ARRA MHE Composite Data Products for Data Through 2011 Q4

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

ARRA MHE Composite Data Products for Data Through 2011 Q4

Jennifer Kurtz, Keith Wipke, Sam Sprik, Todd Ramsden, Chris Ainscough, Genevieve Saur

April 04, 2012

2

CDPARRA-MHE-01Fuel Cell MHE Systems Deployed

2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40

100

200

300

400

500

600

14

122

35

40

131

35

40

131

60

76

172

60

121

221

100

146

221

100

146

258

100

146

258

136

206 206

308

402

467

504 504

Cu

mu

lati

ve S

yste

ms

Dep

loye

d

Fuel Cell Units Deployed - ARRA

Class IIIClass IIClass I

NREL cdparra_mhe_01

Created: Apr-04-12 5:16 PM

3

CDPARRA-MHE-02Fuel Cell System Operation Hours

0

1

2

3

4

5

6

7

8

9

10

02004006008001000

12001400

16001800

20002200

24002600

28003000

32003400

36003800

40004200

44004600

48005000

52005400

56005800

60006200

>6200

% F

uel

Cel

l S

yste

ms

Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2011Q4

25% of FC Systems > 4,860 Hours

FC SystemRetired FC SystemFleet Average FC System Hours

NREL cdparra_mhe_02

Created: Mar-12-12 4:41 PM Fuel Cell Operation Hours

4

CDPARRA-MHE-03Fueling Events by Quarter

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q4 2011Q1 2011Q2 2011Q3 2011Q40

5

10

15

20

25

30

35Fueling Events By Quarter - ARRA

Nu

mb

er o

f F

ills

[100

0]

Cumulative Fuelings = 148,251

0

10

20

30

40

50

60

Cu

mu

lati

ve F

uel

ing

s [1

000]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_03

Created: Mar-14-12 4:21 PM

5

CDPARRA-MHE-04Hydrogen Dispensed by Quarter

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q4 2011Q1 2011Q2 2011Q3 2011Q40

5

10

15

20

25

30

35Hydrogen Dispensed By Quarter - ARRA

Hyd

rog

en D

isp

ense

d [

1000

kg

]

Cumulative Hydrogen Dispensed = 104,916 kg

0

5

10

15

20

25

30

35

Cu

mu

lati

ve A

mo

un

t [1

000

kg]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_04


6

CDPARRA-MHE-05Refueling Time of Day

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 240

1000

2000

3000

4000

5000

6000Refueling Time of Day - ARRA

Time of Day [hours]

Nu

mb

er o

f R

efu

elin

gs

NREL cdparra_mhe_05


7

CDPARRA-MHE-06Histogram of Fueling Times

0 1 2 3 4 5 6 7 8 9 100

2000

4000

6000

8000

10000

12000

14000

16000

18000

Time (min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling TimesARRA Combined Fleet Through 2011Q4

140,959 Events Average = 2.18 min

Range of0

1

2

3

4

5

Site Averages

Ave

rag

e F

uel

ing

Tim

esNREL cdparra_mhe_06

Created: Mar-14-12 4:26 PM Fill data for class 1, 2, and 3 trucks

8

CDPARRA-MHE-07Tank Pressure Level at Fueling

Tank Pressure At Fill: ARRA

FE

23%

NREL cdparra_mhe_07


1. Some refueling events not recorded/detected due to data noise or incompleteness.2. The outer arc is set at 30% total refuelings.3. Full Pressure is either 3600 psi or 5000 psi.

Total refuelings1 = 62,062Median Tank Pressure (At Fill) = 26%

9

CDPARRA-MHE-08Operation Time between Fueling

0 2 4 6 8 10 120

500

1000

1500

2000

2500

3000

Average: 4.8 hours

Operating Time Between Fuelings - ARRACombined Fleet Through 2011Q4

Operating Hours Between Fuelings1,2

Co

un

t

Range of0

2

4

6

8

10

Site Averages

Ave

rag

e O

p H

rs b

etw

een

Fu

elin

gs

NREL cdparra_mhe_08

Created: Mar-15-12 12:46 PM Excludes Data > 12 hours

1) Some fueling events not recorded/detecteddue to data noise or incompleteness.2) Data indicative of actual use and does notrepresent the max capability of the systems.

