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Clean Hydrogen Partnership

LH2 tank cracking

Event

Event ID
457
Quality
Description
During transfer of LH2 from a 200,000 gallon (760 m3) storage vessel to a road trailer, loss of vacuum was detected due to a crack in the outer vessel. The crack was located below an elbow of the 6” diameter pressurisation line. The probable cause of the crack was the formation of liquid air dripping onto the outer vessel.

[Ordin, NASA (1974)]
Event Initiating system
Classification of the physical effects
Unignited Hydrogen Release
Nature of the consequences
Leak No Ignition (No additional details provided)
Macro-region
North America
Country
United States
Date
-
Main component involved?
Cryogenic Insulation Shell
How was it involved?
Leak
Initiating cause
Material Degradation (Thermal Stress/Cycling)
Root causes
Root CAUSE analysis
The INITIATING CAUSE was the failing of outer thermal shield of the vessel, due to thermal cold shock.
During the transfer operation liquid air formed on the vertical run of the pressurisation line, ran down the pipe and then dripped of the elbow onto the vessel. The vertical run did not have drip trays to collect liquid air and the crack formed where the liquid air dropped.
Probable ROOT CAUSE was an installation error (a missing drip tray supposed to be there) or a design error (a not-foreseen safety component).

Facility

Application
Hydrogen Stationary Storage
Sub-application
LH2 storage vessel
Hydrogen supply chain stage
Hydrogen Transfer (No additional details provided)
All components affected
connection, LH2 vessel
Location type
Open
Location description
Industrial Area
Operational condition
Description of the facility/unit/process/substances
The report does not specify the application. It is highly probable that it was a loading of a road tanker at the hydrogen production facility.

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0
Environmental damage
0
Property loss (offsite)
0
Post-event summary
It is unknown if the vessel had to be vented, or mitigting actions were availale to continue the transfer without loosing the whole stored quantity.

Lesson Learnt

Lesson Learnt
The consequence of the loss of thermal insulation capacity on the cryogenic vessel are unknown. The most probable immediate effect would have been the increased boil-off and internal pressure, with the need to vent. However, it is unknown if the whole vessel content had to be vented, or mitigating actions would have allowed to repair the crack and re-install the vacuum without major content loss.

Event Nature

Release type
gas
Involved substances (% vol)
H2 100%
Release duration
unknown
Actual pressure (MPa)
<1.0
Design pressure (MPa)
<1.0
Presumed ignition source
No ignition
Ignition delay
N

References

Reference & weblink

Mishap no 84 in <br />
P. L. Ordin, Review of hydrogen accidents and incidents in NASA operations, 1974, NASA TM X-71565<br />
https://ntrs.nasa.gov/citations/19740020344

Lowesmith et al., Safety issues of the liquefaction, storage and transportation of liquid hydrogen: An analysis of incidents and HAZIDS, Int. J. Hydrogen energy (2014) https://doi.org/10.1016/j.ijhydene.2014.08.002

Hankinson and Lowesmith, Qualitative Risk Assessment of Hydrogen Liquefaction, Storage and Transportation, FCH JU project IDEALHY, Deliverable 3.10 (2013)<br />
confidential<br />
(accessed October 2025)

JRC assessment