A hydrogen leak occurred at a plant's hydrogen fill station when a vendor's hydrogen fill truck trailer pulled away after filling and caught an improperly stored hydrogen fill line. The driver of the hydrogen truck trailer did not properly stow the hydrogen fill line after filling and failed to verify that the hydrogen fill line was clear of the trailer prior to departure. As the driver pulled away from the fill station, the hydrogen fill line caught on the trailer and subsequently pulled on the hydrogen fill station's ground storage tubes distribution manifold. The force of this pull bent the plant's hydrogen distribution manifold and hydrogen began leaking from a threaded connection and from the hydrogen fill line. The truck trailer driver reported hearing a view more
A technician was welding a cable suspended over a stainless steel H2 instrument line. During the welding process, two holes were accidentally burned through the hydrogen tubing. The operator heard a hissing sound and closed the valve, but the hydrogen had already ignited and it burned his hand while he was feeling for a leak.
A short during welding caused the pinholes in the tubing containing the gaseous H2.
A bourdon tube ruptured in a pressure gage after 528 hours of operation in a liquid H2 system. The alarm sounded, the system was isolated and then vented.
A faulty modification to a multiple-gas piping manifold allowed mixing of hydrogen and oxygen that resulted in a storage tube explosion. Several employees suffered severe burn injuries from the incident.
An employee, without authorization, fabricated and installed an adapter to connect a hydrogen tube trailer manifold to an oxygen tube trailer manifold at a facility for filling compressed-gas cylinders for a variety of gases, including hydrogen, oxygen, nitrogen, and helium. A subsequent improper purging procedure allowed oxygen gas to flow into a partially filled hydrogen tube on a hydrogen tube trailer. An ignition occurred in the manifold piping system and a combustion front traveled into the hydrogen tube where, after traveling about a view more
A large, hydrogen-cooled generator is driven by steam turbines at a power station. During maintenance shutdowns, the hydrogen cooling loop in the generator is purged with carbon dioxide. After CO2 concentrations are measured with a densitometer to verify the complete removal of hydrogen, the generator is purged with air and the maintenance is performed.
This purging procedure was used prior to the explosion. The CO2 reading was reported to be 100 percent CO2 at the top of the generator. The cooling system was then purged with air and a 1/2 inch pipe in the cooling loop was cut to install some new instrumentation. When the pipe was cut, pressurized gas was emitted at the opening. Workers assumed the gas was either carbon dioxide or air and proceeded with the new instrument 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
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.
Maintenance personnel presumed that the leak was nonflammable nitrogen because there had recently been a nitrogen piping leak elsewhere in the plant. Using the plant's overhead crane, they removed some of the heavy trench covers. They determined that the leak was in an area that the crane could not reach, so they brought in a forklift with a chain to remove the trench covers in that area.
Eyewitnesses stated that as the first trench cover was wrenched from its position by the forklift view more
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- = Explosion
- = Fire
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- = Explosion
- = Fire