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

Any

Damage and Injuries

Any

Equipment

Valve

Probable Cause

Human Error

Contributing Factors

Any

Damage and Injuries

Any

Equipment

Valve
Show more

Probable Cause

Human Error

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

Incorrect Check Valve Installation

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

Liquid Hydrogen Delivery Truck Offloading Valve Failure
  • Attentiveness to proper procedure would have prevented this incident.
  • This incident also underscores is the need for rigorous training on hydrogen properties and behavior, not only for the operators of fueling equipment but also for…
Hydrogen Lab Fire
  1. Test safety system components even if they are new.
  2. Do not rely on listening for valve movement as confirmation that a valve is closing; measure downstream pressure to determine if the valve is really sealing properly.
  3. …
Hydrogen Leak due to Inappropriate Operator Action results in Fire
  1. Follow the rules (e.g., using a torque-amplifying device requires supervisor approval).
  2. Some valves are susceptible to disassembly, with potentially significant consequences, if excessive torque is applied to the handwheel.…
Unexpected Burst Disk Rupture during Testing Activity

Personnel were focused on the AGES system test and results, not the compatibility of the test equipment. The manual valve was needed to successfully test the system, however the fact that this particular valve could not accommodate the full…

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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