• Unprotected hoses are susceptible to glass shards, abrasion, and burns during normal use. This leak was formed from a glass shard penetrating the tube wall.
• Flexible hoses require protective sheaves to avoid cuts, abrasions and…

The risk of a serious fire occurring inside the chemistry laboratory hood from use of hydrogen gas and/or presence of a small quantity of hydrazine-hydrate was underestimated. Additional control measures were required to reduce the risk of fire…

1. Flexible tubing should be secured so it cannot get dislodged during operations.
2. Fume hoods where hydrogen is used should not be made of combustible materials. 3. Preventative maintenance should be performed on equipment on a…

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…

• A SOP should be developed which prohibits drivers from backing into the fill position.
• As a precautionary measure to mitigate similar events in the future, piping barriers should be installed which protect critical H₂…

Standard procedure must be followed in all cases. Assumptions are made at great risk. Risk also increases with complacency.

The incident resulted from an inadequate design for the storage location of the copper gas supply tubing (too close to an electrical outlet). The gas supply tubing was too long for its intended purpose and posed a hazard in its coiled state near…

The lessons learned from this incident are:

1. Verify the gas that you are using.
2. Avoid using "quick-disconnect" fittings in this type of situation. If they are absolutely needed, there are sets available that ensure that…