A sealed, unclassified electrical control enclosure, part of a listed and certified force-ventilated commercial hydrogen processing unit enclosure, exploded when the equipment manufacturer’s technician pressed the machine stop switch to complete factory commissioning procedure. The technician was forcefully hit by the flying metal panel holding the switch and sustained serious injuries requiring lengthy hospitalization and rehabilitation. Two were hospitalized. Two others were injured. Significant damage to the indoor facility also occurred.
A plume of hydrogen gas escaped from the offloading valve of a liquid hydrogen delivery truck while transporting hydrogen to a commercial facility. The plume ignited, resulting in a flash and concussion loud enough to be heard inside the nearby building and to set off the building’s seismic event detectors. A small amount of hydrogen gas continued to escape from the trailer tank and burn until a company specialist arrived to manually shut off a critical valve almost eight hours later.
Installation of a 9000-gallon liquid hydrogen storage tank by a lessee at a building has not been evaluated for effect on the Safety Authorization Basis (SAB) of nearby facilities.
During review of an Emergency Management Hazard Assessment document, a reviewer questioned whether the SAB of nearby facilities had been reviewed for the effect of the installed 9000-gallon liquid hydrogen tank. Reviews by the facility management and facility safety personnel confirmed the evaluations have not been performed.
A shop supervisor determined that a second shift would be necessary to complete some priority work on the spare hydrogen mitigation pump. The work scope for the shift would be dedicated to continued fabrication of designed tubing runs, repairs to existing tubing with known leaks and pressure testing of other various tubing runs. The shift craft complement would include three pipe fitters, one welder, one QC inspector and a shift supervisor.
An operator began preparations for a cleaning run, and was unaware that a maintenance task to calibrate a pressure transducer was scheduled to also take place that morning. The calibration required a break on a hydrogen line in order to install a Measuring and Test Equipment (M&TE) gage, which was used in the calibration. At the time the operator was informed of the calibration, the cleaning run procedure had been initiated but the actual cleaning had not yet begun.
During inspection of a hydrogen make-up compressor, it was discovered that a 1/4” stainless steel screw and nut that mounted a temperature gauge to a stainless steel pipe was resting against the side of a schedule 160 high-pressure hydrogen pipe. Constant vibration of the process equipment had caused the bolt to rub a hole in the high-pressure suction piping, resulting in the release of make-up hydrogen. The pipe was out of sight, and the problem was identified by an employee who heard the whistling sound of escaping hydrogen. The compressor was taken offline and depressurized.
A demolition technician noted an elevated combustible gas lower explosive limit (LEL) on a pipe that was being tested prior to cutting (No. 2 pipe). The No. 2 pipe was one of four pipes being tested. The other three pipes tested less than detectable for combustible hydrogen gas. Testing involves tapping the pipe and connecting the pipe to an Explosive Gas Detector via a tube. When an elevated LEL is identified, the pipe is allowed to vent and then retested prior to cutting. After tapping the No. 2 pipe, the work crew left the pipe open to vent and departed the area for the end of shift.
A control room received a tank lower flammability limit (LFL) analyzer low sample flow alarm. The control room operator initiated the appropriate alarm response procedure and the facility entered limiting conditions of operation. At the time of the alarm, the facility was experiencing severe weather and the field operator was unable to investigate the alarm in the field. After the severe weather cleared, the field operator investigated the alarm and found the sample flow to be low and out-of-limits.
Hydrogen was stored in a plant in a 42 ½ ft diameter sphere made of 3/16 inch steel. The sphere was partitioned into two hemispheres by a neoprene diaphragm attached around the equator. Hydrogen was stored under the diaphragm, while the upper hemisphere contained air. An explosion-proof fan was situated in the upper portion of the sphere in order to provide a slight positive pressure on the top of the diaphragm.
A water treatment plant used an electrolytic process to generate sodium hypochlorite (NaOCl) from sodium chloride (NaCl). The strategy of using liquid sodium hypochlorite for disinfecting water instead of gaseous chlorine (CL2) is popular because the liquid is generally safer and falls under fewer OSHA and EPA standards. The further idea of generating the liquid sodium hypochlorite on an as-needed basis and in limited quantities also has certain obvious safety advantages.
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