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Bulletin
Incident
Description
On July 28, 2005, at about 6:00 pm,
an RHU hydrogen gas heat
exchanger process pipe ruptured.
The venting hydrogen gas ignited
and a huge fireball erupted in the
unit. One employee sustained a
minor injury while assisting with
the RHU emergency shutdown.
The RHU sustained major damage
from the hydrogen-fed fire that
burned for two hours. There were
z BP personnel examined
the extensively damaged
unit and determined that
an 8-inch diameter pipe
elbow on an RHU heat
exchanger hydrogen gas
outlet pipe ruptured . . .
Incident Analysis
HTHA Failure Mechanism
Incidents involving HTHA date
back to the 1940s. Carbon steel in
hydrogen service at temperatures
above about 450oF and pressures
above 100 psia is susceptible to
HTHA. At these operating
conditions, atomic and molecular
hydrogen permeates the steel and
reacts with dissolved carbons or
carbides1 to form methane gas. The
loss of carbon in the steel, or
decarburization, significantly
degrades the steels mechanical
properties, including tensile
strength and ductility.2 The
methane gas creates high localized
stresses, which combine with the
normal piping system stresses to
create voids and fissures in the
steel, which ultimately causes the
pipe to rupture (API, 2004).
The American Petroleum Institute
(API) Recommended Practice 941,
Steels in Hydrogen Service at Elevated
Temperatures and Pressures in
Petroleum Refineries and
Petrochemical Plants, recommends
operating limits for carbon steel
and low alloy steel piping systems
in hydrogen service. Experiments
and operating plant data show that
HTHA is typically avoided by
using low alloy steels3 containing
1
Key Findings
l
7
z
z As this incident
demonstrated, merely
disassembling and
reassembling piping
components during
maintenance can result in
unacceptable system
modifications.
Lessons Learned
Recommendations
Positive Material
Verification Programs
In-situ alloy steel material
verification using x-ray
fluorescence, or other nondestructive material testing, is an
accurate, inexpensive, and fast
PMI test method. Facility owners,
operators, and maintenance
contractors should ensure that the
verification program requires PMI
testing, such as specified in API
Recommended Practice 578, or
other suitable verification process,
for all critical service alloy steel
piping components that are
removed and reinstalled during
maintenance.
At a minimum, piping components
and their respective locations
should be tagged or marked before
removal, and the correct installed
location is verified after
reinstallation.
2005-04-B-R1
Revise the maintenance quality
control program to require
positive material identification
testing or another suitable
material verification process for
all critical service alloy steel
piping components removed and
reinstalled during maintenance,
and inform work crews of special
material handling precautions.
JV Industrial Companies
2005-04-B-R2
Develop/update the written
piping component installation
quality control procedure to
require positive material
identification testing or other
suitable verification or tracking
process for all alloy steel piping
components removed during
maintenance.
z At a minimum, piping
components and their
respective locations should
be tagged or marked . . .
References
American Petroleum Institute (API),
1999. Material Verification
Program for New and Existing
Alloy Piping Systems,
Recommended Practice 578, May
1999.
API, 2004. Steels for Hydrogen
Service at Elevated Temperatures
and Pressures in Petroleum
Refineries and Petrochemical
Plants, Recommended Practice
941, March 2004.
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