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.

Contributing Factors

Damage and Injuries

Equipment

Probable Cause

CHECK OUT OUR MOST RELEVANT INCIDENT LISTINGS!

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.

H2 Lessons Learned

H2 Analytics

Lessons Learned Corner

Liquid Hydrogen Tank Boiling Liquid Expanding Vapor Explosion (BLEVE) due to Water-Plugged Vent Stack
  1. Place signs on all liquid hydrogen tanks indicating that no water is to be put on the vent stack.
  2. An additional secondary backup vent stack was added to liquid hydrogen tanks. This secondary stack is designed to be used only if…
Fire and Explosion in Autoclave Cell

The ignition of the fireball could have been caused by any of the following mechanisms:

  • The inverse Joule-Thompson effect of hydrogen (i.e., heating upon expansion)
  • Some of the oil and light ends were above their auto-…
Hydrogen Tube Trailer Burst Disc Ruptures Prematurely While Filling
  1. 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.
  2. Performing other tasks while filling hydrogen tube trailers,…
Hole In Ampoule Leads to Explosion
  • Metal hydride materials of a composition which is not well characterized should be handled with procedures that assume a "worst case" for that class of materials, intermediates or precursors.
  • Laboratory procedures should be in…
Hole In Ampoule Leads to Explosion
  • Metal hydride materials of a composition which is not well characterized should be handled with procedures that assume a "worst case" for that class of materials, intermediates or precursors.
  • Laboratory procedures should be in…
Hydrogen Delivery Truck/ Facility Connection Mishap
  • All tank trailers should have a safely accessible auxiliary shut off valve in case of spills.
  • Emergency personnel need to have access to all of the appropriate protective clothing, including shoes. Liquid hydrogen is stored at 20…
Hydrogen Leak Ignites at an Alkylbenzene Manufacturing Plant
  1. The plant tried to increase production and decrease workload, but failed to notice the potential negative outcomes of this change.
  2. It is necessary to thoroughly simulate all potential negative outcomes of a change in procedures…
Check Valve Shaft Blow-Out due to Hydrogen Embrittlement

Facilities should review their process systems to determine if they have valves installed that may be subject to this hazard. If so, facilities should conduct a detailed hazard analysis to determine the risk of valve failure. Detailed internal…

Reactive Chemical Treatment Causes Beaker to Shatter

On-site personnel performing treatment of reactive metals/chemicals must continue to exercise caution. Although there is an inherent risk in treating reactive metals/chemicals, personnel must adhere to conduct of operations principles to include…

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.
Twitter H2Tools Facebook H2Tools Instagram H2Tools YouTube H2Tools

Contact

The portal brings together and enhances the utility of a variety of tools and web-based content on the safety aspects of hydrogen and fuel cell technologies to help inform those tasked with designing, approving or using systems and facilities, as well as those responding to incidents.

Copyright © 2025 by H2Tools; H2 Tools is intended for public use. It was built, and is maintained, by the Pacific Northwest National Laboratory with funding from the DOE Office of Energy Efficiency and Renewable Energy's Hydrogen and Fuel Cell Technologies Office. All Rights Reserved
We are professional and reliable provider since we offer customers the most powerful and beautiful themes. Besides, we always catch the latest technology and adapt to follow world’s new trends to deliver the best themes to the market.

Contact info

We are the leaders in the building industries and factories. We're word wide. We never give up on the challenges.

Recent Posts