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Gas Cylinders Pellet Fall in from Truck in a Plastics Production Plant (794)

In a plastics production plant, a pallet containing 7 cylinders of nitrogen and 1 cylinder of hydrogen fell from a truck traveling in a logistics zone. The driver stopped the vehicle, cut off the engine and noticed a leak on the hydrogen cylinder; he warned his superintendent who alerted the firefighters, established a safety perimeter and interrupted any work with hot sources.The firefighters stopped the leak by closing the cylinder valve and put the basket back on the truck which was then unloaded at the place originally planned.

Unexpected Hydrogen Presence in a Brine Tank (750)

Employee #2 was using a torch to cut a U-bolt on the bypass piping next to a brine surge tank that potentially contained hydrogen gas in a vapour space in the upper portion of the tank. His job was to remove and replace the brine line that was connected to the top of the tank. Just before the accident, Employee #1 was on top of the tank unbolting the brine line. He was launched into the air by an explosion and struck against some piping or other structure, He was killed. Employee #2 was struck by piping and knocked backward. His head struck a curb and he was injured.

Hydrogen Fire in a sulfur Recovery Unit of a Refinery (749)

Three workers were working in the sulfur recovery unit (SRU), trying to restore the hydrogen flow. The workers were trying to isolate the cause of a flow problem: hydrogen was entering the regulators at 200 psi (14 bar), but the pressure was dropping to 18 to 20 psi (approximately 1.3 bar) after the passed through the various components of the unit. They closed a valve preceding the regulators and vented the bleed manifold before removing a flange located beyond the valve. One of the worker then re-opened the closed valve to check the flow.

Explosion in an Metallic Products Plant (746)

Five barrels of aluminum dust that had been removed from an outdoor dust collector were sealed and stored in the plant adjacent to electrical panels. One of them had somehow been contaminated with water, which exothermically reacted with the aluminum dust to form hydrogen gas. The top of the barrel deformed and glowed red. Smoke was observed and an employee sounded a vocal alarm. The lid blew off the barrel and the mushroom cloud of aluminum dust exploded in a fireball. Nearby combustible material ignited and the sprinkler system activated.

Fire at a Desulfurization Unit (735)

Hydrogen gas leaking from drain pipes in a hydrodesulfurization plant: There was a hydrodesulfurisation plant which had a recycle hydrogen compressor fitted with a suction rectifier. Hydrogen gas gushed out through a hole made by corrosion at the drain pipe on the suction rectifier. The process condition (45C and 3.7Mpa) made atmosphere causing hydrogen sulfide-ammonia corrosion in the drain pipe which consisted of about 10m horizontal parts and an upward outlet. This upward outlet made it impossible to drain out completely. Furthermore, steam insulation also contributed to the corrosion.

Accidental Production of Hydrogen in an Manufactory of Electronics Products (726)

The event occurred at the factory producing multilayer circuit boards by a multistep dip operation. An employee inadvertently mixed 55 gal of 50 percent hydrogen peroxide into 110 gal of 30 percent formaldehyde. This resulted in a carbon monoxide and hydrogen release. The facility was evacuated and the local fire department and ambulance responded. 14 workers, out of whom three were from temporary employment agencies, were treated for inhalation and released.The employee did not look carefully at the label on the hydrogen peroxide drum.

Explosion in Gasoil Hydro-Treatment Unit During Start-Up (720)

On a cold morning, the gasoil hydro-treatement unit was being brought back on line after being out of service to repair a governor problem on the recycle gas compressor. Several upset trips had occurred in the previous month but these were not seen to have any direct bearing on the operation of he hydrogen heaters or the unit as a whole, Temperature at the coil outlet of both heaters was at least 100 degrees C lower than normal since the unit was in a start up mode. The reactor circuit was at full operating pressure while hydrogen was recycled via a compressor.
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