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This data is from the European Hydrogen Incidents and Accidents database HIAD 2.1, European Commission, Joint Research Centre.

Explosion in an Electrolytic Coating Facility
The explosion occurred in a copper electroplating plant test furnace when starting the operation of copper plating. EVENT DETAILS A tinned copper pipe had been placed inside another copper pipe and lined with pellets. Inside the furnace, the pellets were intended to adhere to the outer surface of the smaller tinned copper pipe under hydrogen atmosphere. The test was the third in the series. A vacuum was created inside the furnace, and an indicator light showed that a vacuum had been successfully generated. After that, the furnace was switched to automatic operation and the employee exited the hall. The intention was to supply hydrogen to the furnace while it was on automatic operation. However, at the furnace exploded. CAUSE: The furnace was equipped with two bleeding valves, one of which was manual and the other electronically operated by a pushbutton. The pushbutton-operated bleeding valve located in the vacuum under the furnace had remained in the open position when operation was commenced. However, the vacuum suction automation system kept the afore-mentioned valve closed during the period required for reaching the vacuum and the waiting period (57 min) following full vacuum. After that, hydrogen was introduced to the furnace automatically for about 10 min. After the purging gas valve had closed, the automation system no longer prevented the bleeding valve from opening; instead, air was allowed to pass to inside the furnace because the bleeding valve button was in the depressed position. The furnace was equipped with graphite rod elements that very quickly heat up the furnace to the set temperature. When the power supply switched on, the rods became quickly glowing red and ignited the hydrogen-air mixture. The hydrogen-air mixture inside the furnace exploded, the blind flanges of the furnace were dislocated out of their joints, and a pressure wave was propagated to the testing hall where no people were present at the time. The cause of the explosion was the pushbutton-operated bleeding valve that had remained in the open position, which the signal lamp failed to indicate because it was broken. As a result, air found its way into the furnace through the said valve after the hydrogen valve had closed and the waiting period was up, i.e. when the bleeding valve was no longer controlled by programd automation.
Event Date
September 14, 2005
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
Immediate cause was the inlet of air in a furnace filled with hydrogen, which ignited when switching on the heating of the graphite rods.Root cause is unknown, however it is easy to deduce that it lies in a wrong automatic process design and perhaps as well in a non optimal risk assessment..
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
electrolytic coating plant, cupper plating process furnace
Storage/Process Medium
Location Type
Location description
Industrial Area
Pre-event Summary
It seems that the event occurred when testing the furnace. The loading of a copper plant test furnace was started by placing in it a tinned copper pipe inside another copper pipe and lined with pellets. Inside the furnace, the pellets were intended to adhere to the outer surface of the smaller tinned copper pipe in presence of hydrogen The test was the third in the series. A vacuum was created inside the furnace, and an indicator light showed that a vacuum had been successfully generated. After that (10' from start), the furnace was switched to automatic operation and the employee exited the hall. The intention was to supply hydrogen to the furnace while it was on automatic operation. However, after 25'. the furnace exploded.
Currency
Lessons Learned
Lessons Learned
The lesson learned is unknown, however there had been already several fire and explosion affection the electrical installation of this facility, a sign of bad facility and/or process design and poor risk assessment.
Event Nature
Emergency Action
Emergency shut-down of the plantOnsite fire brigade alertedFire brigade alerted
Ignition Source
Ignition Delay (s)
1500
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References

Event as described in the European eMARS database

Detailed description from a source (VARO) whose link is lost

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