First Name
Andy
Last Name
Piatt
Severity
Incident
Was Hydrogen Released?
Yes
Was There Ignition?
No
Incident Date
Mar 16, 2009
Equipment
  • Pressure Relief Devices
  • Burst Disk
  • Hydrogen Storage Equipment
  • Vent line
Damage and Injuries
Characteristics
When Incident Was Discovered
Lessons Learned

Metallurgical examination of the two failed disks by light optical microscopy (LOM), scanning electron microscopy (SEM), and energy-dispersive x-ray spectroscopic analysis (EDS) found them to be fabricated from pure nickel with evidence of extensive fracture. Each of the 24 tubes in the system is protected by a burst disk. Examination of another disk in the system that had not given way found that it, too, possessed surface fracture features, and they extended around the entire periphery of the rupture disk. Such defects are indicative of hydrogen embrittlement. An inspection of all vent circuits found that each of the 24 disks in service was made from nickel. Nickel is a material not recommended for hydrogen service in rupture disks.

Prior to the attempted use of the tube bank for hydrogen service, the vessel had been employed for helium service. The pressure vessel documentation accompanying the system indicated that the burst disks were made of stainless steel and rated to 10,000 psig. Careful physical inspection of system hardware is recommended on any system being adapted to hydrogen service. In this instance, inspection conducted prior to the transfer in service could have alerted operators to the need to install disks with the proper material, and therefore, have prevented the incident.

Relief of hydrogen gas should not lead to movement of the vent line sufficient to cause system damage. Corrective actions included increasing the line diameter and adding bracing between the lines and the system bulkhead to strengthen the components should other releases occur. The hardware that failed was of a commercial origin. Caution should be exercised to insure that all hardware is adequate for its designed purpose, even when procured from a commercial source.

More information on management of change can be found in the Lessons Learned Corner and also in the Hydrogen Safety Best Practices Manual. A web-based resource developed by Sandia National Laboratories to provide data on hydrogen embrittlement of various materials is available at Technical Reference for Hydrogen Compatibility of Materials.

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