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Clean Hydrogen Partnership

Explosion in a refinery

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

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