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

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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

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,…
Tube Trailer Vent System Ice Plugged - Frozen

Follow CGA G-5.5 vent end system designs.

Pressure Relief Valve Triggered on Metal Hydride Storage Tank

Mechanical pressure gauges tend to be imprecise if only used in a narrow portion of the full scale. Digital transducers, although slightly more expensive, offer much more precision. The event happened because the set pressure was only 10% of full…

Hydrogen Vent Blow Down

Mounting hardware incorporated polymeric braces not suitable for long-term exposure to sunlight and temperature extremes. With time, the polymeric materials had disintegrated, allowing the mounting brackets to become loose. In addition, the…

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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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.

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