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.

Difficulties were experienced with two solenoid-operated globe valves in a charging system. When shut, the valves could not be reopened without securing all charging pumps. During a refueling outage, the two valves were disassembled and examined to determine the cause of the malfunction. It was found that disc guide assembly springs in both valves had undergone complete catastrophic failure. The springs, which initially had 25 coils, were found in sections of only 1-2 coils. Metallurgical analysis of the failed springs attributed the probable cause of failure was due to hydrogen embrittlement. The springs are made of 17-7 PH stainless steel.

Discussion with the valve manufacturer revealed that similar failures occurred on three previous occasions. These spring failures were also view more

During an inspection, three potential safety problems were identified concerning the location of a hydrogen storage facility. The hydrogen storage facility is located on a building's roof, which is made of 30-inch-thick reinforced concrete. The following potential safety problems were identified during the inspection:

Leakage of hydrogen gas from the storage facility in proximity to the air intakes of the building's ventilation system may introduce a flammable or explosive gas mixture into the enclosure. Because the hydrogen storage facility, containing four 8,000-scf hydrogen tanks at up to 2,450 psig, is Seismic Category II, a seismic event may result in a hydrogen leak. Furthermore, the pressure relief valves in the hydrogen facility exhaust downward to within 6 view more

A large, hydrogen-cooled generator is driven by steam turbines at a power station. During maintenance shutdowns, the hydrogen cooling loop in the generator is purged with carbon dioxide. After CO2 concentrations are measured with a densitometer to verify the complete removal of hydrogen, the generator is purged with air and the maintenance is performed.

This purging procedure was used prior to the explosion. The CO2 reading was reported to be 100 percent CO2 at the top of the generator. The cooling system was then purged with air and a 1/2 inch pipe in the cooling loop was cut to install some new instrumentation. When the pipe was cut, pressurized gas was emitted at the opening. Workers assumed the gas was either carbon dioxide or air and proceeded with the new instrument view more

A rupture occurred in a 24-inch gas line in a reformer. The pipe contained hydrogen and carbon monoxide at a pressure of about 400 psi and a temperature of 930 °C. The ruptured section of pipe had a high-temperature alloy steel outer wall, a refractory liner, and a stainless steel inner liner. The refractory lining had been repaired several times before (including three months prior to the incident) because of localized deterioration and hot spots. The repair procedure consisted of cutting a section of pipe, re-pouring the refractory liner, and patch-welding the outer wall.

The first rupture occurred when the 42-inch-long welded section of the pipe suddenly blew out. On-site employees heard a rumble and observed a flame above the ruptured pipe. Before the torch fire at the view more

An industrial heater used to heat a naphtha-hydrogen mixture developed a small leak in one of its finned tubes. The leak resulted in a 2-ft long torch flame, which was eventually noticed by an employee. Upon discovering the fire, the hydrotreater was shut down by cutting off the flow of naphtha and the flow of fuel to the burners in the heater. The hydrogen flow was maintained in order to cool and sweep the reactor during the shutdown operation.

The torch flame appeared to diminish significantly while only the hydrogen was flowing. However, molten metal dripping from the heater indicated that a much more severe fire was still in progress. The fire was eventually controlled by reducing the hydrogen flow and injecting steam into the heater. Inspection of the damaged heater view more

A fire occurred in a hydrogen storage facility. The fire was reported by an employee who saw the fire start after he had aligned valves at the hydrogen storage facility in preparation for putting the hydrogen injection system into service. The employee escaped injury because he was wearing fire-retardant protective clothing and was able to quickly scale a 7-foot-high fence enclosing the hydrogen area. The local fire brigade was dispatched and offsite fire fighting assistance was requested. Upon reaching the scene, the local fire department reported seeing a large hydrogen-fueled fire in the vicinity of the hydrogen tube trailer unit. The heat of the fire potentially endangered the nearby hydrogen storage tanks. The onsite fire department, with offsite fire fighting support, fought the view more

Hydrogen was stored in a plant in a 42 ½ ft diameter sphere made of 3/16 inch steel. The sphere was partitioned into two hemispheres by a neoprene diaphragm attached around the equator. Hydrogen was stored under the diaphragm, while the upper hemisphere contained air. An explosion-proof fan was situated in the upper portion of the sphere in order to provide a slight positive pressure on the top of the diaphragm.

When the plant was shut down for a local holiday, the fan on top of the hydrogen sphere was also stopped. During plant startup two days later, a violent explosion occurred in the sphere. The sphere shell was torn into many sections by the explosion, and some of the sections were propelled as far as 1,200 ft. Some of these sections struck flammable liquid storage tanks view more

An anhydrous hydrogen fluoride (AHF) lecture bottle spontaneously exploded in a laboratory. No one was injured, but the lab was extensively damaged. The lecture bottle had split along its seam. Its cap and valve assembly were located to the immediate left.

The explosion was caused by hydrogen gas pressure build up in the cylinder. AHF comes in carbon steel cylinders as a liquefied gas under a pressure of 0.9 psi at 70 oF (i.e., the vapor pressure of the liquid). Though cylinders should be passivated with fluorine, which forms a protective coating, over time AHF may slowly react with the iron in a cylinder to form iron fluoride and hydrogen gas. The generation of hydrogen gas may produce cylinder pressures as high as several hundred psi.

A person working in a hydrogen lab unknowingly closed the wrong hydrogen valve and proceeded to loosen a fitting in one of the hydrogen gas lines. The pressure in the 1/4"-diameter hydrogen line was approximately 110 psig. Hydrogen escaped from the loosened fitting and the pressure release resulted in the tubing completely detaching and falling to the floor. The person noted seeing a white stream around the hydrogen jet leak. The person noted a color change and noise change as the leak ignited (this happened in a matter seconds and he did not have a chance to react). The person left the lab and pushed the emergency stop button. Someone else pulled the fire alarm. Both of these actions were designed to close the main hydrogen solenoid (shutoff) valve. The local emergency response view more

Liquid Waste Disposition Projects (LWDP) has experienced repetitive events involving Hydrogen Monitor/LFL Analyzer degradations over the last year. There have been 12 reportables in the last two years. As a result, a determination was made to issue a recurring occurrence report referencing management concern as its reporting criteria.

Engineering has recently made significant progress in further defining issues and potential corrective actions necessary to address the lower flammability limit (LFL) failures. The engineering path forward to resolution of this issue addresses potential failure contributors, among these are: Drift - This phenomenon is being closely assessed. Initial tests indicate the monitor power supply may be a significant contributor to instability resulting view more