hydrogen car small fire during fuelling

A hydrogen car caught fire at a hydrogen fuelling station. During refuelling of a H2-fueled car the owner heard an abnormal noise and opened the fuel filler door to investigate.
A small fire then occurred after the owner discharged static electricity when making contact with the fuelling cap. Fortunately, the fire suppression system of the refuelling station quickly extinguished the blaze.
An analysis of this incident revealed that material from the fuel inlet receptacle filter detached shortly after fuelling was completed. This allowed hydrogen fuel to leak from the receptacle into the fuel filler compartment.

The INITIATING CAUSE was a small hydrogen release at the end of a refuelling.
The ignition occurred after the owner discharged static electricity when touching the fuelling cap.

The incident investigation revealed that the receptacle filter material could detach after refuelling and that this increases the risk of a fire. The automaker was only aware of one incident related to this fault and concluded that a supplier had used a prototype epoxy-bonded filter in place of the original laser-welded filter.

The ROOT CAUSE could be identified to a design error, but also related to the need to improve the management of the supply chain by the car manufacturer.

hydrogen car, receptacle, refuelling station

The accident took place just after the end of the refuelling.

No property loss on the car involved in the event, or on the dispenser used. However, a considerabe cost related to the call-back action of all vehicles with the same defect.

This is a case where the safety measures were in place and worked as designed.
(1) The fire was extinguished by the automatic fire fighting system of the station.
(2) The car manufacturer performed a recall and replacement action and identified the cause.

The origin of the mishap was identified in a supplier which had modified the type of fuel inlet receptacle filter. The reasons for this modification are not known. Nevertheless, this event highlighted the importance of a trustful and stable supply chain. These conditions are difficult to be met for technologies still in their development phase, such as hydrogen for transport. Therefore, the more becomes important to be develop strict and accurate controls by the manufacturer of the final product.

The car manufacture recalled a number of models built in 2019 and sold in the United States, due to the possible hydrogen fuel leak.
A total of 54 cars (2019 model year) have been recalled in the United States.
Impacted owners have been notified and will need to bring their vehicles to a local dealership where the hydrogen fuel inlet receptacle will be replaced at no cost. The car manufacturer will also reimburse any owners that have previously paid to have the issue resolved.