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Hydrogen Tube Trailer Burst Disc Ruptures Prematurely While Filling

Severity
Incident
Was Hydrogen Released?
Yes
Was There Ignition?
Yes
Incident Date
Incident Attributes
Lessons Learned

Specific response drills/exercises need to be conducted yearly. In this case, all safety systems worked as they should and outside emergency responders were not needed.
Performing other tasks while filling hydrogen tube trailers, such as mechanic work, should be avoided. Most premature failures of hydrogen tube trailer PRD burst discs occur during the fill process.
Grounding, as was done in the incident, should always be done during hydrogen filling. However, even when the fill vessel is grounded, it is not unusual for a hydrogen release to immediately ignite.
The facility safety deluge water system should be checked periodically for coverage. In this case, a water cannon was a little off target from the last time it was operated and has now be repositioned and stabilized to ensure that it does not move in the future.
Emergency responders assumed that adjacent tube trailers were heating up from single-cylinder vent flare as a 300°F (149°C) reading was obtained with a thermal device. This slightly delayed the closing of the cylinder isolation valves on the tube trailer. After-incident investigation found no paint discolored or burnt, so the temperature taken by the emergency responders was likely near the flaming vent discharge point.
Securing hydrogen fill valve(s) at the back of the tube trailer was not dependent on the temperature at the vent stack, as this area was covered by deluge nozzles and located 40 feet (12.2 meters) away from the vent stack.
Media involvement and resulting speculation can portray a situation as being much worse than it actually is.

Key:

  • = No Ignition
  • = Explosion
  • = Fire
Hydrogen Incident Summaries by Equipment and Primary Cause/Issue
Equipment / CauseEquipment Design or SelectionComponent FailureOperational ErrorInstallation or MaintenanceInadequate Gas or Flame DetectionEmergency Shutdown ResponseOther or Unknown
Hydrogen Gas Metal Cylinder or Regulator 3/31/2012
4/30/1995
2/6/2013
4/26/201012/31/1969  3/17/1999
11/1/2001
12/23/2003
Piping/Valves4/4/2002
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
2/7/20091/24/1999
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
1/1/19829/30/2004
10/7/2005
 10/7/2005 
Compressor 10/5/2009
6/10/2007
8/21/2008
1/15/2019
  10/5/20098/21/2008 
Liquid Hydrogen Tank or Delivery Truck4/27/198912/19/2004
1/19/2009
8/6/200412/31/1969 1/1/197412/17/2004
Pressure Relief Device7/25/2013
5/4/2012
1/15/2002
1/08/2007
12/31/1969    
Instrument1/15/20193/17/1999
12/31/1969
2/6/2013
  11/13/73  
Hydrogen Generation Equipment7/27/1999  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
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