Skip to main content

This data is from the European Hydrogen Incidents and Accidents database HIAD 2.1, European Commission, Joint Research Centre.

Fire When Refilling a Cylinder at a Hydrogen Storage Facility
While filling a 9 litre gas cylinder with pressurised hydrogen in the hydrogen storage area, a blast occurred which destroyed the low pressure gauge, followed by a jet fire which damaged the surface of the cylinder.The cylinder to be filled, including pressure gauge and control system, had been provided by a third party. Its nominal pressure was 35 MPa, however the maximal pressure of this filling would have been much lower, less than 20 MPa, corresponding to the maximal pressure of the bulk storage available. The pressure regulator system at the inlet of the cylinder consisted of a classic setup with a needle valve able to control the gas flow, and two pressure gauges for the high pressure (storage side) and low pressure (cylinder outlet). The blast occurred when the cylinder was approximately at 8 MPa, destroying the low-pressure gauge. The hydrogen started leaking through the damaged gauge, ignited forming a jet flame directed downwards, melting the plastic protective external layer of the gas cylinder, and probably starting damaging the carbon-reinforced epoxy layer of the cylinder.
Event Date
June 16, 2022
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The root cause of the incident has been a malfunction of the pressure regulator mounted on the gas cylinder. This could have been linked to a design failure, a mounting failure or a material failure. The investigation results performed by the pressure gauge manufacturer has not ben able to clarify these doubts. The ignition cause was mostly likely due to electrostatic sparks generated by the metallic and glass debris produced by the mechanical failure of the pressure gauge. Other possible cause could be friction of the gas high flow through the gauge pipe.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
Pressure control system, pressure gauge, type-4 cylinder
Storage/Process Medium
Actual Pressure
20
Design Pressure
20
Location Type
Location description
Inhabited Area
Operational Condition
Pre-event Summary
The filling of the tank occurred upon request of a customer. It was not part of the routine operation of the laboratory. Two fillings of the same type had already been performed in the previous weeks, without any remarkable difficulty.
Lessons Learned
Lessons Learned
LESSON LEARNED:The technician involved in the incident was a very experienced operator, since years responsible not only for the hydrogen storage facility, but also for all fuel cells and electrolyzers testing laboratories. Since the start of the incident sequence, the technician acted timely and effectively to reduce the risk (interruption of the hydrogen main supply, realisation of the presence of a flame, use of local fire extinguishers, call of the fire brigade). Nevertheless, the operation which brought to the incident was not part of the normal practices and not explicitly covered by risk assessment and the safety measures put in place for the laboratory operation. Moreover, the incident revealed the difference between theoretical knowledge of the possible risks and consequences, and the practical realisation of the same. The two following facts are worth a mention: the possible existence of a completely transparent hydrogen flame was not considered as a possibility by the technician at the start of the chain of events. He realised this possibility only when he felt by hand a temperature increase on the pressure regulator, and saw the development of fumes on the tank. To stop the supply of hydrogen from the storage to the tank, he moved to the control panel of the storage facility, installed at the wall behind the cylinders bundles. In this way, he has been able to minimise the total release of hydrogen, and excluded the possibility of consequences escalation. However, he put himself in a dangerous situation, trapped between the wall and the hydrogen flame, instead of stepping away of he facility to a safe distance. CORRECTIVE ACTIONS(1) The safety measures in place in the storage facility have been thoroughly reviewed, including the standard connection procedures.(2) A basic training was provided on compressed gases handing, including how to deal with pressure reduction devices, not only to technician directly involved with hydrogen, but to all technicians on site. A list of additional, more advanced and more specific exercises has been collected and sent for prioritisation to the training officer. (3) The refilling of bottles provided by customers and for customers use has been prohibited at the storage facility. The reason is that it is impossible to independently control and assess the quality of the components delivered, often manufactured by different 1st and 2nd Tier producers and assembled by customers. (4) For the regular use of hydrogen by G.I.4 laboratory, other, safer solutions shall be used (for example the delivery of already filled cylinders with the required size by a contractor). (5) The possibility of filling hydrogen cylinders at the storage facility for JRC-internal purposes will be maintained, but it will remain a special operation, to be executed ad-hoc, when special circumstances requires it. (6) Therefore, a dedicated Task Instruction document will be prepared beforehand for the activity at (5), describing in detail the series of actions required. Only components will be used certified according to the European Pressurised Equipment Directive. The Control Panel will be also placed in the most favourable place to facilitate a quick evacuation. (7) The Task instruction will explicitly mention that the filling can only be performed by directly connecting the hydrogen storage system to the receiving cylinder by means flexible connector (cascade filling), without the use of pressure regulator or other pressure conditioning systems.
Event Nature
Emergency Action
The technician performing the filling executed the following actions:1) Isolate and shut down hydrogen supply to the gas cylinder from bulk storage2) Open the cylinder-mounted outlet valve attempting to discharge the hydrogen from the gas cylinder; this action did not have any effect due to the non-returning feature of that valveAfter having noticed that the cylinder had increased in temperature, he suspected the presence of a flame, although this was complete invisible (the incident occurred during the day). He proceeded than the following actions: 3) Tried to extinguish the initial hydrogen flame using the fire extinguisher provided in the storage facility, but the production of fume continued,4) Called fire brigade who extinguished the recurring hydrogen flame and fire on the plastic insulation around the top of the gas cylinder
Emergency Evaluation
The incident could have had much more sever consequences, if the technician would have placed the hand directly under the flame
Release Type
Release Substance
Hydrogen Release Concentration (%)
100.00
Release Pressure (bar)
8.00
Ignition Source
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Flame Type
Source Category
References
References

Publicly not available

We are professional and reliable provider since we offer customers the most powerful and beautiful themes. Besides, we always catch the latest technology and adapt to follow world’s new trends to deliver the best themes to the market.

Contact info

We are the leaders in the building industries and factories. We're word wide. We never give up on the challenges.

Recent Posts