Overview: A hydrogen leak and explosion occurred due to the installation of an incorrectly sized gasket at the suction line of a hydrogen compressor in a refinery hydrodesulfurization plant. The incorrectly sized gasket was mounted during the startup of the plant in 2001 and had never being inspected nor replaced.

Incident synopsis: The operating conditions were stable when the operator received an alarm indicating pressure loss in the circuit. He immediately instructed his field personnel to inspect the area. The hydrogen leak was confined inside the compressor room because the walls and roof were not provided with ventilation devices. An explosion occurred, causing two fatalities and the destruction of the compressor room and some of the surrounding area.

A hydrogen explosion and fire occurred in the benzene unit of a styrene plant in a large petrochemical complex. The unit was being restarted following a scheduled maintenance shutdown. The explosion followed the release of about 30 kilograms of 700-psig hydrogen gas from a burst flange into a compressor shed. Two men were killed and two others were injured. If it had not been a holiday, the death toll and injuries would probably have been much worse.

The operators were bringing the plant online and increasing the hydrogen circulation pressure. About 10-15 seconds before the explosion, they heard a pop and then a loud hiss of pressure being released within the compressor shed. Witnesses reported seeing a white flash and then a large fireball. The fires burned out in 2-3 minutes, view more

A hydrogen explosion occurred in a university biochemistry laboratory. Four persons were taken to the hospital for injuries. Three of these were treated and released shortly thereafter; the fourth was kept overnight and released the following evening. All of the exterior windows in the laboratory were blown out and there was significant damage within the laboratory. One sprinkler was activated that controlled a fire associated with a compressed hydrogen gas cylinder.

First responders from the local community and the university campus were quickly on the scene. Once the injured were attended to and the site secured, response efforts focused first on assessing potential hazards (electrical, fire, hazardous materials, etc). Campus personnel worked into the night to board up windows view more