Topic
Hydrogen Safety
Hydrogen generation, release, ignition and safe handling.
Documents
- 2025Dec
CHIRP Superyacht FEEDBACK 8 (December 2025)
Superyacht incident reports examine a failed mooring attachment, captain harassment, generator starter battery explosions, collision at anchor, unsafe pilot boarding arrangements, unprotected work aloft and defective life rafts. Commentary discusses battery capacity and ventilation, engineering handovers, equipment servicing and testing, reporting concerns and organisational safety culture.
- 2025Sep
Several errors lead to a hydrogen leak & fire — Process Safety Beacon, September 2025
This bulletin examines a hydrogen filling incident in Santa Clara in which a trainee inadvertently restarted filling while piping was dismantled for repair. Escaping hydrogen ignited, producing a deflagration and jet fire. It emphasises isolation procedures, authorised repairs, understandable controls and clear instructions for newer employees.
- 2022May
“ What happens if ?” An important question for hazard reviews — Process Safety Beacon, May 2022
A fatal batch-mixing explosion and an earlier near-miss illustrate the importance of considering material misidentification and unintended reactions during hazard reviews. The bulletin recommends examining human error traps, using reactivity compatibility matrices, rigorously checking materials and keeping operating tanks closed, sealed and vented to a safe location.
- 202124 Sep
AB Specialty Silicones, LLC
Investigation of a fatal hydrogen explosion during silicone-emulsion batch manufacture in Waukegan, Illinois. Reactivity experiments linked unintended potassium hydroxide addition to hydrogen generation. The report examines similar chemical drums, atmospheric batch tanks, ventilation, failed detector trials, evacuation preparedness and procedural checks, alongside process safety culture and regulatory gaps for reactive chemicals.
- 202123 Feb
Lead-acid battery explosion
A generator starting incident destroyed the top of a lead-acid battery case. The flash identifies a hot negative-terminal connection that would have ignited any excess hydrogen accumulated in the battery box. Actions include checking connections, following installation instructions and considering batteries that do not release hydrogen during charging.
- 202016 Dec
LTI: Person injured by a battery explosion on vessel deck
A charged battery for portable subsea magnetic particle inspection equipment exploded during deck checks, projecting its housing lid and injuring a worker. Inadequate post-charge venting allowed an explosive atmosphere to develop; the precise ignition cause remained inconclusive. Lessons address venting times, charging instructions, toolbox talks, protective equipment and emergency response.
- 20203 Jun
Safety Alert 388 - Malfunctioning Storage Batteries Cause Fires and Explosions
This alert describes several lead-acid battery fires and explosions involving internal shorts, ageing circuitry and heat accumulation. BSEE recommends that operators and contractors consider battery dating, inspection and replacement policies, enclosure ventilation, suitable storage, correct battery selection and charger settings. It also highlights hydrogen generation during charging and related UPS hazards.
- 20198 Nov
Safety Alert 370 Overcharged Battery in Non-Ventilated Box
An RTU panel exploded after an overcharged 12-volt battery generated hydrogen in an unventilated enclosure. An unsuitable electrical component was the likely ignition source. No injuries or nearby equipment damage occurred. BSEE recommends operators consider compliant battery enclosures, installation arrangements preventing hazardous hydrogen accumulation, and electrical components rated for their area classification.
- 201928 May
Two battery issues – Step Change
Two battery incidents illustrate different hazards: a lifeboat lead-acid starter battery exploded after repeated overcharging, while a lithium-ion battery caught fire following water exposure and short-circuiting of inspection equipment. Lessons address equipment suitability, clear charging instructions, workforce competence, protection against water ingress and care when drying equipment.
- 2018Dec
High Temperature Hydrogen Attack: Safe use of carbon steel
HSE alerts operators to carbon steel degradation through high temperature hydrogen attack. It distinguishes safer metallurgy for new or replacement equipment from cautious use of Nelson curves for existing plant. Recommendations address operating histories, temperature and hydrogen partial pressure limits, validated complementary non-destructive testing, examination intervals and specialist inspector competence.
- 201811 May
Safety Alert 333 - Floating Production Platform Evacuated Amid Power Outage
This alert examines a floating production platform blackout and evacuation involving UPS failure, a potentially hazardous hydrogen release, deficient battery-room ventilation and shutdown logic that obstructed power restoration. Two further power incidents provide context. BSEE recommends considering reviews of black-start arrangements, electrical handover, ventilation maintenance and blackout-specific evacuation procedures.
