As the United States accelerates toward a net-zero emissions future, hydrogen is emerging as a cornerstone of the national energy strategy. However, transitioning from Liquefied Petroleum Gas (LPG) infrastructure to hydrogen systems is not a plug-and-play upgrade—it requires careful engineering, smart automation, and robust safety controls. With the Department of Energy (DOE) prioritizing hydrogen hubs and clean fuel innovation, engineering leaders must now bridge legacy energy infrastructure with next-generation solutions.
LPG vs. Hydrogen:** Understanding the Infrastructure Shift**
Although Liquefied Petroleum Gas (LPG) and hydrogen are both gaseous fuels used in energy and industrial applications, the infrastructure required to handle each safely and efficiently differs substantially. Hydrogen, being the lightest element in the periodic table, is significantly more diffusive than LPG. This means it can escape through microscopic leaks in containment systems, requiring storage and piping materials that are not just durable but also highly resistant to permeability and hydrogen embrittlement—a condition where hydrogen atoms weaken metal structures over time.
Storage vessels for hydrogen must be engineered to withstand much higher pressures—often up to 700 bar—or in some cases, extremely low cryogenic temperatures when stored as a liquid. In contrast, LPG storage tanks (commonly bullet-shaped) operate at lower pressures and do not require cryogenic insulation. Furthermore, the detection systems used in LPG plants are not sensitive enough for hydrogen, which is odorless, colorless, and burns with an invisible flame, making it far more difficult to detect with conventional leak sensors. Specialized detectors using thermal conductivity or catalytic sensors must be deployed in hydrogen environments to ensure timely alerts.
The distribution infrastructure for hydrogen—comprising pipelines, valves, regulators, compressors, and fittings—must be purpose-built to handle hydrogen’s smaller molecular size and unique diffusion behavior. Even components like gaskets, seals, and lubricants must be carefully selected to avoid chemical degradation. In short, converting an LPG facility to handle hydrogen is not merely a fuel switch; it demands a comprehensive redesign of physical infrastructure, operational protocols, and safety systems.
Smart Safety: SCADA, AI, and Process Safety Management
Ensuring safety in hydrogen infrastructure is more challenging due to its physical properties and higher reactivity. To address these challenges, energy facilities are increasingly relying on intelligent control systems, including SCADA (Supervisory Control and Data Acquisition), PLCs (Programmable Logic Controllers), and integrated AI platforms. SCADA systems provide centralized, real-time monitoring of tank pressures, flow rates, ambient temperatures, and leak detection sensors across hydrogen storage and distribution assets. With these systems, operators can detect minute changes in system behavior and initiate rapid shutdown procedures or safety interventions.
The integration of AI-driven fault prediction models further enhances system resilience. These models use historical data, live sensor inputs, and environmental variables to detect abnormalities such as micro-leaks, valve fatigue, or abnormal temperature gradients that could indicate impending failure. AI can analyze trends that human operators may miss, reducing the likelihood of critical incidents through early warning mechanisms and predictive diagnostics.
In tandem, Smart Process Safety Management (PSM) frameworks provide structured tools to manage hydrogen risks. These include digital risk registers, automated HAZOP (Hazard and Operability Study) workflows, ERP-integrated safety dashboards, and compliance tracking modules. These systems work together to proactively identify hazards, implement mitigation controls, and ensure regulatory compliance under OSHA, NFPA, and DOE standards.
Adar Chowdhury, with over 12 years of experience in LPG terminal development, brings a deep understanding of both the legacy systems and the modern safety technologies needed for hydrogen. His expertise in SCADA integration, CMMS (Computerized Maintenance Management Systems), and regulatory alignment with ISO 45001, NFPA 58, and DOE guidance makes him an ideal leader in the transition from LPG to hydrogen infrastructure. He has successfully deployed digital safety systems across LPG facilities, which are now directly adaptable to hydrogen projects.
Engineering the Transition: Adar’s Experience and the U.S. Opportunity
Throughout his engineering career, Adar has been at the forefront of gas infrastructure development, particularly in high-risk industrial environments. He has led the design and installation of high-pressure gas systems, overseen SCADA-based leak detection platforms, and developed fire protection strategies for LPG terminals. His work includes implementing ERP-integrated maintenance tracking systems, ensuring that compliance, safety checks, and performance audits are all logged digitally and accessible in real time.
Adar has also played a key role in conducting Pre-Startup Safety Reviews (PSSR), coordinating Emergency Response Plans (ERP), and supervising multi-disciplinary teams during large-scale commissioning. His approach bridges technical engineering with process optimization, ensuring that safety and performance are not competing goals, but complementary outcomes. As hydrogen infrastructure rolls out across the U.S., the industry requires professionals who understand not only the technical design of gas systems but also the evolving requirements of smart automation, digital compliance, and net-zero energy alignment. Adar’s track record positions him to provide this critical bridge.
Importantly, the transition to hydrogen is not solely about upgrading physical systems—it also involves transferring institutional knowledge, redesigning workflows, and aligning industrial practices with federal climate goals. With Adar’s multidisciplinary background, he brings together field engineering, digital systems, and policy-informed execution, making him a key enabler of safe and successful hydrogen infrastructure deployment.
A Net-Zero Future Needs Smart Transitions
As the United States pushes forward with its clean energy commitments, hydrogen is expected to play a central role in achieving net-zero emissions across power generation, transportation, and industrial sectors. DOE-backed hydrogen hubs and bipartisan energy investments are accelerating the pace of infrastructure development. However, to ensure that this growth is safe, scalable, and sustainable, it must be anchored in practical engineering experience and smart safety technologies.
Lessons learned from LPG operations—ranging from incident response to asset lifecycle management—should guide the design of new hydrogen facilities. By combining AI, SCADA, CMMS, and PSM systems, energy companies can create predictive, connected, and automated safety environments. Through the leadership of engineers like Adar Chowdhury, who bring a balance of field-tested knowledge and digital innovation, the U.S. can turn hydrogen into not just a fuel of the future, but a safe and reliable solution for today’s energy challenges.
In the end, the transition to hydrogen is not just an energy shift—it’s a transformation in how we engineer, monitor, and protect the systems that power our world.
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