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Clean Hydrogen Partnership

FCEV driving away with the dispenser hose

Event

Event ID
706
Quality
Description

A driver of a fuel cells vehicle terminated the refuelling and drove away without disconnecting the fueling hose from its vehicle.
The breakaway of the fueling hose was supposed to open, but did not. The receptacle fitting sheared off the vehicle.
The hydrogen contained in the hose between the dispenser shutoff valve and the vehicle check valve was released.

Event Initiating system
Classification of the physical effects
Unignited Hydrogen Release
Nature of the consequences
leak no ignition
Macro-region
North America
Country
United States
Date
Component involved
dispenser (breakaway)
Failure mode
failure to activate
Initiating cause
unknown
Root CAUSE analysis

The INITIATING CAUSE was the tearing of the hose and the braking of the receptacle fitting on the vehicle.
The ROOT CAUSE was the error of the driver which forgot to disconnect the hose from the vehicle. CONTRIBUTING CAUSE was the fact that the breakaway system, designed to mitigate the consequences of these cases, did not operate as from design.
Tests of the breakaway, performed after event, showed that the breakaway operated at 210 lbs (95 kg), which was above the design value of 133 lbs (60 kg). This was very probable not a manufacturing error, but an installation error. It is further unclear who was supposed to detect this mishaps: could the station have performed regular check?

Root causes
Unknown
Date entry in HIAD
30/12/2025

Facility

Application
Road vehicles
Sub-application
FCEV (LDV)
Hydrogen supply chain stage
All components affected

breakway, nozzle, receptacle, check valve

Process temperature range [C]
ambient temperature (-50°C to +50°C)
Process pressure range [MPa]
medium to high pressure (10 to 50 MPa)
Location type
Open
Location
unknown
Operational condition

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0

In-depth data

Release type
gas
Involved substances (% vol)
H2 100%
Release temperature [°C]
25
Probable IGNITION SOURCE

References

Sources categories
H2TOOLS
Reference & weblink

Events in database H2TOOLS
https://h2tools.org/lessons/hydrogen-fueling-dispenser-nozzle-drive-away
(accessed December 2025)