Explosion at a Pipeline of a Petrochemical Plant
A gas mixture (25% nitrogen, 73% of hydrogen, 2% methane) leaked, due to the ejection of the check valve from its connection with the inlet pipe. A large amount of the gas mixed with air and ignited, probably due to sparks generated by the ejected check hitting a metal pipe. It followed an explosion. Its pressure wave hit a gas pipeline causing its fracture and a fire. After about 1 hour and 30 minutes the fire was under control. The shockwave from the explosion caused a gas pipe at the back of the workshop to crack and leak, causing a large fire.
Event Date
March 13, 2003
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The immediate cause of the incident is the sudden falling-off of the check valve, due to a large deviation of the dimension of the small diameter of the inner flange thread. Its diameter was too small and eventually lead to the separation of two connections. The root cause is related to quality control not properly done and failed inspection.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
check valve, pipe
Storage/Process Medium
Location Type
Location description
Industrial Area
Operational Condition
Lessons Learned
Lessons Learned
The plant operator has to establish and implement a qualification system for purchased components. This will allow the early detection of wrong or not certified materials. Moreover, an inspection system has to be in place, to assess additional risks related to components replacements and repair.
Event Nature
Emergency Action
The fire was under control after about 1 hour and 30 minutes.
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
ICEMSAFE report available at
https://www.ichemsafe.com/info/3275.html
(last retrieved 20.02.2023)