Skip to main content
Clean Hydrogen Partnership

Explosion in an industrial gas plant

Event

Event ID
97
Quality
Description

Works at the power grid of a hydrogen production unit were at the origin of the following accedental sequence:
1. Fusion of a safe fuse triggering the closure of a valve on the manifold of a pistons compressor, whose function was to raise the pressure from 50 mbar at the exit of the gasometer to 250 bar.
2. As a consequence of the closure of the valve, the dome of the gasometer filled with hydrogen up to the maximal level, after which the regulation valve of the storage system closed.
3. At this moment, a zone of under-pressure at the aspiration pipe of the compressor, causing the suction of air from outside, which formed with hydrogen an explosive mixture which auto-ignited.
4. The explosion caused the failure of the pressurised system: two pressure vessels, pipes and other parts of the plant were largely damaged, including the brick building hosting the unit.
5. Three plant keepers, which were in the near building, were seriously injured by an iron pieces breaking into the building.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
Europe
Country
Germany
Date
Component involved
compressor / booster / pump (valve)
Failure mode
internal explosion
Initiating cause
conventional component failure (electricity, power)
Root CAUSE analysis

Human failure during repair works that led to the malfunctioning of the hydrogen-high pressure condenser.

Root causes
Date entry in HIAD
28/02/2009

Facility

Application
Chemical industry
Sub-application
industrial gases production
Hydrogen supply chain stage
All components affected

pressure condenser, pipe, water trap, plastic tube, hydrogen production unit, hydrogen compressor,

Process temperature range [C]
Above ambient temperature (50°C to 100°C)
Location type
Semiconfined
Location
industrial area
Operational condition
Pre-event occurrences

Works were executed at the power grid of the of the installation.

Emergency & Consequences

Number of fatalities
0
Number of injured persons
2
Post-event summary

Two plant keepers, which were in the near building, were seriously injured by an iron pieces breaking into the building.
More than 3 MEuro of material damage.

Emergency action

A local hydrogen fire on a near measurement pipe was extinguished.

Emergency evaluation

The measurement and control systems necessary for the continuation of the electrolysis operation were examined, the pipes open towards hydrogen outlet and air inlet were closed. The electrical supply of the condenser plant was controlled.

Lesson Learnt

Lesson Learnt

reported by the referred source states: "The building of the compressor plant has to be remade in light structure (design change)."

It seems a rather limited conclusion, focussing to mitigate the consequence of similar accidents.

In-depth data

Release type
gas
Involved substances (% vol)
H2 100%
Release temperature [°C]
25
Probable IGNITION SOURCE
Explosion type

References

Sources categories
eMARS
Reference & weblink

Original event description in eMARS

Event from German database ZEMA
https://www.infosis.uba.de/index.php/de/site/12981/zema/index/2911.html
(accessed December 2023)