Fire at Hydrogen Fueling Station

First Name
Andy
Last Name
Piatt

A fire began in the compression skid for a high-pressure hydrogen fueling station. The initial source of fire was likely a release of hydrogen from a failed weld on a pressure switch. The initial fire cascaded to three stainless steel line failures, release of glycol coolant, and release/combustion of compressor oil. Non-metallic seals and hoses containing hydraulic fluid and coolant melted/burned and caused leakage of the fluid, which was mostly consumed by the fire.

Hydrogen Fueling Dispenser Nozzle Detached

First Name
Andy
Last Name
Piatt

The hydrogen fueling dispenser nozzle could not be completely disconnected from the vehicle after refueling. It was finally disconnected after trying several times. The cover of the nozzle interfered with the disconnection operation. No malfunction of the nozzle was found. It can be easily disconnected when it is withdrawn along its axis. Sometimes misalignment occurred due to the weight of the dispenser hose.

Hydrogen Leakage from Ground Packing of Flow Control Valve

First Name
Andy
Last Name
Piatt

The hydrogen sensor at a hydrogen fueling station detected a slight leakage from the ground packing of the flow control valve during refueling. The refueling operation was stopped immediately. The leak was stopped by tightening the ground packing sealing screw, but it started leaking again in about a week.

Hydrogen Fueling Dispenser Nozzle Drive Away

First Name
Andy
Last Name
Piatt

A fueler drove away without disconnecting the fueling hose from the vehicle. The breakaway did not open and the receptacle fitting sheared off the vehicle. Subsequent testing of the breakaway showed that the breakaway operated at 210 lbs, which was above the design value of 133 lbs. The hydrogen contained in the hose between the dispenser shutoff valve and the vehicle check valve was released.

Breakaway Separation During Fueling

First Name
Andy
Last Name
Piatt

During a 70-MPa fueling, the fueling hose breakaway separated. The separation occurred without any extraneous forces other than the pressure of the gas internal to the fueling hose. Upon investigation, it was determined the pull force set point was incorrectly adjusted. No further issues or actions.

Leak on Compressor at Fueling Station

First Name
Andy
Last Name
Piatt

A vehicle fill depleted the high-pressure hydrogen inventory. The compressor turned on to refill the storage by compressing 60 psig gas from a liquid hydrogen tank up to the 5500 psig storage pressure. After running about 2 hours, a crankshaft bearing started to fail. This allowed greater movement of the shaft, which led to a shaft seal leaking hydrogen. The compressor shut down on low suction pressure and then the system was shut down using the e-stop by the emergency responders.

Leak at Breakaway Fitting

First Name
Andy
Last Name
Piatt

A vehicle fill was initiated by the operator. During the hose pressurization step, a leak was observed at the breakaway fitting. The operator pressed the emergency stop to terminate the fill.

Hydrogen Fueling Dispenser Breakaway Adapter

First Name
Andy
Last Name
Piatt

During maintenance on a breakaway fitting, a review of the pressure rating of the adapter fitting connecting the pipe to the breakaway found the adapter to be under rated for the design pressure. While the male straight-thread side of the "standard" fitting was rated to 7700 psig, the female compression-tube end of the same fitting was rated to only 4900 psig. The adapter was replaced with a fitting of increased wall thickness meeting the design pressure rating.

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