The sensing diaphragm of a pressure transducer (PT), as supplied on an outdoor hydrogen compressor, unexpectedly ruptured and released approximately 0.1 kilograms hydrogen to atmosphere from the compressor discharge line. At time of incident, personnel nearby were alerted by a loud 'pop' and dust disturbance. Simultaneously, the facility monitoring system detected loss of the PT signal and initiated equipment shutdown. Facility personnel then closed isolation hand valves to stop the leak, locked and tagged out the equipment, and restricted the area. The failed component, a cigar type PT rated to 20,000 psi, originally supplied and installed by the manufacturer as part of the compressor package, was removed and inspected. Inspection revealed severed wires, a separated wire housing, view more

Incident Synopsis
A H2 delivery truck accident occurred on a highway. The truck was pulling a trailer containing gaseous H2. Upon entering a sharp curve, the truck and trailer started to weave and pushed to the side of the road. The truck and trailer rolled about 40 feet downhill; the trailer rolled over 1 1/2 times and the tractor once, ending in the upright position with the driver still in his seat. The truck was completely totaled, but little damage was incurred by the trailer. The trailer shell was satisfactory with normal venting through the stack. The rear cabinet doors were warped shut.

Cause

The accident occurred on a bad road, which was steep with many sharp curves. The driver was going too fast for the road conditions and the type of trailer being view more

Incident Synopsis
During transfer of liquid H2 from a commercial tank trailer to a receiving vessel, a leak developed in a bayonet fitting at the trailer/facility connection. The leak produced liquid H2 spray which enveloped the rear of the truck where the hand-operated shutoff valve was located. Emergency trained personnel, wearing protective clothing, except for proper shoes, entered the area and shut off the flow control valve. Reentry personnel suffered frost bite of their feet when shoes became frozen to the water-wetted rear deck of the truck.

Cause
A loose hose flange connection allowed leakage of cold fluid through the lubricated bayonet seal. This allowed cold fluid to contact and shrink the 'O' ring seal (made of Buna-N rubber), thus permitting view more

Incident Synopsis
While disconnecting a liquid H2 fill line from a liquid H2 trailer, liquid H2 escaped, burning a second man who was holding the hose. The man was burned on his hands and on his stomach.

Cause
The liquid H2 shut off valve was partially open, but both men assumed it was closed. Prescribed clothing was being worn.

Incident Synopsis
While a hot air dryer was being used to free a coupling in a hydrogen cryostat (an apparatus used to maintain constant low temperatures), a flash fire occurred. The H2 cryostat was being dismantled.

Causes
The temperature at the center of the cryostat was sufficiently low to liquefy air. The prescribed requirements for purging and bringing the cryostat to room temperature were circumvented. The H2 - air mixture was formed and ignition was assumed to be a spark from an open filament of the dryer.

Incident Synopsis
While attempting to replace a rupture disk in a liquid H2 vessel, H2 gas was released and ignited. In fighting the fire, liquid N2 was sprayed onto a second liquid H2 vessel located nearby. This resulted in cracking of the outer mild steel vacuum jacket. The loss of the vacuum caused a rapid increase in pressure and rupture of the burst disk of the second vessel. H2 boiled off and was burned in the fire.

Cause
The rupture disk was being replaced with a load of liquid H2 in the vessel and no separating inerting gas. The H2-air mixture was probably ignited by static discharges. Rupture of the second vessel burst disk was caused by the low-temperature exposure of the mild steel vacuum jacket.

Incident Synopsis
During pressure testing of a H2 tank for investigation of quick-release manhole cover, the tank burst at a pressure between 60-67 psig. Flow regulators indicated peak pressure of 67 psig.

Cause
The tank was over pressurized. A mistake was made in interpreting the blueprint, believing the tank was designed to withstand 150 psig, yet the actual design limit was 50.7 psig.

Incident Synopsis

A hydrogen compressor had been shut down for repairs and was being put back into service when an explosion occurred, resulting in property damage. The compressor was equipped with interchangeable intake and outlet valves.

Cause

The discharge valve was installed in the intake valve position, causing the cylinder head to blow off and release H2 to the atmosphere. The ignition source was not indicated.

Incident Synopsis
A H2 air explosion occurred near a H2 compressor, located outside. Gaseous H2 had been released from a vent stack when a relief valve was actuated. The source of ignition was not known, but considerable damage was inflicted onto the system by the ensuing fire and explosion. Following the explosion, the shut-off valves were closed and the system was vented.

Cause
Two relief valves were located in the 3,000 psig system downstream of a 5,000/3,000 regulator. The relief valves were sized to handle substantially different flows. (One was designed for another program.) The relief valve was believed to have opened when the pressure setting was being increased from 2,700 to 2,900 psig. The accuracy of the 5,000 psig gauge used to control the dome of the 5 view more

Incident Synopsis
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.

Cause
A short during welding caused the pinholes in the tubing containing the gaseous H2.