Manuals showing the correct connecting and disconnecting procedures were established for each fueling dispenser. Separate manuals were needed since the shape of the grip differs from dispenser to dispenser.

The packing in the flow control valve should be replaced periodically. A planned investigation will determine the optimum time period for packing replacement.

Follow CGA G-5.5 vent end system designs.

1. Ensure that equipment and materials exposed to hydrogen are compatible with a hydrogen environment (even hydrogen-service-rated equipment).

2. Equipment designs in a hydrogen environment that use the fracture toughness for 17-4…

Several recommendations were outlined by the investigating committee to govern future operations of the hydrogen compressor in the synthetic liquid fuels laboratory:

1. Install a cutoff that will shut down the compressor when the…

1. Consider periodic testing of breakaway device.
2. Consider determining shear force limit of vehicle receptacle adapter fittings.

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…

Corrective actions included replacing the breakaway with a new one, which restored normal operation of the dispenser.

Verify and periodically inspect the pull/separation force adjustment if the breakaway is so equipped.

Additional…

A gas detector was added in close proximity to the compressor shaft and a vibration switch is under consideration. Additional predictive measures are being considered to predict bearing failure. In addition, the manufacturer has been contacted…

Included inspection on monthly preventive maintenance plan and evaluated alternate materials for better cold-weather performance.

The fitting was an SAE straight thread and was likely loosened by torque applied to the fueling hose. After the incident, these fittings had additional means applied to restrict loosening, a cover installed to deflect any leakage, and means taken…

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…

Proper installation of check valves and other equipment should be visually inspected prior to pressurization.

Maintenance on the low-pressure venting system was not occurring at regular intervals. Ventilation integrity is now checked before starting an experiment.

Excessive venting of hydrogen from the tank due to lower facility consumption, in combination with extreme temperature conditions, placed thermal stress on the gland nut, causing a leak. The low consumption of hydrogen resulted from the shutdown…

Disable the fueling process if the operator does not follow the proper sequence of steps in the fueling procedure. Improve the fueling procedure to make it inherently impossible for the sequence to be done improperly with the same result.

Shutoff valve location and/or redundant shutoff valves at storage vessels are important for containment to prevent escalation.
Consider design features within equipment skids to reduce the likelihood of cascading events.
Pressure-switch…

• Replace the existing copper and carbon steel hydrogen pipeline with ¾-inch schedule 40 stainless steel.
• Reroute the new hydrogen line in the preferred location.
• Locate new hydrogen shut-off valves in a more convenient…

1. A hydrogen tube pressure indication system needs to be developed that is robust enough to withstand an accident, indicates hydrogen pressure regardless of valve position, and would be visible from a safe distance during an accident…

1. Increased structural protection is needed at the back of a hydrogen tube trailer to protect the vulnerable hydrogen systems components in this location (valves, pressure-indicating devices, manifolds, piping) in case of an accident. Side…