- 20177 Dec
Gas explosions on general cargo ship Nortrader with 1 person injured
Investigation of two explosions aboard Nortrader at anchor in Plymouth Sound, injuring the chief engineer. Hydrogen generated by unprocessed incinerator bottom ash accumulated in the unventilated hold and entered the forecastle store. The report examines probable switchgear ignition, inadequate cargo testing and shortcomings in applying bulk-cargo carriage requirements.
- 201725 Oct
Safety features of the Siemens Maxum Edition II gas chromatograph
This flash describes an explosion causing life-changing injuries to a technician when a Siemens Maxum Edition II gas chromatograph returned to service. Hydrogen had accumulated during hold status, and the automatic purge was not re-engaged. Users should review purge controls against the maintenance manual and discuss operating arrangements with manufacturers.
- 20171 Oct
Siemens - Maxum II Edition Gas Chromatograph - Safety Features
HSE alerts gas chromatograph users to an explosion that caused life-changing injuries during return to service of a Siemens Maxum II. Hydrogen had accumulated while the unit was on hold, and automatic purging was not re-engaged. Users should review purge controls and discuss operating arrangements with manufacturers.
- 201625 Nov
Electrolytic Chlorination Units (Electrolysis) in Marine Ballast Treatment Systems
Safety alert following catastrophic failure of an electrolytic ballast-water treatment unit on a UKCS semi-submersible installation. It describes projectile damage and potential overpressure or hydrogen explosion hazards, including continued electrode operation during low or absent flow. Operators should assess risks, with attention to pressure relief and instrumented protection assurance.
- 201622 Nov
SPHL battery charging – build-up of hydrogen
Hydrogen accumulated in a self-propelled hyperbaric lifeboat cockpit during battery charging, and its ventilation system had no flow. The flash explains that fan alarms may not detect restricted vent pipes and identifies faulty lid seals as a potential problem. Recommended checks include polythene-bag airflow testing and weekly planned-maintenance verification.
- 201515 Dec
NOPSEMA: Fire risks associated with electric storage batteries
This safety flash describes a battery-room fire at a production facility, with no injuries. Leaking electrolyte contacting a conductive cabinet frame was the likely cause. It highlights thermal runaway from short circuits between UPS battery banks and potential explosions involving hydrogen released during lead-acid battery charging.
- 20154 Nov
Risks associated with electric storage batteries
Following a production-facility battery-room fire without injuries, this alert examines thermal runaway, hydrogen explosions, short-circuit energy release and electric shock. It outlines battery installation and maintenance measures, ventilation, fire protection, load testing and consideration of thermography, alongside replacement planning and emergency response arrangements.
- 20141 May
Tesoro Anacortes Refinery Fatal Explosion and Fire
Investigation of the Tesoro Anacortes refinery heat-exchanger rupture that killed seven employees. Metallurgical analysis identified high temperature hydrogen attack in carbon steel. Process modelling, inspection limitations and Nelson curves are examined alongside hazardous startup practices, ineffective safeguards, safety culture and regulatory gaps. Recommendations emphasise inherently safer materials and verified operating conditions.
- 201414 Apr
Silver Eagle Refinery Flash Fire and Explosion and Catastrophic Pipe Explosion
Metallurgical investigation of a refinery discharge-pipe rupture during hot hydrogen catalyst regeneration in Woods Cross, Utah. Ultrasonic thickness measurements, chemical analysis, metallography and fracture alignment document internal wall thinning. The findings are consistent with sulfidation corrosion as the primary cause; gas-release calculations and security-video analysis examine the subsequent explosion.
- 20134 Apr
Explosion causing fatal injury during maintenance of Metocean buoy
A crewman suffered fatal injuries when grinder sparks ignited hydrogen inside a recovered metocean buoy, projecting instrument components outwards. Investigation identified corrosion, cracked battery cases, inadequate maintenance and unfulfilled purging procedures. The flash describes pressure equalisation, air or nitrogen purging, ignition restrictions and precautions against exposure to the compartment lid.
- 20125 Jan
Hoeganaes Corporation Fatal Flash Fires
This case study investigates three incidents involving combustible iron dust and hydrogen at Hoeganaes in Gallatin, Tennessee. It examines dust testing, accumulation and collection failures, hydrogen piping integrity, electrical classification and flame-resistant clothing. Recommendations address combustible dust standards, plant-specific training, gas-system maintenance and near-miss investigation.
