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

Training Issue

Damage and Injuries

Any

Equipment

Gas cylinder

Probable Cause

Any

Contributing Factors

Training Issue

Damage and Injuries

Any

Equipment

Gas cylinder

Probable Cause

Any

CHECK OUT OUR MOST RELEVANT INCIDENT LISTINGS!

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 Gas Leak from Compressed Gas Cylinder

LESSONS LEARNED:

  1. Compressed gas cylinder caps can be very difficult to open as rust often occurs in the threads.
  2. There are wrenches specifically designed to remove…
Hydrogen Cylinder Leak

Hazard analysis should consider potential leak locations, potential ignition sources in the vicinity, and the potential for accumulating flammable gases in that area.

Users should leak-check all cylinders upon installation. This event…

Failure to Meet Safety Requirement for Flammable Gas System

A flammable gas explosion is an analyzed hazard and gas detection/shut off is a safety significant control system that requires a limiting condition for operation (LCO). The rigor of the evaluation of flammable gas systems was inadequate. There…

Hydrogen Explosion in University Biochemistry Laboratory

Several procedural and design changes should be considered for the future:

  1. Replace the use of pure hydrogen with a 95:5 mixture of nitrogen and hydrogen to reduce the possibility of an explosive atmosphere occurring. Laboratory…

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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