Explosion in gases production plant

During functional tests of the system, a major quantity of hydrogen-containing gas was released from an adsorber, followed by its ignition.

After the alarm was released the feed of the adsorber was closed, while the sprinkling system was activated by the high temperatures arising from the fire.
The cause of this event was an assembly error, which caused the failure of a gasket (comb-shaped) at the head flange of the adsorber.

The INITIATING CAUSE was an assembly error, which Caused the failure of a gasket It was due to human error during repair works.

ROOT CAUSE was reported as installation procedure. As in many of these cases, inadequate instructions or procedures could have been a contributing factor.

adsorber, gasket, head-flange of adsorber

The event occurred during the execution of complex functional tests.

Material damage for ca. 25 000 EURO and one person who suffered minor injuries.

Fire-brigades from two different sites intervened, in one hour the fire was under control.

The plant operator modified the sealing system (cantering).
Although the reports do not tackle the aspect of the human error, the measure akin was probably adopted to avoid any further assembly error.