What is Lessons Learned?

What is H2LL?

This database is supported by the U.S. Department of Energy. The safety event records have been contributed by a variety of global sources, including industrial, government and academic facilities.

H2LL is a database-driven website intended to facilitate the sharing of lessons learned and other relevant information gained from actual experiences using and working with hydrogen. The database also serves as a voluntary reporting tool for capturing records of events involving either hydrogen or hydrogen-related technologies.

The focus of the database is on characterization of hydrogen-related incidents and near-misses, and ensuing lessons learned from those events. All identifying information, including names of companies or organizations, locations, and the like, is removed to ensure confidentiality and to encourage the unconstrained future reporting of events as they occur.

The intended audience for this website is anyone who is involved in any aspect of hydrogen use. The existing safety event records are mainly focused on laboratory settings that offer valuable insights into the safe use of hydrogen in energy applications and R&D. It is hoped that users will come to this website both to learn valuable lessons from the experiences of others as well as to share information from their own experiences. Improved safety awareness benefits all.

Development of the database has been primarily supported by the U.S. Department of Energy. While every effort is made to verify the accuracy of information contained herein, no guarantee is expressed or implied with respect to the completeness, causal attribution, or suggested remedial measures for avoiding future events of a similar nature. The contents of this database are presented for informational purposes only. Design of any energy system should always be developed in close consultation with safety experts familiar with the particulars of the specific application.

We encourage you to browse through the safety event records on the website and send us your comments and suggestions. We will continue to add new records as they become available.

How does H2LL work?

If you have an incident you would like to include in the H2LL database, please click the "Submit an Incident" button at the top of the page. You will be asked for a wide range of information on your incident. Please enter as much of the information as possible. In order to protect your and your employer's identities, information that may distinguish an incident (your contact information, your company's name, the location of the incident, etc.) will not be displayed in the incident reports on H2LL.

Lessons Learned Corner

Visit the Lessons Learned Corner Archives.

Key themes from the H2Incidents database will be presented in the Lessons Learned Corner. Safety event records will be highlighted to illustrate the relevant lessons learned. Please let us know what you think and what themes you would like to see highlighted in this safety knowledge corner. You can find all the previous topics in the archives.

An incident involved an explosion of an oven that was heating decaborane for vaporization. In this incident, the heater controller was defective so the heating element was disconnected from the controller and plugged directly into a wall outlet. This situation allowed the oven to reach temperatures in excess of 400 °C within 20 minutes. While the temperature increased, the decaborane continued to expand, causing a significant pressure build-up within the oven. The pressure increase eventually caused the oven's viewing window to burst. A burst of burning hydrogen was emitted from the window and burned the face of a researcher who was hospitalized for approximately three weeks.

A water treatment plant used an electrolytic process to generate sodium hypochlorite (NaOCl) from sodium chloride (NaCl). The strategy of using liquid sodium hypochlorite for disinfecting water instead of gaseous chlorine (CL2) is popular because the liquid is generally safer and falls under fewer OSHA and EPA standards. The further idea of generating the liquid sodium hypochlorite on an as-needed basis and in limited quantities also has certain obvious safety advantages.

One of the disadvantages of the electrolytic process is that hydrogen gas is also created as a byproduct. The hydrogen is supposed to be vented, by design, to the atmosphere before the liquid sodium hypochlorite passes into a holding tank.

For various reasons, in this instance it is believed that the view more

A facility replaced the copper tubing used for hydrogen distribution, with stainless steel tubing. This was done to address a fire protection concern related to the solder on the copper tubing being susceptible to heat, melting, and releasing a flammable gas. The facility maintenance personnel completed the replacement, noted the pressure on the hydrogen bottle, and left the building. When the maintenance person returned on the following day, s/he noticed the pressure on the hydrogen bottle had dropped 500 psi overnight, indicating a leak in the system. S/he notified the appropriate facility personnel and together they began to determine why the hydrogen had dropped 500 psi overnight. The hydrogen line originates at a manifold, which is part of a glove box atmosphere purification view more

While filling a sample cylinder with compressed hydrogen gas, a quick-disconnect coupler fitting came loose within a stainless steel laboratory hood, allowing a small purge of the hydrogen gas to escape directly into the hood through ~1/4-inch Tygon tubing. The stainless steel quick-disconnect fitting struck the stainless steel bottom of the laboratory hood and the hydrogen gas caught fire. It is not known what caused the hydrogen gas to catch fire. The most likely sources of a spark was from metal-to-metal contact of the quick-disconnect fitting with the laboratory hood floor, or the discharge of static electrical charge generated by flow of hydrogen gas through Tygon tubing. The resultant narrow jet of fire, directed toward the left side of the laboratory hood, extinguished itself view more

A laboratory technician died and three others were injured when hydrogen gas being used in experiments leaked and ignited a flash fire.

The incident occurred in a 5,700-square-foot, single-story building of unprotected non-combustible construction. The building was not equipped with automatic gas detection or fire suppression systems.

Employees in the laboratory were conducting high-pressure, high-temperature experiments with animal and vegetable oils in a catalytic cracker under a gas blanket. They were using a liquefied petroleum gas burner to supply heat in the process.

Investigators believe that a large volume of hydrogen leaked into the room through a pump seal or a pipe union, spread throughout the laboratory, and ignited after coming into contact with the view more

Incident Synopsis
While attempting to replace a rupture disk in a liquid H2 vessel, H2 gas was released and ignited. In fighting the fire, liquid N2 was sprayed onto a second liquid H2 vessel located nearby. This resulted in cracking of the outer mild steel vacuum jacket. The loss of the vacuum caused a rapid increase in pressure and rupture of the burst disk of the second vessel. H2 boiled off and was burned in the fire.

Cause
The rupture disk was being replaced with a load of liquid H2 in the vessel and no separating inerting gas. The H2-air mixture was probably ignited by static discharges. Rupture of the second vessel burst disk was caused by the low-temperature exposure of the mild steel vacuum jacket.

Incident Synopsis
A H2 air explosion occurred near a H2 compressor, located outside. Gaseous H2 had been released from a vent stack when a relief valve was actuated. The source of ignition was not known, but considerable damage was inflicted onto the system by the ensuing fire and explosion. Following the explosion, the shut-off valves were closed and the system was vented.

Cause
Two relief valves were located in the 3,000 psig system downstream of a 5,000/3,000 regulator. The relief valves were sized to handle substantially different flows. (One was designed for another program.) The relief valve was believed to have opened when the pressure setting was being increased from 2,700 to 2,900 psig. The accuracy of the 5,000 psig gauge used to control the dome of the 5 view more

A significant hydrogen leak occurred during refueling of the onboard hydrogen storage tank of a fuel cell-powered lift truck while it was completely depowered. The in-tank shutoff solenoid valve had recently been replaced, and this was the initial refueling event after the replacement. The fuel zone access panel was removed to allow constant visual leak checking with Snoop leak-detection fluid. The event occurred during the final pressure testing of the repaired system when an O-ring failed at approximately 4500 psi, releasing the entire contents of the hydrogen tank in about 10 minutes. The dispenser hose/nozzle was immediately disconnected, and the leak location was quickly isolated to the tank/valve interface. A 30-foot boundary around the lift truck was cleared of personnel and view more