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Clean Hydrogen Partnership

Potential pre-mature pressure relief device on fuel cell vehicles

Event

Event ID
1246
Quality
Description

A manufacturer of fuel cells and hydrogen vehicles issued a recall for 35 of its vehicles, due to a manufacturing defect in the Thermal Pressure Relief Device (TRPD). The defect may cause the glass bulb within the TRPD to fracture prematurely, causing hydrogen release from the onboard storage system.

The manufacturer advised that the vehicles can still be operated, but they should not be parked in enclosed spaces like garages, until the TRPD is replaced.

The manufacturer was planning to replace the faulty devices at authorised dealerships as soon as the necessary parts were available.

This recall is part of a larger global action including 1,545 vehicles in the United States and additional numbers in South Korea.

Event Initiating system
Classification of the physical effects
No Hydrogen Release
Nature of the consequences
Macro-region
Oceania
Country
Australia
Date
Component involved
FCEV (TPRD)
Failure mode
n.a.
Initiating cause
manufacturing defect/error
Root CAUSE analysis

The operations consisted predominantly in manual actions and obsolete equipment. This, in combination with highly reactive substances, regularly caused runaway reactions. On top of that, in the period of the incident, there was a pressure to work out a backlog of materials. This made opting for the quicker but also more hazardous direct treatment of the residues by hydrolysis. Despite the absence of negative records on personnel health, the inspection found considerable shortcoming in safety management.

Root causes
Unknown
Date entry in HIAD
25/12/2025

Facility

Application
Road vehicles
Sub-application
FCEV-LDV
Process temperature range [C]
ambient temperature (-50°C to +50°C)
Location type
Open
Location
other
Operational condition

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0

Lesson Learnt

Corrective Measures

The manufacturer advised that the vehicles can still be operated, but they should not be parked in enclosed spaces like garages, until the TRPD is replaced.
The manufacturer was planning to replace the faulty devices at authorised dealerships as soon as the necessary parts were available.
This recall was part of a larger global action including 1,545 vehicles in the United States and additional numbers in South Korea.

In-depth data

Release type
n.a
Involved substances (% vol)
n.a.
Release temperature [°C]
25
Probable IGNITION SOURCE

References

Sources categories
News
Reference & weblink

FCW news of 18 November 2024
https://fuelcellsworks.com/2024/11/18/fuel-cells/hyundai-nexo-recalled-…
(accessed December 2025)

Hydrogen Insight news of 18 November 2024
https://www.hydrogeninsight.com/transport/risk-of-injury-or-death-hyund…
(accessed December 2025)