Event
- Event ID
- 1228
- Quality
- Description
- The incident occurred in the new Residue Upgradation Facility unit of the refinery, which converts the heaviest oils from crude oil into high-quality, cleaner fuels such as Euro 6 diesel. The unit was was still under construction.
Hydrogen gas leaked from a piping connected to a pressure transmitter of the hydrogen compressor and caught fire due to static charges. The automatic sprinklers brought down the fire immediately, after which fire fighters reached the spot and brought the situation under control. No injury. - Event Initiating system
- Classification of the physical effects
- Hydrogen Release and Ignition
- Nature of the consequences
- Fire (No additional details provided)
- Macro-region
- Asia
- Country
- India
- Date
- Main component involved?
- Compressor / Booster / Pump (Pipe)
- How was it involved?
- Leak & Formation Of A Flammable H2-Air Mixture
- Initiating cause
- Material Degradation (Generic)
- Root causes
- Unknown (No additional details provided)
Facility
- Application
- Petrochemical Industry
- Sub-application
- desuphurisation unit
- Hydrogen supply chain stage
- Hydrogen Compression (No additional details provided)
- All components affected
- pressure gauge, piping
- Location type
- Unknown
- Operational condition
- Pre-event occurrences
- There were no workers at the time of the accident. During working times, 200 workers, inlcuding contractors, would be in the surroundings.
- Description of the facility/unit/process/substances
- DESCRIPTION OF THE PROCESS
In a Residue Upgradation Facility (RUF) process, hydrogen acts as a reagent in hydrocracking and hydrotreating reactions to convert heavy hydrocarbon residues into lighter, higher-value products like gasoline and diesel. Specifically, hydrogen:
• Breaks down large molecules: Hydrogen, in conjunction with a catalyst, breaks the strong carbon-carbon bonds in complex, long-chain hydrocarbon molecules, converting them into simpler, shorter-chain molecules.
• Removes impurities: Hydrogen reacts with heteroatoms like sulfur and nitrogen in the residue, removing them in the form of hydrogen sulfide (H₂S) and ammonia (NH₃), respectively.
• Prevents coke formation: Hydrogen saturates reactive species and inhibits coke formation by hydrogenating coke precursors, which can cause issues in the process.
• Increases distillate yields: By upgrading the heavy residue into lighter fractions, hydrogen contributes to maximizing the yield of more valuable products, improving refinery profitability.
{https://environmentclearance.nic.in/writereaddata/Online/TOR/31_Aug_2018_1557428738TGB9AH7BriefSummary.pdf]
Emergency & Consequences
- Number of injured persons
- 0
- Number of fatalities
- 0
- Property loss (offsite)
- 0
Event Nature
- Release type
- gas
- Involved substances (% vol)
- H2 100%
- Presumed ignition source
- Static electricity
References
- Reference & weblink
Deccan Cronicle new of 19 Septemebr 2025<br />
https://www.deccanchronicle.com/southern-states/andhra-pradesh/hydrogen… />
(accessed November 2025)The Time of India news<br />
https://timesofindia.indiatimes.com/city/vijayawada/fire-due-to-gas-lea… />
(accessed Novemebr 2025)
JRC assessment
- Sources categories
- News