A fueler drove away without disconnecting the fueling hose from the vehicle. The breakaway did not open and the receptacle fitting sheared off the vehicle. Subsequent testing of the breakaway showed that the breakaway operated at 210 lbs, which was above the design value of 133 lbs. The hydrogen contained in the hose between the dispenser shutoff valve and the vehicle check valve was released.

A sidewall burst failure of a high-pressure polytetrafluoroethylene-lined hose was experienced. The 4.0-m hose was in service for approximately two years, primarily for 70 MPa fueling of hydrogen at ambient conditions ranging from -40 C to +50 C. The total number of fills during its service life was estimated to be 150. In addition to the high-volume fill events, pressure cycling occurred as part of the routine test procedures and operational protocols. These additional pressure-cycling occurrences were approximated to be 200-250 cycles. During each filling cycle, the hose was allowed to bend during connections, as required by the situation. Failure of the hose occurred while temporarily connected to a gas booster, after 1-2 hours of service at 75 MPa. There were no tight bends in the view more