- 200823 Jul
Ballast tank hydrogen
A crew member lost consciousness after a tank was opened for planned maintenance on a semi-submersible accommodation unit. Later sampling identified unexpectedly high hydrogen levels, explained by an electrolytic reaction in the ballast tank below. The flash recommends regular venting, purging before opening, hydrogen testing before entry and reviewing sampling procedures.
- 200612 Oct
BP America (Texas City) Refinery Explosion — Safety Bulletin: Positive Material Verification
This bulletin examines the July 2005 hydrogen-fed fire at BP’s Texas City refinery. A carbon steel elbow substituted during maintenance failed through high-temperature hydrogen attack. It discusses interchangeable piping components, material verification using x-ray fluorescence, component tracking and maintenance quality controls to prevent incompatible material substitutions.
- 20041 Jun
Underwater explosions
Four underwater oxy-arc cutting incidents injured divers working on ship plating and tanks. The flash discusses trapped gas, hydrogen generation, blow backs and flammable residues. It recommends detailed risk assessment and competent personnel, and describes hard helmets, cold cutting and inert-gas flushing as risk management measures.
- 20036 Oct
Safety Alert 215 - Diving Fatality
A diver died in an explosion while torch-cutting casing during well abandonment. MMS attributed ignition to a cinder carried in an air bubble reaching accumulated hydrogen above adaptor vent holes. The alert highlights inaccurate configuration information and absent task-specific JSA, recommending reviews of contractor information transfer and management of unexpected conditions.
- 20021 Jan
Dangers of battery charging
A vessel battery incident released a small amount of acid without injury or other damage. Investigation identified low electrolyte levels and hydrogen generation during automatic continuous charging, which displaced the cap. The flash presents company requirements for charging areas, ventilation, electrical connections, eye protection and electrolyte checks.
- 20011 Jul
Oxy-arc cutting
A safety flash describes a diver fatality during subsea oxy-arc cutting, with spark ignition of trapped gas identified as the most likely explosion cause. Company instructions address alternatives, task approval, risk assessment, training and cavity venting, alongside oxygen flow through the Broco rod to prevent electrolytic hydrogen accumulation.
- 199822 Jul
Safety Alert 176 - Mud Logging Unit Explosion and Fire
An explosion and fire during mud logging unit setup involved hydrogen-fed analytical instruments. Connections had not been pressure-tested or checked for leaks, and damaged polyurethane hose allowed continued hydrogen flow. The alert recommends considering automatic shutdown, gas detection and positive purge arrangements, alongside piping material review and post-installation leak checks.
- 19986 May
Mud Logger Explosion & Fire
An explosion and fire occurred during the final rig-up phase of a mud logging unit, which was completely destroyed. Calibrated gas analysers remained operating to stabilise while external sample points and drains were connected. The flame ionisation instrumentation used hydrogen supplied into the unit as fuel.
- Undated
Battery Explosion in Platform Communications Enclosure
BSEE investigates a battery explosion on the Amberjack platform. Replacing two batteries with one exposed the replacement to a hazardous overcharge, releasing hydrogen into an unventilated communications enclosure. Findings address unsuitable electrical component ratings, inadequate hazard analysis and limited personnel awareness. No injuries or pollution occurred.
- Undated
Backup-Generator Battery Explosion Projects Acid into Operator’s Face
An investigation examines a backup-generator battery explosion at High Island A368 ‘A’ platform. Sparks from a loose terminal were suspected of igniting accumulated hydrogen, projecting acid into an operator’s face and eyes. The report identifies absent protective equipment, possible contributing factors, first aid and helicopter evacuation.
- Undated
Explosion of starboard boiler on liquid natural gas tanker Hilli with 1 person injured and loss of 1 life
Investigation synopsis of a fatal boiler explosion aboard Hilli at Freeport, Grand Bahama. Hydrogen generated during acid cleaning accumulated in the steam drum and was ignited when a halogen lamp was introduced. The account examines inhibitor protection, ventilation and atmospheric testing, with recommendations addressing cleaning procedures and risk assessment.
- Undated
Statoil - Mongstad - Investigation of gas leak
Investigation of a hydrogen-rich gas leak during inspection at Mongstad’s operating isomerisation plant. Severe external corrosion weakened a drainage pipe, with inadequate maintenance identified as a cause. The report examines inspection risks, conditional fire and explosion consequences, gas-detection deficiencies, manual blowdown, risk communication and evacuation accountability.