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Small Fire in Fuel Cell Test Stand

Severity
Incident
Was Hydrogen Released?
Yes
Was There Ignition?
Yes
Incident Date
Incident Attributes
Setting
Damage and Injuries
Probable Cause
Contributing Factors
When Incident Was Discovered
Describe the incident, including corrective steps taken and their result.

A small electrical fire occurred (due to what is believed to be an electrical short circuit) inside a fuel cell test stand. Subsequently, a nearby hydrogen line made of flexible tubing was melted through and ignited the hydrogen, causing a small fire.

The electrical fire was easily extinguished. The hydrogen flame was extinguished by snuffing the flame, shutting off the gas lines and power to the test stand. No one was injured, but damage was incurred in the test stand.

Causes

  1. An electrical short circuit occurred, causing a small electrical fire.
  2. Electrical fire caused a flexible tubing hydrogen line to melt, thus exposing hydrogen to the fire.
Lessons Learned

Immediate Corrective Actions

  1. Fuel cell test stand was shutdown and sent to manufacturer for investigation.
  2. Carbon dioxide fire extinguisher installed in laboratory.
  3. Formal process hazard review performed

Long-Term Corrective Actions

  1. Replaced all flexible tubing in test stand with stainless steel (316).
  2. Replaced water knockout device with latest manufacturer's design on both the H2 and O2 lines to reduce the risk of gas flame by leached catalyst.
  3. Installed a “High-pressure trip – Carbon dioxide” fire suppression system in the lab.
  4. Installed a redundant hydrogen detector inside the test stand.
  5. Installed an external hydrogen delivery system with stainless steel feed lines into the lab.
  6. Revised the Standard Operating Procedure for the fuel cell test stand.

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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