Severity
Near-Miss
Leak
No
Ignition
No

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.

Incident Date
Feb 10, 2009
Setting
Fueling Station
Equipment
  • Vehicle & Fueling Systems
  • Fueling Dispenser
  • Vehicle & Fueling Systems
  • Fueling Hose
Damage and Injuries
None
Probable Cause
Design Flaw
Contributing Factors
Inadequate Inspection
Characteristics
High Pressure (> 100 bar)
When Incident Discovered
During Maintenance
Lessons Learned

Consider design review of all adapter fittings.

Post date
September, 2017

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