10

CDPARRA-MHE-09Histogram of Fueling Rates

0 0.2 0.4 0.6 0.8 1 1.20

2000

4000

6000

8000

10000

12000

14000

Avg Fuel Rate (kg/min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling RatesARRA Combined Fleet Through 2011Q4

140,959 Events Average = 0.31 kg/min

Range of0

0.2

0.4

0.6

0.8

Site Averages

Ave

rag

e F

uel

ing

Rat

es

NREL cdparra_mhe_09


11

CDPARRA-MHE-10Histogram of Fueling Amounts

0 0.5 1 1.5 20

2000

4000

6000

8000

10000

12000

14000

16000

18000

Amount Fueled (kg)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling AmountsARRA Combined Fleet Through 2011Q4

Average = 0.59 kg

Range of0

0.2

0.4

0.6

0.8

1

1.2

1.4

Site Averages

Ave

rag

e F

uel

ing

Am

ou

nts

NREL cdparra_mhe_10


12

CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter

2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40

50

100

150

200

250

To

tal O

per

atio

n H

ou

rs [

1,00

0]

Fuel Cell Operation Hours by Quarter - ARRA

Total Hours = 959,887

0

50

100

150

200

250

300

350

Cu

mu

lati

ve F

leet

Ho

urs

[10

00]

All FleetsIndividual Fleet

NREL cdparra_mhe_11


13

CDPARRA-MHE-12Fuel Cell System Maintenance by Category

11%

11%

12%

14%15%

16%

21%

Classified Events = 2,5741

74% unscheduled

multiplesystems

25

misc 483

entiresystem

611

classified

events1 2574

Event Count

14%

8%

19%

9% 6%

19%

24%

Total Hours = 4,84779% unscheduled

thermal management

fuel system

software

sensors

energy storage system

control electronics

air system

NREL cdparra_mhe_12

Created: Mar-27-12 8:07 AM

Fuel Cell System Maintenance By Category - ARRA

MISC includes the following failure modes: 'software', actuators, dispenser, userinterface, seal, fittings&piping, valves, fc stack, electrical, other

14

CDPARRA-MHE-13Fuel Cell System Scheduled and Unscheduled Maintenance by Category

0 100 200 300 400 500 600 700

MISC

ELECTRICAL

AIR SYSTEM

CONTROL ELECTRONICS

ENERGY STORAGE SYSTEM

SENSORS

SOFTWARE

FUEL SYSTEM

THERMAL MANAGEMENT

ENTIRE SYSTEM

Fuel Cell System Maintenance Scheduled vs. Unscheduled - ARRANumber of Maintenance Events by Category

Number of Events

Total Events = 3,69374% were unscheduled

ScheduledTotal

0 100 200 300 400 500 600 700 800 900

MISC

SOFTWARE

CONTROL ELECTRONICS

SENSORS

ELECTRICAL

AIR SYSTEM


FUEL SYSTEM

ENTIRE SYSTEM

THERMAL MANAGEMENT

Number of Labor Hours by Category

Hours

Total Hours = 4,84779% were unscheduled Scheduled

Total

NREL cdparra_mhe_13


MISC includes the following categories:'SOFTWARE'ACTUATORSDISPENSER

USER INTERFACESEAL

MULTIPLE SYSTEMSFITTINGS&PIPING

VALVESFC STACK

OTHER

15

CDPARRA-MHE-14Average Fuel Cell System Maintenance by Quarter

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2Maintenance Events

Ave

rag

e #

of

Eve

nts

Per

Veh

icle

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

0

0.5

1

1.5

2

2.5

3Maintenance Hours

Ave

rag

e H

ou

rs P

er V

ehic

le

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

ScheduledUnscheduledOperator

NREL cdparra_mhe_14


Average Maintenance Per Unit by Quarter - ARRA

16

CDPARRA-MHE-15Operating Time at Fuel Cell Voltage Levels

0 10 20 30 40 50 60 70 80 90 100 >1000

5

10

15

20

25

30

35

40

% Rated Max Fuel Cell Voltage

% F

uel

Cel

l Op

erat

ing

Tim

e

Operating Time at Fuel Cell Voltage Levels - ARRA

NREL cdparra_mhe_15


1

1) 100% max fuel cell voltage is approximately open-circuit voltage

17

CDPARRA-MHE-16Operating Time at Fuel Cell Current Levels

0 10 20 30 40 50 60 70 80 90 1000

5

10

15

20

25

30

% Rated Max Fuel Cell Current

% F

uel

Cel

l Op

erat

ing

Tim

e

Operating Time at Fuel Cell Current Levels - ARRA

NREL cdparra_mhe_16


18

CDPARRA-MHE-17Operating Time at Fuel Cell Power Levels

0 10 20 30 40 50 60 70 80 90 100 >1000

5

10

15

20

25

% Rated Max Fuel Cell Power

% F

uel

Cel

l Op

erat

ing

Tim

e

Operating Time at Fuel Cell Power Levels - ARRA

NREL cdparra_mhe_17


19

CDP-MHE-18Infrastructure Maintenance by Category

7%

7%

8%

8%

11%

12%

19%

28%

Classified Events = 6461

77% unscheduled

multiplesystems

8

misc 102

entiresystem

127

classified

events1 646

Event Count

6%

9%

9%

5%

17%

48%


hydrogen compressor

feedwater system

dispenser

electrical

reformer

valves

sensors

air system

NREL cdp_mhe_18


Infrastructure Maintenance By Equipment Type

MISC includes the following failure modes: actuators, safety, seal, thermal management,unspecified, software, fuel system, fittings&piping, control electronics, other

