Training Issue

Hydrogen Explosion due to Failure of an Incorrectly Sized Spirometallic Gasket at a Refinery Hydrodesulfurization Plant

11:23 AM Thu Jan 13, 2011 -- Anonymous (not verified)

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.

Hydrogen Gas Explosion in Municipal Refuse Incineration Facility

11:23 AM Tue Nov 16, 2010 -- Anonymous (not verified)

An explosion occurred in a 90-ton-per-day incinerator at a municipal refuse incineration facility. Three workers were seriously burned by high-temperature gas that spouted from the inspection door, and one of them died 10 days later. The accident happened during inspection and repair of the furnace ash chute damper. The workers injected water to remove some blockage, and the water reacted with incinerated aluminum ash to form hydrogen, which caused the explosion.

Hydrogen Explosion in a Styrene Plant

11:23 AM Fri Nov 12, 2010 -- Anonymous (not verified)

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.

Hydrogen Explosion in University Biochemistry Laboratory

12:23 PM Mon Aug 23, 2010 -- Anonymous (not verified)

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.

Fatal Accident due to Bacterial Hydrogen Production in Atmospheric Storage Tank

12:23 PM Mon May 3, 2010 -- Anonymous (not verified)

A fatal accident took place at an onshore processing facility for slop water from the offshore petroleum industry.

Drilling fluids, or mud, are typically oil-water emulsions consisting of base oil (continuous phase), water (dispersed phase), and emulsifying agents. Used drilling mud, or slop, is mud enriched with water and rock cuttings from drilling --- typically 60-80% water, 10-20% emulated base oil, and 10-20% rock cuttings. The used drilling fluids are collected in slop tanks on oil platforms and later shipped to onshore facilities for further processing.

Hydrogen Gas Leak from Compressed Gas Cylinder

11:23 AM Mon Mar 1, 2010 -- Anonymous (not verified)

Two scientists were changing hydrogen gas cylinders in an analytical laboratory. They were in the process of removing the cylinder cap from the new cylinder when a loud hissing noise occurred and they quickly realized that the tank was leaking. After making a quick attempt to shut off the tank, which was not possible, they left the lab and notified their supervisor.

Refinery Hydrocracker Pipe Ruptures and Releases Explosive Mixture with Hydrogen

11:23 AM Tue Jan 12, 2010 -- Anonymous (not verified)

A refinery hydrocracker effluent pipe section ruptured and released a mixture of gases, including hydrogen, which instantly ignited on contact with the air, causing an explosion and a fire. Excessive high temperature, likely in excess of 1400°F (760°C), initiated in one of the reactor beds spread to adjacent beds and raised the temperature and pressure of the effluent piping to the point where it failed. An operator who was checking a field temperature panel at the base of the reactor and trying to diagnose the high-temperature problem was killed.

Over-Pressurization of Laboratory Ball Mill

11:23 AM Thu Mar 6, 2008 -- Anonymous (not verified)

The over-pressurization of a laboratory ball mill reactor designed for operation under slightly elevated pressures resulted in a serious injury. The apparatus had been routinely operated under argon and hydrogen pressures of 5-10 atmospheres for nearly two years. The apparatus had not been tested for operation at pressures greater than 10 atm.


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