A zero-dimensional thermodynamic real gas simulation model for a tank filling process with hydrogen is presented in this paper. Ideal gas and real gas simulations are compared and the entropy balance of the filling process is formulated. Calculated results are validated for a type I tank (steel vessel) with measurements. The simulation is used to accurately predict the maximum gas temperature during the refueling of pressurized gaseous hydrogen storages, which must not exceed 85 degrees C according to international standards. The influences of ambient temperature, initial pressure and pressure ramp rate on the resulting hydrogen gas temperature in the tank are investigated. In experiments, the effect of pressure pulses applied in practice on the resulting gas temperature is investigated as is the influence of the Joule Thomson effect of hydrogen and methane. Finally simulations and experimental results are used to develop a refueling protocol for hydrogen powered industrial trucks, in operation at Europe's first indoor hydrogen filling station in Linz, Austria. Copyright (C) 2014, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.