20

CDP-MHE-19Infrastructure Scheduled & Unscheduled Maintenance by Category

0 20 40 60 80 100 120 140 160 180 200

MISC

CONTROL ELECTRONICS

AIR SYSTEM

SENSORS

VALVES

REFORMER

ELECTRICAL

DISPENSER

FEEDWATER SYSTEM

ENTIRE SYSTEM

HYDROGEN COMPRESSOR

Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category

Number of Events

Total Events = 88377% were unscheduled

ScheduledTotal

0 200 400 600 800 1000 1200 1400 1600

MISC

CONTROL ELECTRONICS

FEEDWATER SYSTEM

REFORMER

FITTINGS&PIPING

AIR SYSTEM

SENSORS

VALVES

DISPENSER

ENTIRE SYSTEM

HYDROGEN COMPRESSOR

Number of Labor Hours by Category

Hours

Total Hours = 4,75070% were unscheduled Scheduled

Total

NREL cdp_mhe_19


MISC includes the following categories:ACTUATORS

SAFETYOTHERSEAL

THERMAL MANAGEMENTUNSPECIFIED

MULTIPLE SYSTEMSSOFTWARE

FUEL SYSTEMFITTINGS&PIPING

21

CDP-MHE-20Infrastructure Maintenance by Quarter

0

2

4

6

8

10

12

14

16

18

20Maintenance Events

Ave

rag

e #

of

Eve

nts

Per

Th

ou

san

d F

ills

09Q

109

Q2

09Q

309

Q4

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

0

20

40

60

80

100

120

140Maintenance Hours

Ave

rag

e H

ou

rs P

er T

ho

usa

nd

Fill

s

09Q

109

Q2

09Q

309

Q4

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

ScheduledUnscheduledOperator

NREL cdp_mhe_20


Average Infrastructure Site Quarterly Maintenance

22

CDPARRA-MHE-21Average Daily Hydrogen Dispensed by Location

Average Daily Hydrogen Dispensed by Location - ARRA

1-10

11-20

21-30

31-40

41-50

51-60

61-70

71-80

81-90

91-100

>100

NREL cdparra_mhe_21


99,650 kg Hydrogen Dispensed

23

CDPARRA-MHE-22Average Daily Dispensing Operations by Site

Hydrogen Use0

10

20

30

40

Avg

Dai

ly k

g

Hydrogen Use0

0.2

0.4

0.6

0.8

1

Avg

Dai

ly k

g/s

yste

m

Fill Frequency0

20

40

60

80

100

Avg

Dai

ly f

ills

Fill Frequency0

0.5

1

1.5

Avg

Dai

ly f

ills/

syst

em

NREL cdparra_mhe_22


Average Daily Dispensing Operations by Site - ARRA

Shaded areas represent the min and max site average hydrogen use and fill frequency

24

CDPARRA-MHE-23Average Daily Fuel Cell Operation Hours per Fleet

A B C D E F G H I J0

1

2

3

4

5

6

7

8

9

10

Fleet

Ho

urs

Average Daily Fuel Cell Operation Hours per System - ARRA

25th and 75th PercentileMedian

NREL cdparra_mhe_23


25

CDPARRA-MHE-24Average Daily Fuel Cell Operation Hours per System

0 1 2 3 4 5 6 7 8 9 10 11 120

5

10

15

20

Hours of Operation Per Day1

Day

s o

f O

per

atio

n [

%]

Fuel Cell System Operation Hours Per Day

0 1 2 3 4 5 6 7 8 9 10 11 120

5

10

15

Average Hours of Operation Per Day1

Fu

el C

ell S

yste

ms

[%]

Average Daily Fuel Cell System Operation Hours

66.1% Fuel Cell SystemsAverage > 6 Hours Daily

NREL cdparra_mhe_24

Created: Mar-28-12 3:09 PM 1) Excludes 0 hour operation days

26

CDP-MHE-25Infrastructure Safety Reports by Quarter

2009 Q1 2009 Q2 2009 Q3 2009 Q4 2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40

5

10

15

20

25

30

Eve

nts

Rep

ort

ed

0

14

28

43

57

71

85Infrastructure Safety Reports By Quarter

Hu

nd

red

s o

f F

ills

Per

Rep

ort

Incident2

Near Miss1

Hundreds of Fills Per Safety Report

NREL cdp_mhe_25


1) Near Miss is an event that under slightly different circumstances could have become an incident -unplanned H2 release insufficient to sustain a flame

