Field Engineer - Hyrdrogen Leak Detection

Hydrogen Leak Detection and System Integrity

Jim Hangge, Applications Engineer, has been with Swagelok Minnesota for 3 years.

Hydrogen is a small and highly diffusive molecule, making leak detection a critical and important concern. Swagelok Minnesota | North Dakota | Appleton provides advanced hydrogen leak detection services, both onsite at customer facilities and in manufacturing processes, to identify and address leaks before they become hazardous and dangerous.

Swagelok Minnesota | North Dakota | Appleton provides the following services to robustly improve your energy facility:

Onsite Hydrogen Leak Audits: Our experienced engineers visit customer sites and conduct helium leak detection tests. Because of helium's similarity in size to hydrogen molecules, these tests are incredibly accurate, and crucial in detecting leaks. The engineers also utilize hydrogen detectors that test the lines while the process is running.
Component-Level Leak Testing: Every fitting and assembly produced by Swagelok Minnesota | North America | Appleton is rigorously tested to meet industry-leading leak integrity standards, ensuring leak-free performance up to 20,000 PSI.
Minimizing Flammability Risks: Since hydrogen becomes flammable between 4-75% in the air or 4-95% in oxygen concentration, and detonation limits are 18-59% in air or 15-90% in oxygen, Swagelok’s components are engineered with this in mind to minimize leak paths and prevent dangerous gas accumulation.

Photography-Field Engineer7-1

Schedule your hydrogen leak audit today!

Case Study: Hydrogen Leak Detection & Prevention

One of Swagelok Minnesota | North Dakota | Appleton’s customers* —a hydrogen producer—had been experiencing gradual pressure loss in their storage and transport systems, but could not identify the source of the leaks.

"[They] were losing hydrogen, but it was happening so slowly that it wasn’t immediately obvious where the issue was…" Swagelok application engineer Jim Hangge shared. "We performed an onsite helium leak test and found multiple micro-leaks in their system. By replacing outdated fittings with Swagelok’s high-integrity components, they significantly reduced gas loss and improved operational efficiency."

In another case, a hydrogen refueling station had concerns about pressure instability and potential leaks during high-volume dispensing. Swagelok engineers went in and quickly identified sealing inconsistencies in the station’s pressure regulators and fittings.

"We helped them upgrade to components with tighter sealing tolerances, which eliminated leaks and made their fueling process safer and more consistent," Hangge explained.

These proactive hydrogen leak detection strategies help hydrogen producers, transporters, and fuel stations prevent energy loss, safety hazards, and compliance issues, ensuring reliable hydrogen infrastructure growth.

*details have been generalized to maintain customer anonymity.

Swagelok Fluid Systems Blog

Want more insights on fluid system solutions? Our blog is packed with expert advice, industry trends, and practical tips to help you optimize performance. Explore more articles on our blog page!