A distillate dewaxing unit at an oil refinery was undergoing hot hydrogen regeneration of the catalyst when an explosion occurred. Catalyst regeneration is a periodically performed procedure, in which the normal liquid hydrocarbon feed is stopped and a hydrogen-rich gas mixture is fed through the catalyst bed for which the normal operating temperature is raised from 700F to 800F. During the catalyst regeneration process the reactor pressure is increased from normal operating levels just below 600 psig to about 640 psig. A pipe failure occurred as a sudden and complete rupture of the 10-inch diameter line at the exit of one of the two reactors. Security video revealed that the release rapidly exapnded and the hot gas mixture ignited shortly after rupture. A shock wave from the resulting view more

A pressure relief device (PRD) valve failed on a high-pressure storage tube at a hydrogen fueling station, causing the release of approximately 300 kilograms of hydrogen gas. The gas ignited at the exit of the vent pipe and burned for 2-1/2 hours until technicians were permitted by the local fire department to enter the station and stop the flow of gas. During this incident the fire department evacuated nearby businesses and an elementary school, closed adjacent streets, and ordered a high school to shelter in place.

There were no injuries and very little property damage. The corrugated roof on an adjacent canopy over a fueling dispenser was slightly singed by the escaping hydrogen flame, causing less than $300 in damage.

The station's operating systems worked as view more

Within the International Space Station (ISS) oxygen generator, an increase in differential pressure across a pump supplying return water to a PEM electrolyzer fuel cell stack had persisted over a 4-month period and was approaching the shut-off limit for the system. This decrease in performance was suspected to be caused by water-borne catalyst fines containing platinum black and TeflonĀ®* binder materials, shed by the fuel cell stack, and accumulated within the pump's inlet filter. Maintenance in the field was required.

The system had been designed for factory maintenance, and no contingency had been planned to handle field maintenance for such a circumstance. An initial assessment of hazards for the proposed filter maintenance raised the concern that opening the water line view more