2) Incident is an event that results in: -a lost time accident and/or injury to personnel -damage/unplanned downtime for project equipment, facilities or property -impact to the public or environment -any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited -release of any volatile, hydrogen containing compound (other than the hydrocarbons uses as common fuels)

Total kg of H2 Dispensed: 131,474

Total Reports: 73Lifetime kg H

2 Dispensed per Report: 1,801

27

CDPARRA-MHE-26Fuel Cell System Safety Reports by Quarter

2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40

5

10

15

20

25

30

35

40

45

50

55

60

Eve

nts

Rep

ort

ed

0

5

9

14

18

23

28

32

37

41

46

50

55Fuel Cell System Safety Reports by Quarter - ARRA

Sta

ck H

ou

rs P

er R

epo

rt [

1,00

0]

Incident2

Near Miss1

Stack Hours Per Report [1,000]

NREL cdparra_mhe_26


1) Near Miss is an event that under slightly different circumstances could have become an incident -unplanned H2 release insufficient to sustain a flame

2) Incident is an event that results in: -a lost time accident and/or injury to personnel -damage/unplanned downtime for project equipment, facilities or property -impact to the public or environment -any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited -release of any volatile, hydrogen containing compound (other than the hydrocarbons uses as common fuels)

Total Stack Hours: 973,006Total Reports: 217Lifetime Stack Hours per Report: 4,484

28

CDPARRA-MHE-27Fuel Cell System Safety Reports by Severity and Type

0 50 100 150 200 250

Incident

Near Miss

Number of Reports

Sev

erit

y

Fuel Cell System Safety Reports by Severity - ARRA and Report Type 2011Q4

Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionNon-H2 FireOperator ProtocolOther 1 (user defined)

NREL cdparra_mhe_27


An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

29

CDP-MHE-28Fuel Cell System Reliability Growth by Site for Quarter

0

0.5

1

1.5

2

2.5

3

Sh

ape

Par

amet

er (

)1

Overall Site Reliability Growth: MHE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous MTBF

3. Some sites are no longer active. Final results are shown for those sites.

Entire historyLast 20% of eventsFirst 120 Days

NREL cdp_mhe_28


Instantaneous MTBF improved for the last

20% of events for 10 of 16 fleets.3

Fleets Sorted by Increasing Age (Average Hours Per Vehicle)

Fa

ilure

Ra

te In

cre

asi

ng

Fa

ilure

Ra

te D

ecr

ea

sin

g

81%2

51%2

-18%2-53%2

27%2

-69%292%2

143%2

209%2

39%2

-2%2

16%2

5%2

76%2

-27%2 -24%2

30

CDP-MHE-29Fuel Cell System Reliability Growth by Top 4 Categories

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Average Vehicle Operating Hours

Sh

ape

Par

amet

er (

)*


Failure Rate Increasing

Failure Rate Decreasing

Fleet

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

THERMAL MANAGEMENT



Fleet

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

FUEL SYSTEM



Fleet

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

CONTROL ELECTRONICS



Fleet

NREL cdp_mhe_29

Created: Mar-27-12 9:02 AM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164 These represent the top four equipment failure categories from all combined data.

31

CDP-MHE-30Fuel Cell System Mean Time Between Failure

0 500 1000 1500 2000 2500 3000 3500 4000 4500 50000

10

20

30

40

Unit MTBF1 (Hours)

Per

cen

t o

f U

nit

s

Unit MTBF by Operating Hours

17%

17%

18%20%

27%19%

15%

16% 16%

19%

15%26%

28%

26%

19% 13%

13%

13%

13% 13%

13%

13%

13%

AIR SYSTEMCONTROL ELECTRONICSELECTRICALENERGY STORAGE SYSTEMFUEL SYSTEMSENSORSSOFTWARETHERMAL MANAGEMENT

NREL cdp_mhe_30


1Mean Time Between Failure

Class 1 Class 2 Class 3

Equipment Categories for Units with MTBF<=250 hours.2

2 Categories representing <10% of the total are not shown

32

CDP-MHE-31Fuel Cell System Mean Time Between Scheduled Maintenance

0 1000 2000 3000 4000 5000 60000

10

20

30

Unit MTBSM1 (Hours)

Per

cen

t o

f U

nit

s

Unit MTBSM by Operating Hours

0 1000 2000 3000 4000 5000 60000

10

20

Unit MTBPM2 (Hours)

Per

cen

t o

f U

nit

s

Individual Unit MTBPM2 All Sites

0 1000 2000 3000 4000 5000 60000

10

20

Unit MTBU3 (Hours)

Per

cen

t o

f U

nit

s

Individual Unit MTBU3 All Sites

NREL cdp_mhe_31


1. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades

2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade

33

CDP-MHE-32 Site Operation Hours and Voltage Durability

Site Max Op Hours(1) Site Ave Op Hours(1)0

2000

4000

6000

8000

10000

12000

14000

7,476

5,646

Max of Site Projections512,823

Ave of Site Projections55,157

Ho

urs

Operation Hours and Projected Hours to 10% Voltage Drop(2-4)

NREL cdp_mhe_32


(1) Range bars created using one data point for each fleet. Some stacks have accumulated hours beyond 10% voltage degradation.(2) 10% voltage drop level is a DOE metric for assessing fuel cell performance.(3) Projections using field data and calculated at a high stack current.(4) 10% voltage drop is NOT an indication of an OEM's end-of-life criteria and projections do not address catastrophic stack failure.(5) Each site has one voltage projection value that is the weighted average of the site's fuel cell stack projections.

