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Clean Hydrogen Partnership

Explosion on the Saturn stage

Event

Event ID
387
Quality
Description
[Note HIAD validator: this an incident where the hydrogen systems were invovled as effects of the initiating event. There is nevertheless and addtional possible contribution by hydrogen embrittlement]
During preparations for static firing tests of liquid oxygen - liquid hydrogen S-IVB stage, an explosion occurred prior to the lift off command. All systems indicated normal. Extensive damage was received by the test stand and stage. Sides of the stage and liquid hydrogen tankage were fragmented. Many small fires around stand. Estimated fire ball diameter was about 300 feet. Propellant mixing resulted in a detonation estimated to be 1 percent of the TNT equivalent.

[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
Root causes
Root CAUSE analysis
Explosion caused by failure of high pressure titanium spheres used to store gaseous helium. The tanks, located below the thrust ring, failed due to the use of incorrect and out of specification filler wire in the fabrication. Results of incorrect wire were to lower the ultimate strength and introduce hydrogen embrittlement. Subsequent explosions were considered effects rather than causes.

Facility

Application
Non-Road Vehicles
Sub-application
Aerospace
Hydrogen supply chain stage
All components affected
LH2 tank, rocket stage
Location type
Unknown
Operational condition

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0

Event Nature

Release type
no release
Released amount
0
Presumed ignition source
Open flame
Ignition delay
Y

References

Reference & weblink

Mishap no 46 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