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Clean Hydrogen Partnership

Explosion in a hydrogen production unit

Event

Event ID
865
Quality
Description

An explosion and fire occurred at a hydrogen production plant serving the hydrocracker and the diesel hydroteater of a nearby refinery.
According to the plant owner, the incident occurred in the collection manifold, also referred to as a collection header or a transfer line, due to the failure of an external carbon steel pipe of the collection manifold.
No injuries were reported among the employees and no damage to the nearby refinery, but exnsive damage to the hsyrogen production unit.

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
manifold
Failure mode
rupture & ignition
Initiating cause
over-heating
Root CAUSE analysis

The INITIATING CAUSE was the rupture of a carbon steel pipe, for undisclosed reasons.

According to one of the sources, the plant owner and operator suited a contractor for the "for causing the energy release, saying they negligently failed to provide it with accurate safe operating temperatures, failed to warn of the potential for a cracked refractory inside the collection manifold and failed to design the collection manifold from materials able to withstand the potential operating temperature."
This statement suggests the failure of the pipe because experiencing to too high temperatures, due to (1) inadequate materials design, (2) deterioration of heat insulator. It also implies shortcoming in the communication between contractor responsible for the plant operation and its owner.

The ROOT CAUSE could be a combination of shortcomings in design, inspection/maintenance/repair and eventually additional responsibility in the management of the plant.

Root causes
Date entry in HIAD
01/01/2020

Facility

Application
Hydrogen production
Sub-application
SMR
Hydrogen supply chain stage
All components affected

unknown

Location type
Open
Location
populated area
Operational condition
UNKNOWN
Description of the facility/unit/process/substances

DESCRIPTION OF THE FACILITY
The hydrogen plant, which at the time of the incident had a capacity of 100 million standard cubic feet a day, was connected to a 300-mile hydrogen pipeline that runs along the Gulf Coast.

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0
Post-event summary

The vent caused damage to the manifold, a gas boiler, the facility's electrical system and other equipment near the manifold. The costs are unknown.
No injuries were reported among the employees and no damage to the nearby refinery, but exnsive damage to the hsyrogen production unit.

Emergency action

According to the spokeswoman, the fire was quickly under control.

In-depth data

Release type
gas
Involved substances (% vol)
H2 100%
Probable IGNITION SOURCE
Explosion type

References

Sources categories
News
Reference & weblink

Southeast Texas Records
(notavailable anymore on line)