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HIAD Causes: Material/Manufacturing Error


An aerosol of hydrogen, hydrogen chloride and sulfuric acid is released in a plant producing chlorine via electrolysis.The exhaust pipe on the water circuit of the electrolyzer was blinded due to the…
The release took place in a metal cold rolling workshop.The hydrogen leaked from a cylinder of 15 m3, which was part of a storage system of 250 m3.Half of the workshop and the surrounding roads were…
A hydrogen release occurred in a storage area of a nuclear power plant.. The storage consisted of three trailers made of 14 compressed gas cylinders each. The cylinders, mounted horizontally, had a…
A release of contents of a pressure vessel occurred when a longitudinal weld tore open. The vessel had been shut down and had just been put into use again when the incident occurred.The gas mixture…
Although the ARIA report (see references) does not mention it, the unit affected was very probably the oil desulfurisation unit. The release occurred following the rupture of a pipe of 250 mm in…
The operator detected a leak of aerosol hydrocarbons (diesel, hydrogen and hydrogen sulfide) in the diesel desulfurisation unit, causing a release of hydrogen and hydrogen sulfide at the top of the…
In an ammonia production unit, a 350-bar leakage of synthesis gas (ammonia + hydrogen) occurred in the compressor room. The leak was the result of the failure of a weld on a line (2") at the outlet…
During a patrol, an operator detects a hydrogen leak in a refinery on a footbridge 30 meters high. The origin of the leak is identified 4 days later on a pipe under insulation. The operator proceeds…
In a fertilizer manufacturing plant, during his inspection round, an operator detected a hydrogen leak at a flange of an exchanger located between the conversion and decarbonisation stages of the…
Ejection of rotor wedge material lead to vibration induced failure of components, including hydrogen seals. Serious fire resulted from hydrogen leakage, which subsequently lead to an oil fire.…
A petroleum refinery experienced a catastrophic rupture of a heat exchanger in the catalytic reformer / naphtha hydrotreater unit (the NHT unit). The heat exchanger, catastrophically ruptured because…
On 17 February 2000, THOR EMILIE was lost. The ship had been chartered by a Swiss company to carry about 2,000 tonnes of oxide zinc ore in bulk from Dunkerque in France to Porto Vesme on Sardinia.…
A short circuit developed in the wiring of a fire eye system on one of two 600 psig boilers serving a refinery. This triggered a rapid sequence of events that resulted in a one week shutdown of much…
It was a small incident in a heat-electric power plant. The alarm was registered at 11:26 and the fire was extinguished at 12:03. The incident took place during tests using the reserve power…
There was a small leak of syngas (a mixture mainly consisting of hydrogen and carbon monoxide) resulting in a localized fire at a bolted flange joint on the outlet carbon steel pipework of the High…
The leak occurred at the ammonia reactor after a technical shutdown of 4 days. When the production was resumed and the syngas compressor restarted 14 hours later, a jet-fire occurred. The Internal…
A 24" pipe carrying synthesis gas (Hydrogen = 43.5%, Nitrogen = 14.08%, Methane = 0.2%, Carbon Dioxide = 12.3%, Water = 29.3% by volume) ruptured. About 60 kg of hydrogen contained in the gas…
Employee #2 was using a torch to cut a U-bolt on the bypass piping next to a brine surge tank that potentially contained hydrogen gas in a vapour space in the upper portion of the tank. His job was…
In the collective treatment plant of a chemical platform, the truck tank of 25 m containing hydrochloric acid (HCl) rose in pressure at 11 am; leakage of acid solution and gas evolution occurred in…
Release from a welding of a hydrogen transmission pipeline At 12:45 pm the operation control centre (OCC) recognised that a customer flow and pressure dropped significantly. At 13:28 the OCC made the…
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