Release of Hydrogen and Hydrocarbons from a Reactor
A high pressure reactor ruptured during a catalyst activation operation. A gaseous stream of hydrogen and light hydrocarbons was released and spontaneously ignited. The unit was immediately shutdown and depressurized. The fire was limited to the vicinity of the ruptured reactor and was extinguished within twenty minutes by onsite emergency services. There were no injuries but damage to equipment included the reactor and some piping, instrumentation and air-fin heat exchangers on an adjacent structure.This was only the second time that the activation had been performed on this catalyst system. In hindsight, the actual processes occurring within the reactor were not fully understood and the job preparation could have been improved. However, the root cause of the incident was that temperature instrument readings were discounted. Safety refresher training must emphasize that instrumentation and alarms must not be discounted and, where data conflict, a defensive position should be chosen and a safe operating regime established at all times.
Event Date
January 1, 2000
Record Quality Indicator
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
This was only the second time that the activation had been performed on this catalyst system. In hindsight, the actual processes occurring within the reactor were not fully understood and the job preparation could have been improved. However, the root cause of the incident was that temperature instrument readings were discounted. The Operator error brought to spontaneous combustion.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
gas heater outlet pipe
Storage/Process Medium
Location Type
Location description
Unknown
Operational Condition
Lessons Learned
Lessons Learned
The root cause of the incident was that temperature instrument readings were discounted. Safety refresher training must emphasize that instrumentation and alarms must not be discounted and, where data conflict, a defensive position should be chosen and a safe operating regime established at all times.
Event Nature
Emergency Action
The fire was limited to the vicinity of the ruptured reactor and was extinguished within twenty minutes by onsite emergency services.
Ignition Source
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
Source lost