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

Release Without Ignition from Heat Exchanger of a Fertilizers Production Plant
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 ammonia processing unit. He alerted the control room. A steam hose is installed blowing towards the flange to dilute the leak. Explosive gas measurements are taken twice per shift to ensure that the consequences of the leak are under control. The area is placed under surveillance. A few days later, 2 vapour rings were placed around the flange. A marker was also placed around the flange to indicate that access to the area was prohibited. Several control points are defined. Three weeks later, a leak sealing system under is put in place. Two weeks later, the injection of sealing paste into the collar does not seal the leak. Two months after detection of the initial leak, an operator notices short term changes in noise and direction at the leak. The operator finally decides to work on the leaking flange. The main process gas supply is shut down more than 9 weeks after the initial leak detection while maintaining a nitrogen flow. The gas flow stops in the pipe.
Event Date
June 14, 2019
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
After the stop of the plant operation, inspection of the site revealed that the flange was loose at the time of the accident.
Facility Information
Application Type
Specific Application Supply Chain Stage
Components Involved
heat exchanger, hydrogen supply line
Storage/Process Medium
Location Type
Location description
Industrial Area
Pre-event Summary
The normal operation of the plant continued all along the attempt to stop the hydrogen leakage.A leak on a gasket due to a flange tightening defect had already occurred on site 2 months earlier
Currency
Lessons Learned
Lessons Learned
The consequence of a cold shut-down would have been 3 weeks of stop of the production. The company decided for the alternative to control and possibly reduce the leak. It succeeded in avoiding ignition, but the event report does not assess the safety margin of the measures adopted.
Event Nature
Emergency Action
Several attempt to stop the hydrogen release, 9 weeks long.
Release Type
Release Substance
Hydrogen Release Concentration (%)
100.00
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References

ARIA event no. 54336

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