Event
- Event ID
- 737
- Quality
- Description
While a FCEV was being refuelled at 70-MPa hydrogen dispenser. fueling, the fueling hose breakaway separated. No externalfoces were applied on the compnent, it failed only due to the internal pressure of the gas in the fueling hose. Post-incident inspection revealed that the pull force set point was incorrectly adjusted.
- Event Initiating system
- Classification of the physical effects
- No Hydrogen Release
- Nature of the consequences
- Macro-region
- North America
- Country
- United States
- Date
- Component involved
- dispenser (hose)
- Failure mode
- damage, no release
- Initiating cause
- wrong installation
- Root causes
- Unknown
- Date entry in HIAD
- 15/04/2026
Facility
- Application
- Hydrogen refuelling station
- Sub-application
- Dispenser
- Hydrogen supply chain stage
- All components affected
breakaway
- Process temperature range [C]
- ambient temperature (-50°C to +50°C)
- Process pressure range [MPa]
- high pressure (above 50 MPa)
- Location type
- Open
- Location
- unknown
- Operational condition
Emergency & Consequences
- Number of fatalities
- 0
- Number of injured persons
- 0
- Environmental damage
- 0
- Property loss (onsite)
- 0
Lesson Learnt
- Lesson Learnt
The H2TOOLS report does not identify a root cause of this event. For this, it would be necessary to know the responsibility of the hose or dispenser manufacturer on delivery and if a procedure was in place to verify that the hose parameters were meeting specification.
Nevertheless, a generic lesson learnt from this event regards the need for the HRS operator to verify and periodically inspect the pull/separation force adjustment of the breakaway.- Corrective Measures
The breakaway was replaced with a new one, and the dispenser operations were resumed.
In-depth data
- Release type
- gas
- Involved substances (% vol)
- H2 100%
- Release pressure [MPa]
- 70
- Probable IGNITION SOURCE
References
- Sources categories
- H2TOOLS
- Reference & weblink
Event of the US database H2TOOLS
https://h2tools.org/lessons/breakaway-separation-during-fueling
(accessed April 2026)
