEN LEAKS SO EASILY Hydrogen H2 is the smallest and lightest of molecules, composed of two protons and two electrons. The small molecular size makes it far more likely to escape containment than other gases. There are three main reasons for its high leakage potential:
Small molecular size: Hydrogen molecules can penetrate microscopic imperfections in materials or poorly sealed connections that would easily contain larger gases.
Low viscosity: This allows hydrogen to flow and spread more easily, increasing the likelihood of escape through small gaps or poor seals.
High diffusivity: Hydrogen can diffuse quickly through many materials, including metals, leading to a phenomenon known as hydrogen embrittlement over time.
These factors combine to make hydrogen highly prone to leakage.
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A critical step in hydrogen system design
As hydrogen systems scale up and become more widespread, attention to detail in design is crucial. Preventing hydrogen leakage isn’t just about plugging holes, it’s about understanding the unique behaviour of the gas and engineering solutions that meet those challenges. Using rupture discs in combination with pressure relief valves is one
such simple and cost-efficient solution. This prevents leakage, enables easier testing, reduces maintenance costs, and extends equipment life. For any industry moving toward hydrogen, this pairing should be a standard part of the containment strategy.
A rupture disc in PRV
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