Event
- Event ID
- 978
- Quality
- Description
The event occurred at a hydrogen tank (another source reports a 'conduit in an enclosed space') of a hydrogen generation unit of a refinery. The explosion caused a flare and a displacement of air that threw the contract workers against the refinery's metal structure.
The workers were using an electric rotary sander on the inside the tank which had been had been drained three days before. The workers had already done previously the same work without incident.
- Event Initiating system
- Classification of the physical effects
- Hydrogen Release and Ignition
- Nature of the consequences
- Macro-region
- South America
- Country
- Brazil
- Date
- Component involved
- CGH2 tank (stationary)
- Failure mode
- rupture & ignition
- Initiating cause
- inadequate or no purge
- Root CAUSE analysis
The INITIATING CAUSE was an explosion inside a hydrogen tank, which was still containing hydrogen despite workers were working in it.
According to the sources, the possible causes could have been "inadequate maintenance, failure of following procedures, lack of work procedures or procedures". Additional job related causes could also have contributed, such as mental and physical stress due to long shift and tight deadlines.
All these are plausible, however, absolutely no evidence is provided to support these theses. The ROOT CAUSES remain unknown.
- Root causes
- Unknown
- Date entry in HIAD
- 01/01/2024
Facility
- Application
- Petrochemical industry
- Sub-application
- hydrogen production unit, SMR
- Hydrogen supply chain stage
- All components affected
hydrogen tank, pipe
- Process temperature range [C]
- ambient temperature (-50°C to +50°C)
- Location type
- Confined
- Location
- industrial area
- Operational condition
- Pre-event occurrences
Maintenance works were ongoing.
- Description of the facility/unit/process/substances
DESCRIPTION OF THE FACILITY
Acording to www.nsenergybusiness.com, tThe process units in the this refinery included an atmospheric distillation unit (ADU), a vacuum distillation unit (VDU), a catalytic cracking unit (CCU), a hydrodesulphurisation unit (HDS), a hydrotreating unit (DHTD), a hydrogen generation unit (HGU), a sulphur recovery unit (SRU), and a lubricant and paraffin plant.
According to the Oil and Gas Journal, the hydrogen generation unit has a hydrogen generation capacity of 1.1 million normal m3/day (approx. 100 kgH2/day). It produced high-purity hydrogen by SMR for for several downstream units within the refinery complex.
Emergency & Consequences
- Number of fatalities
- 0
- Number of injured persons
- 3
- Post-event summary
The injuries were severe.
In-depth data
- Release type
- gas
- Involved substances (% vol)
- H2 100%
- Release temperature [°C]
- 25
- Probable IGNITION SOURCE
- Explosion type
References
- Sources categories
- News
- Reference & weblink
REUTERS news of January 19, 2015
https://www.reuters.com/article/idUSL1N0UY0K720150119HazardEx News
https://www.hazardexonthenet.net/article/88918/Petrobras-refinery-explo…
(Accessed December 2025)The incident is also listed in
P. Kannan, A web-based collection and analysis of process safety incidents
Journal of Loss Prevention in the Process Industries 44 (2016) 171-192