Release of Light Hydrocarbons in a Refinery
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 unit. The leak was located at the outlet of the desulfurization reactor, in the cooling towers. The cloud of hydrocarbon aerosols was released at a 10 m height due to the fan of the cooling tower at the origin of the leak. The cloud quickly dispersed into the air. The operator initiated the automatic shut-down of the unit and the cooling of the walls of the furnace. The unit was depressurised by sending the diesel content to the torch, an inertised by nitrogen injection.
Event Date
April 28, 2011
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The immediate cause is related to corrosion / erosion of a the cooling pipe of one of the cooling towers. The investigation showed that the leak was due a piercing on a section of ordinary carbon steel pipe in one of the four air coolers units. The boring was caused by ammonium disulfide, formed by the combination of H2S coming from the desulfurization process and the nitrogen coming from the denitrification process in the reactor. As normal practice, an injection of water upstream was continuously provided, to dissolve solid substance and avoid deposits, but a retrofit of the unit five years ago had increased the rate of denitrification in the reactor. An additional degradation mechanism was the erosion derived from the excess of penetration of the weld beads on an elbow of the tube, thereby creating a turbulent flow erosion after a pipe elbow. An examination of the radiographic controls made three months before by the plant inspection service had captured a residual thickness of 1.5 mm on the tube; nevertheless, the radiography operator and service employees did not note this date, due to the difficulties to spot it on the radiographic device. The normal plant procedure in these cases involved replacing the tube when reaching a residual thickness below 2 mm. The uniform nature of the loss of thickness in this part of the tube is more difficult to detect than a punctual loss of thickness on the radiographic films. Similar cases related to corrosion / erosion had already occurred on some of the 92 tubes and 368 elbows belonging to the 2 oldest cooling towers, bringing to replacements without releases.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
diesel desulfurization unit, cooling towers
Storage/Process Medium
Location Type
Location description
Industrial Area
Currency
Lessons Learned
Lessons Learned
Following the detailed inspection of the affected cooling installation, the operator deduced the following lessons learned (see ARIA report in the references): 1) It was difficult to perform adequate inspections on this type of installations; one single out-of-specification elbow out of a total of 368 elbows could cause an accident;2) The radiography inspections regularly were designed to detect of localized degradation causing very irregular surfaces, not for the corrosion really occurring, on a straight part of the pipe after the weld, characterised be a rather smooth surface. The plant operator decided to replace the old cooling installation with a new one using steel with higher resistance to the corrosion phenomena occurring in the unit, and an improved design of the elbow and the welds.
Event Nature
Emergency Action
The plant firefighters team was alerted, which installed a water curtain around the unit.
Release Type
Release Substance
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
Event description in the French database ARIA
https://www.aria.developpement-durable.gouv.fr/accident/40173_en/?lang=…
(accessed October 2020)