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Clean Hydrogen Partnership

Explosion on the Saturn stage

Event

Event ID
387
Quality
Description

[Note HIAD validator: this an incident where the hydrogen systems were involved as effects of the initiating event. There is nevertheless and additional possible contribution by hydrogen embrittlement]
During preparations for static firing tests of liquid oxygen - liquid hydrogen S-IVB stage, an explosion occurred prior to the lift off command. All systems indicated normal values. Extensive damage was received by the test stand and stage. Sides of the stage and liquid hydrogen tankage were fragmented. Many small fires around stand. Estimated fire ball diameter was about 300 feet. Propellant mixing resulted in a detonation estimated to be 1 percent of the TNT equivalent.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
North America
Country
United States
Date
Component involved
LH2 tank (stationary)
Failure mode
internal explosion
Initiating cause
manufacturing defect/error
Root CAUSE analysis

Explosion caused by failure of high pressure titanium spheres used to store gaseous helium. The tanks, located below the thrust ring, failed due to the use of incorrect and out of specification filler wire in the fabrication. Results of incorrect wire were to lower the ultimate strength and introduce hydrogen embrittlement. Subsequent explosions were considered effects rather than causes.

Root causes
Date entry in HIAD
01/11/2025

Facility

Application
Non-road vehicles
Sub-application
Aerospace
Hydrogen supply chain stage
All components affected

LH2 tank, rocket stage

Process temperature range [C]
cryogenic temperature (below -50°C)
Location type
Unknown
Location
countryside or desert
Operational condition

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0

In-depth data

Release type
no release
Released amount (kg)
0
Probable IGNITION SOURCE
Explosion type

References

Sources categories
ORDIN
Reference & weblink

Mishap no 46 in
P. L. Ordin, Review of hydrogen accidents and incidents in NASA operations, 1974, NASA TM X-71565
https://ntrs.nasa.gov/citations/19740020344

Hankinson and Lowesmith, Qualitative Risk Assessment of Hydrogen Liquefaction, Storage and Transportation, FCH JU project IDEALHY, Deliverable 3.10 (2013)
confidential
(accessed October 2025)

Lowesmith et al., Safety issues of the liquefaction, storage and transportation of liquid hydrogen: An analysis of incidents and HAZIDS, Int. J. Hydrogen energy (2014) https://doi.org/10.1016/j.ijhydene.2014.08.002