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

Hydrogen Leak in a Refinery
The leak occurred at the hydro-isomerisation unit of a refinery. Following the observation of a pressure drop between two heat exchangers, controls were carried out on site. A noise was heard, but no gas detection was activated on the unit. A hydrogen leak was detected but the source was not identified. Following the detection of hydrogen, the access to the unit was forbidden and emergency services and the fire department alerted. The unit was decompressed using the safety flare. When the pressure was sufficiently reduced, two operators looked for the origin of the leak. They located it on a flange at the level of a heat exchanger/beam gasket. The line was depressurized under nitrogen.The pressure drop was accompanied by a rise in temperature between the 2 exchangers, causing fragility to the flange assemblies. The hydrogen leak is estimated at 100 kg.The bundles of the 2 exchangers were dismantled. It was then noticed that the baffles were mounted upside down on the 2 exchangers (baffles not mounted in the direction of fluid flow: baffles located on the outlet and not on the inlet of the load). Maintenance on these exchangers had been carried out during the previous major shutdown. The deflectors were deformed at the tube plate. In addition, an imprint of the outlet line of the heat exchanger on the deflector was noted. The deflectors are repositioned in the good direction and reintroduced in their respective heat exchanger.
Event Date
September 24, 2019
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The root cause is probably the wrong re-assembly of the unit after maintenance. The baffles inside the two heat exchangers were wrongly mounted after a maintenance step during the last shutdown. This had probably an impact on the behavior of the connecting pipe between the two heat exchangers and lead to a weak point on the gasket.
Facility Information
Application Type
Specific Application Supply Chain Stage
Components Involved
hydro-isomerization unit, flange
Storage/Process Medium
Location Type
Location description
Industrial Area
Consequences
Number of Injured Persons
4
Currency
Lessons Learned
Lessons Learned
The tightness of gasket on the affected flange was re-assessed. The plant operator established a control procedure for the reassembly of the exchanger.
Event Nature
Emergency Action
Unknown
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References

Event description no 56324 in the French database ARIA (accessed October 2021)

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