Implement rigorous assembly, verification, and documentation procedures for equipment.

Increase automated leak detection frequency.

The project team concluded that the jar contained a sufficient vapor pressure of isopropanol to ignite when it came into contact with the decomposing hydride. The lesson learned was that hydrides react rapidly in air and can lead to combustion of…

As stated on the MSDS and also on the container labels, LiAlH4 should be handled under argon. LiAlH4 is advertised and sold as a powder. If the researcher had to scrape it out of the jar, then it was no longer a powder, which seems indicative of…

1. The presence of other flammable impurities (e.g., oil carryover from compressors, hydrocarbon contamination of the gas) is an additional hazard and should be eliminated before cryogenic purification.
2. Potential sources of oxygen in…

Because the bottle was located outside at the time of the event, and the hydrogen did not find a source of ignition while venting through the relief valve, nothing serious happened. The failed regulator was replaced and operations continued.…

Three root-causes were noted during the investigation: (1) the use of incompatible materials in the manufacturing of the PRD valve, (2) improper assembly resulting in over-torquing of the inner assembly, and (3) over-hardening of the inner…

1. Follow the rules (e.g., using a torque-amplifying device requires supervisor approval).
2. Some valves are susceptible to disassembly, with potentially significant consequences, if excessive torque is applied to the handwheel.…

The investigation team concluded that hydrogen gas was released through a failed 19-inch diameter gasket and ignited under the roof of the compressor shed where it was partially confined. Some gas escaped from the shed prior to the explosion, but…

The investigation determined that hydrogen was formed by the reaction of hot aluminum and water, air was admitted via the inspection door, and the mixture was ignited by the hot clinker or sparks from the chisel. Aluminum should have been…

The ignition of the fireball could have been caused by any of the following mechanisms:

• The inverse Joule-Thompson effect of hydrogen (i.e., heating upon expansion)
• Some of the oil and light ends were above their auto-…

1. Include the tanks in a regular inspection program. Evaluate their condition and replace if necessary.
2. Fill the tanks only half full with leach material.
3. Keep the material completely submerged in solution.
4. …

Do not interconnect hydrogen drain trap lines with other drain lines

Thoroughly inspect equipment installation to manufacturer’s installation instructions

Warn against unauthorized field modifications

Consult the…

Maintain an internal process for verifying component wetted material compatibility for intended use as part of the procurement process for hydrogen system equipment. 

Don’t rely solely on a manufacturer to provide appropriately rated…