I got a faceful of ammonia once - carrying a full cargo of the stuff (6000 cubic metres of it) and on a short voyage involving cooling it down whilst en route, so it was important to keep all cargo plant running at maximum capacity in order to attain desired discharge temperature without delays. Normal practice. Anyway, we developed a leak at a joint on a line in one of the 3 compressor units. I did a risk assessment and decided, in conjunction with the Master and Chief Officer, that a repair could safely be done by isolating the affected unit, purging the pipeline and then removing the affected pipe, repairing it, then refitting it and restarting the unit. This was possible because I would have 2 valve separation from all 'live' pipework. I even lashed the necessary valves shut and tagged them. It was a procedure well accepted and should have been perfectly safe.
So, I'm busy with the job, having proved the line was depressurised and liquid free before dismantling, and am about to replace the affected pipe when I hear the sound that nobody should hear - the sound of something under pressure coming down the open line... I tried to get clear, but was a fraction too late, and was struck by a jet of ammonia. The pain was awful - I managed, pretty much blind, to stagger to fresh air and the emergency shower, but my body wasn't wanting to breathe in any more air, as I had received a lungful of vapour and I suppose it was a natural instinct not to want any more...
Anyway, assistance arrived quickly, and my sight returned after copious flushing with fresh water. It took a while to feel OK though. I wouldn't wish that on my worst enemy. Horrendous.
What had happened? The Chief Officer, forgetting what was going on, despite his having been in agreement with the procedure, had decided that he wanted to change the popeline configuration, and removed the lashings and opened the valves... Needless to say, the Master fired him on the spot and he was off immediately on arrrival at our discharge port. I was very, very lucky