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)