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 single-stage regulator "failed" while flowing hydrogen gas from a standard 200 cu.ft. gas bottle. The regulator had functioned properly prior to the event through several on-off cycles. During the event, a solenoid valve was opened to allow hydrogen to flow, when a rather loud noise was noted and gas began flowing out of the pressure relief valve on the side of the regulator. It was noted that the low-pressure gauge on the regulator was "pegged" at the high side (>200 psi). The valve on the bottle was shut off, and hydrogen flow was immediately stopped. Hydrogen flowing out of the relief valve did not ignite. With the bottle shut off, the regulator was removed and replaced with another regulator of the same type, and activities continued.
The failed view more
A hydrogen leak at the flange of a 6-inch synthesis turbocharger valve in an ammonia production plant ignited and exploded. Hydrogen detectors and the fire alarm alerted the control room, which immediately shut down the plant, and the fire was then extinguished rapidly. There were no injuries caused by the accident, since the operator heard a wheezing sound and was able to run away just before the explosion occurred. The leaking gas was composed of 70% hydrogen at a flow rate of 15,000 cubic meters per hour. Property damages in the turbocharger included electrical cabling, melted siding, and heavily damaged pipes. The ammonia plant was shut down for more than a month.Five days before the incident, a problem with the CO2 absorber column led operators to open the vent downstream of the view more
Severe vibrations caused by broken low-pressure turbine blades damaged the main turbine generator at a nuclear power plant. These vibrations also caused multiple hydrogen leaks at equipment connections to the generator, resulting in hydrogen flames outside of the generator casing that caused minimal damage to the facility. Hydrogen is used to internally cool the plant's electric generators. Water from the fire suppression system and oil released from the turbine lube oil system during the event were contained within the plant, resulting in no impact to the environment. The plant's nuclear systems were unaffected by the event.
In early afternoon, a northbound tractor-semitrailer with horizontally mounted tubes filled with compressed hydrogen at approximately 2400 psi (166 bar) was struck by a northbound pickup truck that veered into the semitrailer's right rear axle. According to witnesses, the tractor-semitrailer then went out of control and left the roadway, coming to rest approximately 300 feet (91 meters) from the point of impact. As a result of rotational torque and impact, the end of one tube was sheared off at the bulkhead and left the tube bundle. During the process, some of the tubes, valves, piping, and fittings at the rear of the semitrailer were damaged and released hydrogen. The hydrogen ignited and burned the rear of the semitrailer. In the meantime, the pickup truck had also run off the view more
A previously identified generator hydrogen gas leakage into the stator cooling water system exceeded the predetermined maximum operational allowance and the nuclear plant was shut down from 100 percent power in accordance with plant operating procedures. The leak was identified by monitoring the stator water cooling system detraining tank. Following reactor shut down and generator rotor removal, a small hole was located in the collector end winding area of a slot on the top stator bar. A small particle of carbon steel (estimated to be 2 mm/0.078 inch by 0.6 mm/0.023 inch) is believed to have caused the damage. The source of the carbon steel particle was either foreign material introduced during previous generator internal work or from a phenomenon called "back-of-core burning view more
A 9,000-gallon (34,069-liter) cryogenic liquid hydrogen storage vessel, installed outdoors at a manufacturing plant in an urban area, over-pressurized and released hydrogen into the atmosphere through a safety relief device (burst disk). When the burst disk released pressure, a loud bang was heard by neighbors and reported to the local police. The police investigated and heard the sound of gaseous hydrogen escaping from the vessel's vent stack, which rose approximately 15-20 feet (4.6-6.1 meters) in the air.
Police called the local fire department. Firefighters entered the facility and told employees inside that there was an explosion on the property and they needed to evacuate. As a precautionary measure, some nearby city buildings were also evacuated and the street was view more
A hydrogen leak and subsequent explosion occurred when tie-downs on a hydrogen transport trailer securing hydrogen cylinder packages failed. The tie-down failure caused the hydrogen cylinder packages to fall off the trailer and eject some cylinders onto the roadway (see Figure 1). The cause of the accident is unknown, but it appears to be unrelated to hydrogen (i.e., likely tie-down strap weakness or error in properly securing tie-downs). The cylinders contained compressed hydrogen gas at 200 bar (2900 psi). The accident caused some hydrogen cylinders to leak and the associated cylinder package plumbing systems were breached. A spark or other local heat source (e.g., from a nearby vehicle motor) ignited the leaking hydrogen and caused a deflagration/explosion that damaged a car view more
A hydrogen leak occurred when hydrogen tube trailer traveling on a rural roadway left the road, overturned on its side, and resulted in a single hydrogen tube valve being opened or broken. The cause of the accident is unknown, however, it appears to be unrelated to hydrogen (i.e., it is likely that human driving errors caused the accident). The hydrogen tubes contained compressed hydrogen gas at 200 bar (2,900 psi). The back end of the tube trailer containing the high-pressure hydrogen plumbing and valves contacted the ground and resulted in the valve opening or breaking and losing all the hydrogen from one tube. The tube/valve that leaked was located on the bottom tier in the center position. The first firefighter crew to arrive at the accident scene verified that the leakage was view more
Hydrogen was found to be leaking from a vent line during cryogenic loading operations. The leak was attributed to a cracked weld on a hydrogen vent line that consisted of (1) double wall aluminum piping and (2) slotted spacers between the inner and outer line to provide a hydrogen gas blanket for insulation. The weld that failed was repaired using a "clamshell" over the area of the failed weld in order to support continued operations. A portion of the failed weld was removed for analysis prior to the repair. After operations, the clamshell repair was excised from the non-vacuum-jacketed double wall piping to allow further analysis of the failed weld. It was later replaced with a new half shell piping section.