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Fire in Cyclone (617)

The accident occurred on the hopper fine powders from a pair of cyclones (the hopper is the bottom conical part of the cyclone collecting the powder/dust separated from gas phase). A bursting disc ruptured on the hopper., releasing ethylene and hydrogen gases, followed by a flash and explosion. Two men were injured.

Fire in a Transformer (616)

A short circuit occurred in a bus bar system in a transformer building, causing a fire in adjacent switches. This was followed by the tripping out of the three refinery turbo-alternators, cutting off the National Grid supply, and loss of refinery electrical power, steam and air supplies for some 30 minutes.The cause of the incident was a fault in a 15 kiva circuit breaker voltage transformer which led to a bus bar fault During the power loss and shutdown of plant, a hydrogen leak developed on a valve, and a tube of a fin-fan condense bank failed.

Explosion at a Hydrocracking Reactor of a Refinery (614)

An explosion occurred in a hydrocracking reactor fitted with TOC which is a automatic cut-off system for raw oil and hydrogen supply. On the day of the incident, the operation was stopped with TOC being triggered, but the cause was not identified. Hydrogen circulation was restarted, and some 5 hours later, the loud explosion took place around a low pressure separator, rupturing the reactor and throwing debris in all directions. The contents were released to form a vapour cloud which ignited followed by a fire ball.

Hydrogen Leak Ignites in Compressor Crank Room, Injuring Operator (613)

While making preparation for operation of a compressor supplying hydrogen to a heavy oil desulfurization unit, an operator got injured as the checking cover of a crank room came off, emitting a hot wind. Usually, nitrogen is supposed to be supplied to purge hydrogen leaking from the shaft of a cylinder at the compressor, on the day of the incident, a nitrogen flow meter failed to stop the nitrogen purging. As a result, hydrogen leaking from the shaft entered the crank room and was ignited by a spark, with the checking cover scattering away by an expansion force.

Explosion at Oil Storage Tank in a Refinery (612)

This incident occurred unit at a demonstration of a new technology for the catalytic cracking of vacuum residual oil. An oil storage tank failed due to high pressure. The overpressure in the tank was the result of a backflow of compressed hydrogen gas. When operators reduced the discharge pressure of the feedstock feed pump, high-pressure hydrogen gas in the reaction system flowed back into a feedstock surge drum and then into the cooling oil receiver. The pressure of the cooling oil receiver increased and the oil blew out and the feedstock surge drum ruptured and a fire occurred.
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