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.

Investigators believe that a large volume of hydrogen leaked into the room through a pump seal or a pipe union, spread throughout the laboratory, and ignited after coming into contact with the view more

An incident involved an explosion of an oven that was heating decaborane for vaporization. In this incident, the heater controller was defective so the heating element was disconnected from the controller and plugged directly into a wall outlet. This situation allowed the oven to reach temperatures in excess of 400 °C within 20 minutes. While the temperature increased, the decaborane continued to expand, causing a significant pressure build-up within the oven. The pressure increase eventually caused the oven's viewing window to burst. A burst of burning hydrogen was emitted from the window and burned the face of a researcher who was hospitalized for approximately three weeks.

An apprentice mechanic lacerated his right forearm while quickly sliding out from under a hydrogen prototype bus when the bus slipped off a hydraulic jack. The apprentice and another mechanic had raised the bus about 1 foot from the ground to position it on jack stands when the hydraulic jack tipped over. The apprentice went to the site medical facility, where he needed five stitches to close the wound in his forearm.

The mechanics were raising the rear of a hydrogen prototype bus, like the one in the figure below, and placing it on jack stands. After chocking the wheels, they used bottle jacks on each side of the rear axle to raise the bus high enough to place a 20-ton hydraulic jack under the differential. With the bus resting on a pair of small jack stands, they raised the view more

While filling a sample cylinder with compressed hydrogen gas, a quick-disconnect coupler fitting came loose within a stainless steel laboratory hood, allowing a small purge of the hydrogen gas to escape directly into the hood through ~1/4-inch Tygon tubing. The stainless steel quick-disconnect fitting struck the stainless steel bottom of the laboratory hood and the hydrogen gas caught fire. It is not known what caused the hydrogen gas to catch fire. The most likely sources of a spark was from metal-to-metal contact of the quick-disconnect fitting with the laboratory hood floor, or the discharge of static electrical charge generated by flow of hydrogen gas through Tygon tubing. The resultant narrow jet of fire, directed toward the left side of the laboratory hood, extinguished itself view more