Lessons learned from a hydrogen explosion at a photovoltaic research facility

Hydrogen gas is used in research reactors to deposit amorphous silicon thin-films for solar cells at the Institute of Energy Conversion (IEC), University of Delaware. A hydrogen explosion occurred on September 1, 1992 at IEC. A formal investigation was conducted. Suggestions provided by the Accident Investigation Team formed the basis for a complete review and upgrade of the compressed gas handling systems and procedures. In this paper, the causes of the explosion are discussed along with resulting modifications made to the gas handling system, facility, and procedures to prevent a recurrence of this type of incident and to improve the safety of this facility. Lessons learned from this incident and the resulting investigation and response are highlighted, including the need to regularly review both hardware and procedures to ensure that all aspects of the research program and facilities are up-to-date