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Clean Hydrogen Partnership

Explosion in testing equipment

Event

Event ID
393
Quality
Description
During a test in which GH2 was driving gas, an explosion occurred in the test section. The drive chamber was over-pressurized to 3500 psi (240 bar).
The test section failed; windows designed for a lower pressure release failed and the walls, which were covered with wall board, ignited causing more damage.

[Ordin, NASA (1974)]
Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
North America
Country
United States
Date
-
Main component involved?
Reactor / Oven / Furnace / Test Chamber
How was it involved?
Internal Explosion (Hp Explosion)
Initiating cause
Over-Pressurisation
Root causes
Root CAUSE analysis
Window in test section failed due to excessive pressures. A higher pressure was obtained than calculated due to choked flow conditions in the tube.

Facility

Application
Laboratory / R&d
Sub-application
auronautics
Hydrogen supply chain stage
All components affected
unknown
Operational condition
Description of the facility/unit/process/substances
EXPLANATION OF 'CHOCKED FLOW'
Choked flow is a condition in which the flow rate of a fluid becomes constant, regardless of any further increase in the pressure drop across a restriction.

[https://en.wikipedia.org/wiki/Choked_flow]
"Choked flow is a compressible flow effect. The parameter that becomes "choked" or "limited" is the fluid velocity.
Choked flow is a fluid dynamic condition associated with the Venturi effect. When a flowing fluid at a given pressure and temperature passes through a constriction (such as the throat of a convergent-divergent nozzle or a valve in a pipe) into a lower pressure environment the fluid velocity increases. At initially subsonic upstream conditions, the conservation of energy principle requires the fluid velocity to increase as it flows through the smaller cross-sectional area of the constriction. At the same time, the Venturi effect causes the static pressure, and therefore the density, to decrease at the constriction. Choked flow is a limiting condition where the mass flow cannot increase with a further decrease in the downstream pressure environment for a fixed upstream pressure and temperature."

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0
Environmental damage
0
Post-event summary
test equipment destroied and building damaged

Event Nature

Release type
gas
Involved substances (% vol)
H2 100%
Release duration
immediate
Actual pressure (MPa)
24
Design pressure (MPa)
<24
Presumed ignition source
Short circuit
Ignition delay
Y

References

Reference & weblink

Mishap no 55 in <br />
P. L. Ordin, Review of hydrogen accidents and incidents in NASA operations, 1974, NASA TM X-71565<br />
https://ntrs.nasa.gov/citations/19740020344

Lowesmith et al., Safety issues of the liquefaction, storage and transportation of liquid hydrogen: An analysis of incidents and HAZIDS, Int. J. Hydrogen energy (2014) https://doi.org/10.1016/j.ijhydene.2014.08.002

Hankinson and Lowesmith, Qualitative Risk Assessment of Hydrogen Liquefaction, Storage and Transportation, FCH JU project IDEALHY, Deliverable 3.10 (2013)<br />
confidential<br />
(accessed October 2025)

JRC assessment