Pressure sensor diaphragm rupture on H2 compressor

First Name
Larry
Last Name
Moulthrop

The sensing diaphragm of a pressure transducer (PT), as supplied on an outdoor hydrogen compressor, unexpectedly ruptured and released approximately 0.1 kilograms hydrogen to atmosphere from the compressor discharge line. At time of incident, personnel nearby were alerted by a loud 'pop' and dust disturbance. Simultaneously, the facility monitoring system detected loss of the PT signal and initiated equipment shutdown.

Pressure Sensor Diaphragm Rupture on Hydrogen Compressor

First Name
Larry
Last Name
Moulthrop

The sensing diaphragm of a pressure transducer (PT), as supplied on an outdoor hydrogen compressor, unexpectedly ruptured and released approximately 0.1 kilograms hydrogen to atmosphere from the compressor discharge line. At time of incident, personnel nearby were alerted by a loud 'pop' and dust disturbance. Simultaneously, the facility monitoring system detected loss of the PT signal and initiated equipment shutdown. Facility personnel then closed isolation hand valves to stop the leak, locked and tagged out the equipment, and restricted the area.

Flash Fire Occurs on Construction Project

First Name
Andy
Last Name
Piatt

A subcontractor employee was using a band saw to cut a 1" metal pipe when a flash fire occurred on the third floor hydrogen fluoride area. Subcontractor employees were removing all piping associated with the Anhydrous Hydrofluoric Acid (AHF) system. These lines were being removed during plant decontamination and demolition (D&D). The subcontractor employee was attempting to cut a 90-degree elbow located at the highest elevation on the 1" line, but the lowest elevation of the overall piping run.

Check Valve Shaft Blow-Out due to Hydrogen Embrittlement

First Name
Andy
Last Name
Piatt

Several workers sustained minor injuries and millions of dollars worth of equipment was damaged by an explosion after a shaft blew out of a check valve. The valve failure rapidly released a large vapor cloud of hydrogen and hydrocarbon gases which subsequently ignited.Certain types of check and butterfly valves can undergo shaft-disk separation and fail catastrophically or "blow-out," causing toxic and/or flammable gas releases, fires, and vapor cloud explosions. Such failures can occur even when the valves are operated within their design limits of pressure and temperature.

Storage Battery Explosion

First Name
Andy
Last Name
Piatt

A battery that was left on a charger over a given weekend was used to start a gasoline power generator. This battery was connected in series with another battery and the connection on the negative post was hand tightened. When an attempt was made to start the generator, the battery exploded on approximately the fifth click of the starter solenoid. No damage was done to any equipment or facilities and no one was injured.

Portable Battery Power Supply Explosion

First Name
Andy
Last Name
Piatt

Incident Synopsis
One man was killed and another severely injured while working with a portable battery power supply.

At a test facility, a water-submersible portable battery power supply was used to power lighting. The battery power supply contained two 12-volt lead-acid automotive batteries, a wiring harness, and switching relays mounted in an air-tight case suitable for submersion in water. The case possessed ½-inch aluminum walls and a 13.8-pound lid. The box had been used periodically over two years.

High-Pressure Burst Disk Failure

First Name
Andy
Last Name
Piatt

An operation to increase the pressure within a hydrogen tube-trailer to 6000 psig was in progress when a burst disk failed at approximately 5200 psig and hydrogen was released. A vent line attached to the burst disk was not sufficiently anchored and bent outward violently from the thrust of the release over an approximate 4-inch moment arm, causing considerable damage to the adjacent vent system components. The operation is conducted with personnel present, but fortunately no one was in proximity when the burst disk failed.

Tube Trailer Leak through Over-Pressure-Protection Rupture Disk

First Name
Andy
Last Name
Piatt

A pressure relief device (frangible burst disk) on one of a hydrogen delivery tube trailer's 26 tubes failed prematurely and released hydrogen while filling a hydrogen storage tank at a government facility (see Attachment 1). Prior to the filling process, all procedures and safety checks, including connection to the facility's regulator/distribution control system with leak checking and follow-up verification of leak checking by facility personnel, were completed (see Attachment 2 for more details).

Hydrogen Fire in a Storage Vessel

First Name
Andy
Last Name
Piatt

In the fall of 2007, the operations team began a procedure (a written procedure was being followed) to sample the liquid hydrogen (LH2) storage vessels ("tanks"), and associated transfer system. This procedure was being performed to determine the conditions within the system, and if necessary, to purge the system of any excess gaseous hydrogen (GH2) in preparation for reactivation of the system. The system had not been used since 2003.

Gaseous Hydrogen Leak and Explosion

First Name
Andy
Last Name
Piatt

Only 25 minutes after the normal work shift ended, an explosion occurred at a hydrogen storage and use facility that had been in a non-operational mode for several months while undergoing modifications for future tests. No one was in the facility at the time of the explosion. The event was viewed about 30 seconds after the explosion by two engineers in a blockhouse 1000 feet away. Authorities were notified and calls were placed to other personnel needed to secure the area. About 8 minutes later, the engineers moved to a vantage point about 450 feet from the facility.

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Key:

  • = No Ignition
  • = Explosion
  • = Fire
Hydrogen Incident Summaries by Equipment and Primary Cause/Issue
Equipment / Cause Equipment Design or Selection Component Failure Operational Error Installation or Maintenance Inadequate Gas or Flame Detection Emergency Shutdown Response Other or Unknown
Hydrogen Gas Metal Cylinder or Regulator   3/31/2012
4/30/1995
2/6/2013
4/26/2010 12/31/1969     3/17/1999
11/1/2001
12/23/2003
Piping/Valves 4/4/2002
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
2/7/2009 1/24/1999
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
1/1/1982 9/30/2004
10/7/2005
  10/7/2005  
Compressor   10/5/2009
6/10/2007
8/21/2008
1/15/2019
    10/5/2009 8/21/2008  
Liquid Hydrogen Tank or Delivery Truck 4/27/1989 12/19/2004
1/19/2009
8/6/2004 12/31/1969   1/1/1974 12/17/2004
Pressure Relief Device 7/25/2013
5/4/2012
1/15/2002
1/08/2007
12/31/1969        
Instrument 1/15/2019 3/17/1999
12/31/1969
2/6/2013
    11/13/73    
Hydrogen Generation Equipment 7/27/1999     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