SummaryA fire occurred in a battery manufacturing plant that was about to cease operations for the night. The fire caused an estimated $2.4 million in property damage when an electrical source ignited combustible hydrogen vapors.BackgroundThe incident occurred in the forming room, where wet cell batteries were stored for charging on metal racks. The facility had a wet-pipe sprinkler system, but no automatic hydrogen detection equipment.Incident SynopsisAt 11:52 pm, a security guard on patrol noticed a free burning fire in the forming room and notified the fire department. It took fire fighters almost three hours to bring the fire under control.Although the facility was equipped with a wet-pipe sprinkler system, the forming room's branch had been disconnected 10 to 15 years before view more

Incident Synopsis
During routine facility maintenance of an automatic battery charging system, 6 of 27 nickel cadmium batteries being reinstalled exploded.

Inadequate work procedures in that a probable cause was ignition of accumulated hydrogen gas by a spark generated during the replacement work, and inadequate ventilation of the battery area; a second probable cause was stopped up vent caps, resulting from contaminated electrolyte, which permitted hydrogen pressure build up to an explosive force in the 6 batteries.


A power plant reported a hydrogen leak inside an auxiliary building. The given plant was in cold shutdown at the time of the event. The discovery of this problem was as a result of an unassociated event involving the activation of a chlorine monitor in the control building. When additional samples indicated no chlorine gas, the shift supervisor ordered further investigation into other plant areas. Because there was no installed detection equipment, portable survey instruments were used to determine gaseous mixtures. Hydrogen was detected in the auxiliary building at 20 to 30 percent of the lower flammability limit (LFL) for hydrogen. A level of about 30 percent of LFL corresponds to about 1.2 percent hydrogen by volume.

When hydrogen was discovered in the auxiliary building, the view more

A hydrogen explosion occurred in an Uninterruptible Power Source (UPS) battery room. The explosion blew a 400 ft2 hole in the roof, collapsed numerous walls and ceilings throughout the building, and significantly damaged a large portion of the 50,000 ft2 building. Fortunately, the computer/data center was vacant at the time and there were no injuries.

The facility was formerly a large computer/data center with a battery room and emergency generators. The company vacated the building and moved out the computer equipment; however the battery back-up system was left behind. The ventilation for the battery room appeared to be tied into a hydrogen monitoring system. The hydrogen sensor was in alarm upon emergency responders arriving at the scene (post-explosion). 911 callers view more

A routine security patrol reported a strong odor of sulfur coming from a battery charging facility. The battery charging facility is used for charging the various forklift batteries for the shipping and receiving operation. The building is approximately 450 sq. ft. and has four charging stations. Emergency response was initiated and the incident commander responded to the scene. Initial air monitoring indicated readings above the Lower Explosive Limit (LEL) for hydrogen gas. The local fire department responded and setup for the situation. Facilities personnel responded and turned power off to the building. The building was ventilated and verified to be safe by the fire department. There were no injuries or damage.

The exhaust fan for the building failed, allowing hydrogen gas to view more