34

CDP-MHE-33 Fuel Cell Stack Voltage Durability as a Function of Voltage Drop Levels

10 15 20 25 300

5000

10000

15000Fuel Cell Stack Durability as a Function of Voltage Drop4

% Voltage Drop

Pro

ject

ed H

ou

rs2,

3

25th/75th Percentile Projections3

Average of Fleet Projections1,5

Max of Fleet Projections1,5

NREL cdp_mhe_33


1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life criteria.2) Projections using field data and calculated at high stack current.3) 25th and 75th percentiles spans the range of stack projection. The included stacks satisfy a minimum number of operation hours and weighting factor.4) The projected hours vary based on the percentage of voltage degradation, but the projected hours do not imply that all stacks will (or do) operate to these voltage degradation levels.5) Each site has one voltage projection value that is the weighted average of the site's fuel cell stack projections.

35

CDP-MHE-34 Fuel Cell Stack Power Degradation over Time

0

20

40

60

80

100

120

0 200 400 600 800 1000120014001600180020002200240026002800300032003400360038004000

Stack Op Hour Segments2

% P

ow

er1

Max Fuel Cell Stack Power Degradation Over Operation

1) Normalized by fleet maximum power.2) Each segment point is median FC power (+-100 hrs). Box not drawn if fewer than 3 points in segment.

Data Range25th & 75th PercentilesGroup MedianOutlier

NREL cdp_mhe_34


Median power differencefrom 0 hour segment to3800 hour segment = -6.49%

36

CDPARRA-MHE-35Refuel Events by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

5

10

15

20

25Refueling by Day of Week

% o

f F

ills

in a

Day

DayNREL cdparra_mhe_35


37

CDPARRA-MHE-37Fuel Cell System Downtime

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 180

100

200

300

400

Average of 3.2 hours of downtimefrom refueling each month

Refueling Downtime1 (in hours) per Month

Fre

qu

ency

[M

on

ths]

Refueling Downtime Per Material Handling Unit

Fleet Averages

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150

20

40

60

80

Average of 2.4 hours of downtimefrom refueling per 100 hours of operation

Refueling Downtime (in hours) per 100 Operational Hours

Fre

qu

ency

[U

nit

s]

Fleet Averages

NREL cdparra_mhe_37


1 Refueling downtime represents total refueling time from "drive-up" to "drive-away" not only hydrogen gas dispensing time

Note: Some refueling events not recorded/included due to data noise or incompleteness

38

CDP-MHE-38Histogram of Fuel Cell Stack Voltage Degradation

0 1500 3000 4500 6000 7500 9000 10500 12000 13500 15000 >150000

10

20Fuel Cell Stacks Projected Hours to 10% Voltage Degradation

5,51

7

FC

Sta

cks

[%]

Projected Hours to 10% Voltage Degradation 1,3

Time 0 Fit (In Service)

Time 0 Fit (Retired or Not in Service)2

Weighted Average (Fleet)

NREL cdp_mhe_38


1) Projection using field data, calculated at high stack current, from operation hour 0. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.

39

CDP-MHE-39Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation

0 1000 2000 3000 4000 5000 6000 7000 8000

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

16000Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation

Pro

ject

ed H

ou

rs1

,2,4

Operation Hours

projected hrs = operation hrs

FC System

FC System (Limited)2

FC System (Retired)3

Unity Line

NREL cdp_mhe_39


15% of stacks arebelow the unity lineand have operatedpast 10% voltagedegradation.

On average, thesestacks haveoperated for 2,480hours.

Stacks above theunity line have notoperated past 10%voltage degradation.

1) Indicates the projected hours to a 10% voltage degradation based upon curve fitting data from operation hour 0.2) Projected hours limited based on demonstrated hours.3) Stacks retired due to low-performance or catastrophic failure.4) Each projection has uncertainty based on the confidence intervals of the fit.

40

CDPARRA-MHE-40Site Summary

0 200 400 600 800 10000

10

20

30

40

50

60

70

80

90

100

110

120

130

140

Facility Size (thousand sq.ft.)

