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Clean Hydrogen Partnership

hydrogen fire in the hydro-desulphurisation unit of a refinery

Event

Event ID
902
Quality
Description

A hot oil line (8-inch) in the hydrodesulphurisation unit failed due to fatigue cracking. Hot oil at 50 bar and 343°C sprayed across the roadway into the hydrogen units where ignition occurred. The pipe break was a guillotine -type, probably in the heat affected zone at 2 inches from a welding.
The intense fire around the pipe rack in the hydrogen plant caused a hydrogen line (16-inch) to rupture, adding a second blow torch to the fire. In successive order, more pipes ruptured with explosions.
After six-and-a-half hours, the fire was extinguished.
Damage was extensive. The three hydrogen units and the four HDS units were heavily damaged or destroyed.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
fire followed by an explosion
Macro-region
South America
Country
Venezuela
Date
Component involved
pipe (generic)
Failure mode
rupture & ignition
Initiating cause
conventional component failure (fire)
Root CAUSE analysis

The INITIATING CAUSE is fatigue cracking of the oil pipeline, which caused the failure of a hydrogen pipe.
Sources refer to probable fatigue cracking, possibly hydrogen assisted.
Before the loss, the line which failed was judged as having excessive vibration.

Failure of managing out-of-specification fatigue phenomena may be the root cause, or at least a contributing cause.

Root causes
Date entry in HIAD
01/01/2018

Facility

Application
Petrochemical industry
Sub-application
Hydrodesulphurisation process
Hydrogen supply chain stage
All components affected

hydrogen (generation) unit

Process temperature range [C]
High temperature (100°C to 500°C)
Process pressure range [MPa]
medium pressure (2 to 10 MPa)
Location type
Open
Location
industrial area
Operational condition
Pre-event occurrences

9 years earlier vibrations had been noted on the gas line which failed. The structure had been stiffened by means of gussets. An hypothesis is that this intervention had amplified/accelerated the fatigue phenomena which was caused the break of the line., together with blistering due to hydrogen attack.

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0
Currency
US$
Property loss (onsite)
75.000.000.000
Post-event summary

Damage was extensive. The three hydrogen plants and the four HDS units were heavily damaged
or destroyed.
Other source report M$89(Excluding Production loss.)

Emergency action

The fire lasted 6h30

In-depth data

Release type
gas mixture
Involved substances (% vol)
oil
H2
Release temperature [°C]
343
Probable IGNITION SOURCE
Flame type

References

Sources categories
ARIA
Reference & weblink

Description of the event in the database ARIA
https://www.aria.developpement-durable.gouv.fr/accident/7315/
(accessed September 2020)

MARSH report, 100 largest losses in the hydrocarbon industry, 27th edition 2022
https://www.marsh.com/cz/en/industries/energy-and-power/insights/100-la…
(accessed January 2024)

A. Goel, Refinery Reliability Through Advanced NDT Methodologies,
Proc. National Seminar on Non-Destructive Evaluation Dec. 7 - 9, 2006, Hyderabad
http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.216.4819&rep=r…
(accessed September 2020)