Event
- Event ID
- 1228
- Quality
- Description
The incident occurred in the new Residue Upgradation Facility unit of the refinery, which converts the heaviest oils from crude oil into high-quality, cleaner fuels such as Euro 6 diesel. The unit was was still under construction.
Hydrogen gas leaked from a piping connected to a pressure transmitter of the hydrogen compressor and caught fire due to static charges. The automatic sprinklers brought down the fire immediately, after which fire fighters reached the spot and brought the situation under control. No injury.- Event Initiating system
- Classification of the physical effects
- Hydrogen Release and Ignition
- Nature of the consequences
- fire
- Macro-region
- Asia
- Country
- India
- Date
- Component involved
- compressor / booster / pump (pipe)
- Failure mode
- rupture & ignition
- Initiating cause
- material degradation (generic)
- Root causes
- Unknown
- Date entry in HIAD
- 31/10/2025
Facility
- Application
- Petrochemical industry
- Sub-application
- Hydrodesulphurisation process
- Hydrogen supply chain stage
- All components affected
pressure gauge, piping
- Process temperature range [C]
- ambient temperature (-50°C to +50°C)
- Location type
- Unknown
- Location
- populated area
- Operational condition
- Pre-event occurrences
There were no workers at the time of the accident. During working times, 200 workers, inlcuding contractors, would be in the surroundings.
- Description of the facility/unit/process/substances
DESCRIPTION OF THE PROCESS
In a Residue Upgradation Facility (RUF) process, hydrogen acts as a reagent in hydrocracking and hydrotreating reactions to convert heavy hydrocarbon residues into lighter, higher-value products like gasoline and diesel. Specifically, hydrogen:
• Breaks down large molecules: Hydrogen, in conjunction with a catalyst, breaks the strong carbon-carbon bonds in complex, long-chain hydrocarbon molecules, converting them into simpler, shorter-chain molecules.
• Removes impurities: Hydrogen reacts with heteroatoms like sulfur and nitrogen in the residue, removing them in the form of hydrogen sulfide (H₂S) and ammonia (NH₃), respectively.
• Prevents coke formation: Hydrogen saturates reactive species and inhibits coke formation by hydrogenating coke precursors, which can cause issues in the process.
• Increases distillate yields: By upgrading the heavy residue into lighter fractions, hydrogen contributes to maximizing the yield of more valuable products, improving refinery profitability.
{https://environmentclearance.nic.in/writereaddata/Online/TOR/31_Aug_2018_1557428738TGB9AH7BriefSummary.pdf]
Emergency & Consequences
- Number of fatalities
- 0
- Number of injured persons
- 0
- Emergency action
Automatic sprinklers came into action, followind by the intervention of plant fire brigade and the ocal fire fighters.
In-depth data
- Release type
- gas
- Involved substances (% vol)
- H2 100%
- Release temperature [°C]
- 25
- Probable IGNITION SOURCE
References
- Sources categories
- News
- Reference & weblink
Deccan Cronicle new of 19 Septemebr 2025
https://www.deccanchronicle.com/southern-states/andhra-pradesh/hydrogen…
(accessed November 2025)The Time of India news
https://timesofindia.indiatimes.com/city/vijayawada/fire-due-to-gas-lea….
(accessed Novemebr 2025)