Inadequate Maintenance at a Soap Manufacturing Plant Causes a Hydrogen Flash Fire

First Name
Andy
Last Name
Piatt

An employee at a soap manufacturing plant died in a flash fire outside the facility's hydrogenation building. Responding personnel encountered a fire at the base of the plant's hydrogen storage towers, and they found the victim, who was burned over 90 percent of his body, some 50 feet away.

Officials determined that a pipe connection failed and that hydrogen, pressurized at 1,800 psi, ignited when it was released into the atmosphere, killing the plant operator.

Laboratory Technician Fatally Burned When Leaking Hydrogen Ignites

First Name
Andy
Last Name
Piatt

A laboratory technician died and three others were injured when hydrogen gas being used in experiments leaked and ignited a flash fire.

The incident occurred in a 5,700-square-foot, single-story building of unprotected non-combustible construction. The building was not equipped with automatic gas detection or fire suppression systems.

Employees in the laboratory were conducting high-pressure, high-temperature experiments with animal and vegetable oils in a catalytic cracker under a gas blanket. They were using a liquefied petroleum gas burner to supply heat in the process.

Hydrogen Leakage from Ground Packing of Flow Control Valve

First Name
Andy
Last Name
Piatt

The hydrogen sensor at a hydrogen fueling station detected a slight leakage from the ground packing of the flow control valve during refueling. The refueling operation was stopped immediately. The leak was stopped by tightening the ground packing sealing screw, but it started leaking again in about a week.

Leak in Liquid Hydrogen Pump Causes Explosion/Fire at Hydrogen Transfilling/Pumping System

First Name
Andy
Last Name
Piatt

A leaking liquid hydrogen cryogenic pump shaft during the process of filling a gaseous tube delivery trailer to 2400 psi at a liquid hydrogen transfilling location caused a series of explosions and a fire. After approximately 30 minutes of filling, the operator heard a single loud explosion and then saw flames and ripples from heat generation near the ground in the hydrogen fill area. The operator quickly actuated the emergency alarm system that shut down the cryogenic pump and closed the air-actuated valves on the cryogenic pump supply line.

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.

Hydrogen Explosion and Iron Dust Flash Fires in Powdered Metals Plant

First Name
Andy
Last Name
Piatt

Operators in a powdered metals production facility heard a hissing noise near one of the plant furnaces and determined that it was a gas leak in the trench below the furnaces. The trench carried hydrogen, nitrogen, and cooling water runoff pipes as well as a vent pipe for the furnaces.

Hydrogen Fire from Valve Packing During Maintenance Shutdown at Chemical Manufacturing Plant

First Name
Andy
Last Name
Piatt

A chemical plant experienced a valve failure during a planned shutdown for maintenance that caused hydrogen to leak from a valve and catch fire. Four chemical reactor chambers in series were being emptied of liquid using hydrogen gas as part of a maintenance procedure. Two heater valves were opened allowing 3000 psi hydrogen to flow in reverse direction to purge the reactor system for approximately 25 minutes. At completion of the purging process, a "light" thud was heard as the reactor empty-out valves are being closed.

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