Severity
Incident
Leak
Yes
Ignition
No

A sidewall burst failure of a high-pressure polytetrafluoroethylene-lined hose was experienced. The 4.0-m hose was in service for approximately two years, primarily for 70 MPa fueling of hydrogen at ambient conditions ranging from -40 C to +50 C. The total number of fills during its service life was estimated to be 150. In addition to the high-volume fill events, pressure cycling occurred as part of the routine test procedures and operational protocols. These additional pressure-cycling occurrences were approximated to be 200-250 cycles. During each filling cycle, the hose was allowed to bend during connections, as required by the situation. Failure of the hose occurred while temporarily connected to a gas booster, after 1-2 hours of service at 75 MPa. There were no tight bends in the hose during its final service application and no vibration present in the assembly.

Examination of the hose provided additional information. Failure of the hose occurred approximately 30 cm from the crimped end fitting. The hose contained three distinct kinks, or bent areas, all within the immediate area of the failure. However, the burst area did not show any obvious signs of previous damage or flaws. Some strands of the metal braiding exhibited corrosion attack, as well as gouge-type mechanical damage, but no fatigue characteristics or discontinuities were noted on the failed strands that were examined.

Incident Date
Jun 11, 2007
Setting
Equipment
  • Vehicle & Fueling Systems
  • Fueling Dispenser
  • Vehicle & Fueling Systems
  • Fueling Hose
Damage and Injuries
Probable Cause
Contributing Factors
Characteristics
When Incident Discovered
Lessons Learned

High-pressure fueling hoses should be examined daily for signs of external damage, including corrosion, abrasion, cuts, and kinking. High-use fueling hoses should be replaced every six months.

Key:

  • = No Ignition
  • = Explosion
  • = Fire
Hydrogen Incident Summaries by Equipment and Primary Cause/Issue
Equipment / Cause Equipment Design or Selection Component Failure Operational Error Installation or Maintenance Inadequate Gas or Flame Detection Emergency Shutdown Response Other or Unknown
Hydrogen Gas Metal Cylinder or Regulator   3/31/2012
4/30/1995
2/6/2013
4/26/2010 12/31/1969     3/17/1999
11/1/2001
12/23/2003
Piping/Valves 4/4/2002
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
2/7/2009 1/24/1999
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
1/1/1982 9/30/2004
10/7/2005
  10/7/2005  
Compressor   10/5/2009
6/10/2007
8/21/2008
1/15/2019
    10/5/2009 8/21/2008  
Liquid Hydrogen Tank or Delivery Truck 4/27/1989 12/19/2004
1/19/2009
8/6/2004 12/31/1969   1/1/1974 12/17/2004
Pressure Relief Device 7/25/2013
5/4/2012
1/15/2002
1/08/2007
12/31/1969        
Instrument 1/15/2019 3/17/1999
12/31/1969
2/6/2013
    11/13/73    
Hydrogen Generation Equipment 7/27/1999     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