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Fuel Cell Evaporator Pad Fire

Severity
Incident
Was Hydrogen Released?
No
Was There Ignition?
Yes
Incident Date
Ignition Source
unknown
Incident Attributes
Equipment
Damage and Injuries
Probable Cause
Contributing Factors
When Incident Was Discovered
Describe the incident, including corrective steps taken and their result.

The evaporator pad in a fuel cell power unit installed in a hydrogen-powered forklift caught fire during operation. The evaporator pad is used for wicking the product water created by the fuel cell. The operator dismounted the forklift, observed flames coming from the fuel cell unit, and called for help. The facility fire brigade used a fire extinguisher to put out the fire. The upper left corner of the fuel cell evaporator pad was burned entirely; the plastic bracket that holds the evaporator pad in place was distorted; there was some discoloration of the radiator. No injuries were sustained by the operator and no damage was sustained by the forklift.

The fuel cell unit continued to run during the incident, as did the onboard data acquisition device. Hydrogen concentrations from an array of six hydrogen sensors around the unit during low and high duty cycles measured at less than 0.2%.

Lessons Learned

The root cause of the fire that burned the evaporator pad and distorted the plastic evaporator pad bracket remains unknown. The initial investigation did not reveal any obvious signs of an ignition source in the vicinity of the forklift operation. The on-board data acquisition system did not indicate any abnormalities in the operating parameters of the fuel cell system (e.g., temperature, pressure, voltage, current). The fuel cell was disassembled, but no evidence was found of any electrical shorts or other potential ignition sources. Thus it was concluded that the fuel cell unit itself was not the ignition source for this incident.

One theory presented the possibility of a spark (caused by static electricity) being the source of the ignition that caused the fire. Due to the proximity of the fuel cell unit to a shrink-wrap packaging machine at the time of the incident, this seemed to be a plausible hypothesis. However, sparking tests on evaporator pad materials failed to confirm this, and it seems highly unlikely that a wet evaporator pad would ignite from static electricity. The true ignition source for this incident remains unknown.

After the initial investigation, the company used a hydrogen meter to monitor hydrogen levels near the evaporator pad during fuel cell start-up (which they expected to be the highest, due to a system purge). They also wanted to investigate if hydrogen could become trapped near the vent covering the evaporator pad. The tests indicated hydrogen levels well below the lower flammability limit (0.022%). Similar readings were also detected from the exhaust on the other make/model fuel cells operating in the facility. They detected no sign that high levels of hydrogen were trapped near the vent of any fuel cell make/model.

Key:

  • = No Ignition
  • = Explosion
  • = Fire
Hydrogen Incident Summaries by Equipment and Primary Cause/Issue
Equipment / CauseEquipment Design or SelectionComponent FailureOperational ErrorInstallation or MaintenanceInadequate Gas or Flame DetectionEmergency Shutdown ResponseOther or Unknown
Hydrogen Gas Metal Cylinder or Regulator 3/31/2012
4/30/1995
2/6/2013
4/26/201012/31/1969  3/17/1999
11/1/2001
12/23/2003
Piping/Valves4/4/2002
2/2/2008
5/11/1999
4/20/1987
11/4/1997
12/31/1969
8/19/1986
7/27/1991
12/19/2004
2/6/2008
10/3/2008
4/5/2006
5/1/2007
9/19/2007
10/31/1980
2/7/20091/24/1999
2/24/2006
6/8/1998
12/31/1969
2/7/2009
9/1/1992
10/31/1980
10/3/2008 
Tubing/Fittings/Hose 9/23/1999
8/2/2004
8/6/2008
9/19/2007
1/1/19829/30/2004
10/7/2005
 10/7/2005 
Compressor 10/5/2009
6/10/2007
8/21/2008
1/15/2019
  10/5/20098/21/2008 
Liquid Hydrogen Tank or Delivery Truck4/27/198912/19/2004
1/19/2009
8/6/200412/31/1969 1/1/197412/17/2004
Pressure Relief Device7/25/2013
5/4/2012
1/15/2002
1/08/2007
12/31/1969    
Instrument1/15/20193/17/1999
12/31/1969
2/6/2013
  11/13/73  
Hydrogen Generation Equipment7/27/1999  10/23/2001   
Vehicle or Lift Truck 7/21/2011    2/8/2011
12/9/2010
Fuel Dispenser 8/2/2004
5/1/2007
6/11/2007
9/19/2007
 2/24/2006
1/22/2009
   
Fuel Cell Stack      5/3/2004
12/9/2010
2/8/2011
Hydrogen Cooled Generator   12/31/1969
2/7/2009
   
Other (floor drain, lab
anaerobic chamber,
heated glassware,
test chamber,
gaseous hydrogen
composite cylinder,
delivery truck)
 11/14/1994
7/21/2011
7/27/1999
6/28/2010
8/21/2008
12/31/1969
3/22/2018
  6/10/2019
  • = No Ignition
  • = Explosion
  • = Fire
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