First Name
Andy
Last Name
Piatt
Severity
Near-Miss
Was Hydrogen Released?
Yes
Was There Ignition?
No
Incident Date
Jul 21, 2011
Equipment
  • Vehicle & Fueling Systems
  • Fueling Dispenser
  • Hydrogen Production/Use Systems
  • Fuel Cell
  • Piping/Fittings/Valves
  • Gasket
  • Vehicle & Fueling Systems
  • Fuel Cell Vehicle
  • Vehicle & Fueling Systems
  • Fueling Hose
  • Hydrogen Storage Equipment
  • Gas cylinder
Damage and Injuries
Characteristics
When Incident Was Discovered
Lessons Learned

A hydrogen release of this type is a significant event. The event highlighted a number of procedural contributing factors that will influence the manner in which these fuel cell systems will be serviced in the future. A complicating factor in this event was that multiple companies were involved, and communications among them were inadequate. It is likely that the condition existed from the original manufacture of the fuel cell systems, and may even have been understood by the Company A fuel cell team, but the history is not fully known since that team no longer exists. Company B’s investigation also discovered that a similar leak had been experienced at the same facility and a similar replacement had been required, but there was no corporate memory of the repair or the underlying failure mode.

If a situation arises as a result of consolidation or equipment transfer wherein another entity takes ownership or service and support responsibility for fuel cell systems, the full design history and operating records of the systems must be fully documented and accessible. This will allow for proper knowledge transfer of underlying design considerations or problematic reliability or safety-related issues, and potentially prevent this type of avoidable incident from occurring again.

Another lesson relates to how high-pressure components within the hydrogen fuel storage system are qualified following a repair. It is envisioned that in the near future, there will likely be regional service centers equipped with re-manufacturing capabilities to support commercial fuel cell deployments. These repair shops would be equipped with the infrastructure to properly purge and pressurize equipment with small-molecule gas to test for leaks.

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