To

tal U

nit

s a

t S

ite

Units Deployed vs Facility Size

GreenfieldRetrofitFutureDelivered - LiquidOn-Site Reforming

NREL cdparra_mhe_40


504 Units 8 Sites

Class IClass IIClass IIIHeight proportional to units deployed.

MHE Deployment - ARRA

Marker size proportional to number of units.

Forklift Units (I,II,III) 0,26,72 0,14,0 35,0,0 25,0,0 45,14,2 0,36,100 40,0,0 0,25,70Operation

Shifts per Day 2 2 3 1-2 3 2 2 3Hours per Shift 8-10 9.5 8 10 8 8-10 8 8Days per Week 6 N/A N/A 7 7 6 6 6

41

CDP-MHE-41Infrastructure Safety Categories

0 10 20 30 40 50 60

Incident

Near Miss

Number of Reports

Sev

erit

y

Infrastructure Safety Reports by Severity - All Sites and Report Type 2011Q4

Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Minor, YES IgnitionH2 Release - Significant, NO IgnitionNon-H2 ReleaseOperator ProtocolStructural Issue

NREL cdp_mhe_41



42

CDPARRA-MHE-42Amount of Hydrogen Dispensed by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

5

10

15

20

Dis

pen

sed

Hyd

rog

en [

% o

f to

tal]

Day of Week

Dispensed Hydrogen per Day of Week

0

35

70

105

140

128 kg/day avg

Dai

ly A

vera

ge

[kg

]

All SitesIndividual Site

NREL cdparra_mhe_42


43

CDPARRA-MHE-43MHE Maintenance Labor Hours

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0

10

20

30

40

50

60

70

Labor Hours Per Event

Fre

qu

ency

(%

of

tota

l)

Maintenance Labor Hours Breakdown: ARRA MHE

NREL cdparra_mhe_43

1 2 30

10

20

30

40

Class

Max

imu

m E

ven

t H

ou

rs

Maximum Event Labor Hoursfor each fleet, by Class

0

1

2

3

Med

ian

Eve

nt

Ho

urs

Median Event Labor Hoursfor each fleet, by Class

NREL cdparra_mhe_43


>24

63% of repairs require less than the mean of 1.7 hours of labor.Median labor hours: 1.0

1Mean:

2.2

2Mean:

1.8

3Mean:

1.4Class

44

CDP-MHE-44Infrastructure Maintenance Labor Hours

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0

5

10

15

20

25

30

Labor Hours Per Event

Fre

qu

ency

(%

of

tota

l)

Breakdown of Maintenance Event Labor Hours: Infrastructure

NREL cdp_mhe_44

1 2 3 4 5 6 7 8 9 0

20

40

60

80

100

Site

Eve

nt

Lab

or

(hrs

)

Maximum and Mean Event Labor Hoursfor each site.

MeanMax

NREL cdp_mhe_44


>24

51% of repairs require less than the mean of 7.6 hours of labor.Median labor hours: 7.0

45

CDP-MHE-45Infrastructure Reliability Growth

0

0.5

1

1.5

2

2.5

3

3.5

4

Sh

ape

Par

amet

er (

)1

Overall Site Infrastructure Reliability Growth

1 2 3 4 5 6 7 8 9 10

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous MTBF

3. Some sites are no longer active. Final results are shown for those sites.

Entire historyLast 20% of eventsFirst 120 Days

NREL cdp_mhe_45


Sites Sorted by Increasing Age (Calendar Days)

Fa

ilure

Ra

te In

cre

asi

ng

Fa

ilure

Ra

te D

ecr

ea

sin

g

Instantaneous MTBF improved for 7 of 10 sites for the last 20% of events.3

68%2

-23%2

0%2

0%2

56%2

31%2

16%29%2 86%2

45%2

46

CDP-MHE-46Infrastructure Equipment Category of Safety Events

5%

14%

21%

48%

By Number of ReportsTotal Near Miss Reports = 56

7%

7%

86%

By Number of IncidentsTotal Incidents = 14hydrogen compressor

fittings & piping

dispenser

seal

valves

reformer

Misc

NREL cdp_mhe_46


Safety Reports By Equipment Category: Infrastructure

MISC includes the following categories:FUEL SYSTEM

OTHER


47

CDP-MHE-47Infrastructure Maintenance by Mode

6%

7%

7%

7%

7%

8%8%

9%

10%

11%

15%


77% unscheduled

upgrade 42

preventativemaintenance

157

misc 193

classified

events1 491

Event Count

5%

10%

5%

11%

18%

9%

10%

17%

6%


flow low

pressure high

hydrogen leak

pressure low

out of calibration

metal fatigue

fluid leak_non_hydrogen

temperature high

inspect trouble alarm or report

flow high

excessive noise

failed closed

data error

NREL cdp_mhe_47


Infrastructure Maintenance By Mode

MISC includes the following failure modes: animal damage, cavitation, debris infiltration,electrical short, power outage, vandalism, voltage low, manufacturing defect, software

bug, cleanup device failed, maintenance error, network malfunction, broken wire, ambienttemperature too low, drive off, failed open, replace failed parts, moisture infiltration,

operator protocol, other

48

CDP-MHE-48Infrastructure Mean Time Between Failures

0 5 10 15 20 25 30 350

1

2

3

4

5

Site MTBF1 (Days)

