Severity
Incident
Leak
Yes
Ignition
Yes

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

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

Incident Date
May 03, 2004
Setting
Laboratory
Equipment
  • Electrical Equipment
  • Piping/Fittings/Valves
  • Flexible Tubing
  • Hydrogen Production/Use Systems
  • Fuel Cell
Damage and Injuries
Property Damage
Probable Cause
Equipment Failure
Contributing Factors
Design Flaw
When Incident Discovered
During Operations
Lessons Learned

Immediate Corrective Actions

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

Long-Term Corrective Actions

Replaced all flexible tubing in test stand with stainless steel (316).
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.
Installed a “High-pressure trip – Carbon dioxide” fire suppression system in the lab.
Installed a redundant hydrogen detector inside the test stand.
Installed an external hydrogen delivery system with stainless steel feed lines into the lab.
Revised the Standard Operating Procedure for the fuel cell test stand.

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