Event
- Event ID
- 705
- Quality
- Description
A fuel cell and hydrogen vehicle terminated the refueling, but the dispenser nozzle could not be completely disconnected from the the vehicle receptacle. It could be disconnected only after several attempts. The cover of the nozzle interfered with the disconnection operation. It was not a problem of malfunction of the nozzle. It could be easily disconnected when withdrawn along its axis. However, because if its weight, a misalignment could take place which made difficult the desconnection.
- 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 (nozzle)
- Failure mode
- malfunctioning
- Initiating cause
- wrong operation
- Root CAUSE analysis
It is plausible to assume the first prototype design of the hose and nozzle assembly were very heavy and of difficult handling.
- Root causes
- Date entry in HIAD
- 30/12/2025
Facility
- Application
- Road vehicles
- Sub-application
- FCEV (LDV)
- Hydrogen supply chain stage
- All components affected
nozzle, receptacle
- 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
Lesson Learnt
- Corrective Measures
H2TOOLS reported the following actions:
Manuals showing the correct connecting and disconnecting procedures were established for each fuelling dispenser.
Separate manuals were needed since the shape of the grip differs from dispenser to dispenser.
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-detached
(accessed December 2025)