Co

un

t o

f S

ites

Site MTBF (Calendar Days In Operation): Infrastructure

NREL cdp_mhe_48


1. Cumulative Mean Time Between Failure

49

CDP-MHE-49Infrastructure Mean Time Between Scheduled Maintenance

0 5 10 15 20 25 30 35 40 450

1

2

3

4

5

Site MTBSM1 (Days)

Co

un

t o

f S

ites

Site MTBSM by Calendar Days In Operation: Infrastructure

0 20 40 60 800

1

2

3

4

5

Site MTBPM2 (Days)

Co

un

t o

f S

ites

Individual Site MTBPM2 All Sites

0 20 40 60 80 100 1200

1

2

3

4

5

Site MTBU3 (Days)

Co

un

t o

f S

ites

Individual Site MTBU3 All Sites

NREL cdp_mhe_49


1. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades

2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade

50

CDP-MHE-50Infrastructure Reliability Growth by Category

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Calendar Days In Operation

Sh

ape

Par

amet

er (

)*

ELECTRICAL



Site

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

HYDROGEN COMPRESSOR



Site

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

VALVES



Site

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5


Sh

ape

Par

amet

er (

)*

AIR SYSTEM



Site

NREL cdp_mhe_50

Created: Mar-12-12 6:23 PM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164 These represent the top four equipment failure categories from all combined data.

51

CDP-MHE-51Infrastructure Hydrogen Leaks by Equipment Type

6%

6%

6%

16%

18%

47%


100% unscheduled

misc 0

classified1

events49

Event Count

7%

8%

5%

18%

25%

39%

Total Hours = 442100% unscheduled

hydrogen compressor

fittings&piping

dispenser

valves

seal

reformer

NREL cdp_mhe_51


Hydrogen Leaks By Equipment Category: Infrastructure

52

CDP-MHE-52Infrastructure Compressor Failures by Mode

5%

9%

9%

14%

17%

21%

26%


98% unscheduled

misc 45

classified1

events137

Event Count

12%

7%

14%

22%

36%


metal fatigue

excessive noise

hydrogen leak

pressure low

temperature high



NREL cdp_mhe_52


Hydrogen Compressor Failures By Mode

MISC includes the following failure modes: cavitation, debris infiltration, failed closed,flow high, manufacturing defect, moisture infiltration, operator protocol, preventative

maintenance, maintenance error, upgrade, replace failed parts, other

53

CDPARRA-MHE-53MHE Hydrogen Leaks by Equipment Type

7%

7%

8%

8%

13%

14%

28%


91% unscheduled

misc 1

classified1

events208

Event Count

7%

5%

13%

28%

30%

Total Hours = 38295% unscheduled

fuel system

air system

thermal management

sensors

entire system

energy storage system

control electronics

valves

software

electrical

fittings&piping

fc stack

seal

multiple systems

NREL cdparra_mhe_53


Hydrogen Leaks By Equipment Category: ARRA MHE

54

CDP-MHE-54MHE Availability

90

91

92

93

94

95

96

97

98

99

100

% A

vaila

bili

ty

MHE Availability - ARRA & DLA1

Jan-1

0

Feb-1

0

Mar

-10

Apr-10

May

-10

Jun-1

0

Jul-1

0

Aug-10

Sep-1

0

Oct-1

0

Nov-10

Dec-1

0

Jan-1

1

Feb-1

1

Mar

-11

Apr-11

May

-11

Jun-1

1

Jul-1

1

Aug-11

Sep-1

1

Oct-1

1

Nov-11

Dec-1

1

MonthlyMean

NREL cdp_mhe_54


1. Availability is calculated as follows: Availability starts at 100% for each vehicle on each calendar day. If the vehicle has a maintenance record on a given day, unavailable hours are subtracted from availability. The number of unavailable hours is calculated according to the following schedule: A. Unavailable hours = 21 hours if maintenance hours is blank or > 6 hours. B. Unavailable hours = if maintenance hours are between 4 and 6 hours. C. Unavailable hours = the actual maintenance hours if it is less than 4 hours. D. If maintenance hours are > 21 , the rules A-C above are applied recursively to any remainder above 21 hours.

