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Explosion in a Rocket Development Center (605)

An explosion occurred at testing equipment of a fuel-feeding system for a space rocket engine. According to the original source of this event, now lost, the test envisaged a 42 MPa high-pressure hydrogen gas flow system, an exhaust gas duct outlet was damaged and hydrogen blew out and exploded. High-pressure hydrogen was flowing during the test, and burned not in the burner (a gas generator), but in a silencer tower after flowing through an exhaust gas duct.

Hydrogen Release from a Desulfurization Unit in a Refinery (601)

The charge pump on a hydro-desulfuriser unit tripped. The charge flow control valve then opened wide on low flow. The high pressure hydrogen supply to the unit flowed backwards through a faulty non-return valve to the charge tank.The tank vents were not designed for this high flow of gas and so the weak roof to the wall seam failed. Fortunately, the gas did not find a source of ignition and so there was no fire. The pump could have failed due to reverse rotation, but did not.

Near Miss on a Flange of a Heat Exchanger in a Refinery (600)

An operator noted a loose tube sheet flange stud on a high temperature, high pressure heat exchanger in an hydrodealkylation unit.The stud was found to be cracked through. Analysis proved to be made of standard steel instead of the alloy type specified. Some of the other studs had started to crack.The studs had been replaced on the previous shutdown when the heat exchanger was opened up to clean the tube bundle.

Explosion During Reduction Process in Para-Phenetidine (PPD) Manufacturing (598)

An explosion occurred during a reduction process for the manufacture of para-phenetidine (PPD). The explosion took place due to the convergence of several events. Workers did not firmly close a valve on discharge pipes of para-nitrophenetole (PNP) and forgot to close a valve fitted with an air-operated flow meter, so that hydrogen got into the PNP discharge pipes.

Fire from a Dehydrogenation Reactor (597)

This incident occurred at a linear alkylbenzene manufacturing plant. It affected dehydrogenation reactor of normal paraffin, during the operation of catalyst exchange in the reactor. This is usually happening by isolating the reactor and its peripheral part from the slightly pressurised section by closing a 20-inch remotely controlled valve. The hydrogen pressure of the peripheral part was set at 20 KPa, and the reactor was opened to the atmosphere. Assuming the possibility of small hydrogen leakage, a vacuum device was used to evacuate the piping and a nitrogen purging was performed.
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