LESSONS
LEARNED
Disclaimer: The Lessons Learned Database includes the incidents that were voluntarily submitted. The database is not a comprehensive source for all incidents that have occurred.

Stainless Steel (403) Failure in Liquid Hydrogen Line

Severity
Near-Miss
Was Hydrogen Released?
No
Was There Ignition?
No
Incident Attributes
Setting
Laboratory
Equipment
Measurement / Sensing Device
Piping
Damage and Injuries
Property Damage
Probable Cause
Design Flaw
Contributing Factors
Human Error
Characteristics
Low Temperature (< -100°C)
When Incident Was Discovered
During Operations
Describe the incident, including corrective steps taken and their result.

A bourdon tube ruptured in a pressure gage after 528 hours of operation in a liquid H2 system. The alarm sounded, the system was isolated and then vented.

Lessons Learned

The tube was 403 stainless steel, which is subject to hydrogen embrittlement. It is requested that all gauges that have bourdon tubes be replaced with 303 stainless steel.

A web-based resource developed by Sandia National Laboratories to provide data on hydrogen embrittlement of various materials is available at Technical Reference for Hydrogen Compatibility of Materials.

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

This material was prepared as an account of work sponsored by an agency of the United States Government.
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