Mean Availability: 98 %

55

CDP-MHE-55Infrastructure Mean Time Between Safety Events

0 50 100 150 200 250 300 350 400 450 5000

10

20

30

40

50

Site MTBSE1 (Calendar Days in Operation)

Per

cen

t o

f S

ites

Mean Calendar Days Between Safety Reports (MTBSR): Infrastructure

0 200 400 600 8000

102030405060708090

100

Site MTBSI2 (Calendar Days in Operation)

Pe

rcen

t o

f S

ite

s

Mean Calendar Days Between Incidents

0 100 200 300 400 5000

10

20

30

Site MTBSNM3 (Calendar Days in Operation)

Pe

rcen

t o

f S

ite

s

Mean Calendar Days Between Near Miss

NREL cdp_mhe_55


1. Cumulative Mean Time Between Safety Report (days)

2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)

56

CDPARRA-MHE-56MHE Mean Time Between Safety Events

0 100 200 300 400 500 600 7000

10

20

30

40

50

Unit MTBSR1

Per

cen

t o

f U

nit

s

Mean Calendar Days Between Safety Reports (MTBSR): ARRA MHE

0 100 200 300 400 500 6000

10

20

30

40

50

Unit MTBSI2

Pe

rcen

t o

f U

nit

s

Mean Calendar Days Between Incidents

0 200 400 600 8000

10

20

30

Unit MTBSNM3

Pe

rcen

t o

f U

nit

s

Mean Calendar Days Between Near Miss

NREL cdparra_mhe_56_mhe


1. Cumulative Mean Time Between Safety Report (days)

2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)74% of unitshave no safety issues.

57

CDPARRA-MHE-57MHE Equipment Category of Safety Events

5%

5%

7%

10%

21%

50%

By Number of ReportsTotal Near Miss Reports = 210

14%

14%

14%

14%

14%

29%

By Number of IncidentsTotal Incidents = 7

control electronics

operator protocol

electrical

fuel system

fc stack

valves

air system

fittings & piping

thermal management

Misc

NREL cdparra_mhe_57


Safety Reports By Equipment Category: ARRA MHE

MISC includes the following categories:SOFTWAREELECTRICALREFORMERSENSORS

SEALOTHER


58

CDP-MHE-58MHE Total Cost of Ownership

59

CDP-MHE-59MHE Total Cost of Ownership - Sensitivity

60

CDP-MHE-60MHE Intensive Deployment Total Cost of Ownership

61

CDPARRA-MHE-61MHE Maintenance Event by Mode

5%

5%

8%

8%

9%

11%

16%

19%

Classified Events = 2,2411

74% unscheduled

preventativemaintenance

465

misc 487

upgrade 499

classified

events1 2241

Event Count

5%

6%

8%

7%

6%

12%

15%

13%

18%


flow low

replace failed parts

voltage low

hydrogen leak

out of calibration


failed open


software bug

data error

pressure low

broken wire

unspecified electronics failure

NREL cdparra_mhe_61


MHE Maintenance By Mode - ARRA

MISC includes the following failure modes: cavitation, drive off, improper handling,excessive noise, flow high, load above design limit, loose fastener, metal fatigue,

ambient temperature too low, moisture infiltration, false alarm, fire, temperature low,debris infiltration, voltage high, current high, failed closed, pressure high, manufacturingdefect, low cell voltage, low coolant, electrical short, improper installation, maintenance

error, operator protocol, temperature high, other

62

CDPARRA-MHE-62Final Pressure of Hydrogen Fills

200 250 300 350 400 450 5000

0.5

1

1.5

2

2.5

3x 10

4 Fueling Final Pressures

Nu

mb

er o

f F

uel

ing

s

Final Pressure [bar]NREL cdparra_mhe_62


63

CDPARRA-MHE-63Key Performance Areas by Classification


0.2

0.4

0.6

0.8

1

Avg

Fill

Am

ou

nt

[kg

]


5

10

15

20

Avg

Op

erat

ion

per

Fill

[h

ou

r]


2000

4000

6000

8000

10000

12000

14000

Avg

Tim

e to

10%

Vo

lt D

rop

[h

ou

r]Class 1 Class 2 Class 3

0

2

4

6

8

10

12

14

Avg

Op

erat

ion

per

Day

[h

ou

r]


1000

2000

3000

4000

Avg

Op

erat

ion

per

Yea

r [h

ou

r]


200

400

600

800

1000

1200

1400

Avg

MT

BF

[h

ou

r]NREL cdp_mhe_63


Material Handling Equipment Performance By Class

64

CDPARRA-MHE-64aGeneral & Capital Cost Inputs for Class I/II MHE

65

CDPARRA-MHE-64bGeneral & Capital Cost Inputs for Class I/II MHE

66

CDPARRA-MHE-64cGeneral & Capital Cost Inputs for Class III MHE

67

CDPARRA-MHE-64dGeneral & Capital Cost Inputs for Class III MHE

ARRA MHE Composite Data Products for Data Through 2011 Q4

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Transcript of ARRA MHE Composite Data Products for Data Through 2011 Q4