Hydrogen Gas Present in Forklift Battery Charging Facility

First Name
Andy
Last Name
Piatt

A routine security patrol reported a strong odor of sulfur coming from a battery charging facility. The battery charging facility is used for charging the various forklift batteries for the shipping and receiving operation. The building is approximately 450 sq. ft. and has four charging stations. Emergency response was initiated and the incident commander responded to the scene. Initial air monitoring indicated readings above the Lower Explosive Limit (LEL) for hydrogen gas. The local fire department responded and setup for the situation.

Battery Room Explosion

First Name
Andy
Last Name
Piatt

A hydrogen explosion occurred in an Uninterruptible Power Source (UPS) battery room. The explosion blew a 400 ft2 hole in the roof, collapsed numerous walls and ceilings throughout the building, and significantly damaged a large portion of the 50,000 ft2 building. Fortunately, the computer/data center was vacant at the time and there were no injuries.

Emergency Battery Container Incident

First Name
Andy
Last Name
Piatt

Incident Synopsis

A hydrogen explosion occurred in an emergency battery container used to transfer fuel elements. The container had five emergency power batteries. Damage was incurred by the explosion.

Cause

The H2 concentration in the container increased because the battery charger had been left on charge. In addition, the container was placed in an un-ventilated airlock. Ignition of the H2-air mixture was believed to be caused by the relays and micro switches activated when the airlock door was opened.

Nickel Cadmium Battery Explosion

First Name
Andy
Last Name
Piatt

Incident Synopsis
During routine facility maintenance of an automatic battery charging system, 6 of 27 nickel cadmium batteries being reinstalled exploded.

Cause
Inadequate work procedures in that a probable cause was ignition of accumulated hydrogen gas by a spark generated during the replacement work, and inadequate ventilation of the battery area; a second probable cause was stopped up vent caps, resulting from contaminated electrolyte, which permitted hydrogen pressure build up to an explosive force in the 6 batteries.

 

Combustible Hydrogen Gas Vapors Ignited in a Battery Plant

First Name
Andy
Last Name
Piatt

SummaryA fire occurred in a battery manufacturing plant that was about to cease operations for the night. The fire caused an estimated $2.4 million in property damage when an electrical source ignited combustible hydrogen vapors.BackgroundThe incident occurred in the forming room, where wet cell batteries were stored for charging on metal racks. The facility had a wet-pipe sprinkler system, but no automatic hydrogen detection equipment.Incident SynopsisAt 11:52 pm, a security guard on patrol noticed a free burning fire in the forming room and notified the fire department.

Hydrogen Alarm Sounds in Battery Room due to Ventilation Fan Failure

First Name
Andy
Last Name
Piatt

A hydrogen alarm sounded when hydrogen buildup occurred in an unmanned switching room containing backup lead acid batteries after the exhaust ventilation fans failed to start at the 1% hydrogen trigger level. Failure of the ventilation fans to vent the normal off-gassing hydrogen from the lead acid batteries resulted in the hydrogen concentration in the room increasing to 2%, which triggered the hydrogen alarm. The alarm was automatically sent to an alarm-monitoring company that alerted the local fire department as well as company personnel of the condition.

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