Fuel Cell Balance of Plant Reliability Testbed · durability and reliability of components that...
Transcript of Fuel Cell Balance of Plant Reliability Testbed · durability and reliability of components that...
Fuel Cell Balance of Plant Reliability Testbed
PI: Susan ShearerPresenters:
Rob Shutler - Lockheed Martin MS2&
Educational Project Coordinator: Vern Sproat, PE - Stark State College
10 May 2011Project ID #: FC075
This presentation does not contain any proprietary, confidential, or otherwise restricted information
• Start – Aug 2008• Finish – July 2011• 75% Complete
Timeline
• Total project funding– DOE $787,200– Contractor 196,800
Budget
• Technology Validation: Project will generate a reliability database for candidate PEM fuel cell BOP components
• Education: Project will enhance the education of technical workforce trained in PEM fuel cell system technology
Barriers
• Stark State College: Project Lead and location of 2 testbeds built by students
• Lockheed Martin: Location of 1 of 3 testbeds and design
Partners
Overview
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Relevance
Balance of Plant (BOP) – Evaluation of components for use in hydrogen fuel cell systems and workforce development
– Reliability
– Durability as defined by Mean Time Between Failure (MTBF)
– Hands on workforce / technician training for maintaining fuel cell systems and documentation of component capability
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• Develop testbeds to address the challenge to the fuel cell industry for the durability and reliability of components that comprise the complete system - Balance of Plant (BOP).
• Develop test plan to address the candidate BOP components and basic testbed design for long-term operation.
• Collaborate with component manufacturers to develop and enhance final product performance.
• Develop statistical models for extremely small sample sizes while incorporating manufacturer validation data for future evaluation of candidate components.
• Conduct real-time, in-situ analysis of critical components’ key parameters to monitor system reliability.
• Utilize testbeds to enhance the education of the technical workforce trained in PEM fuel cell system technology.
Approach
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Approach / ProgressTask # Project Milestones
Task Completion DateProgress Notes
Original Planned
Revised Planned
ActualPercent
Complete
1 Test Bed Design 3/31/09 3/31/09 100%2 Renovation of College Facility 3/31/09 9/30/09 9/31/09 100%3 College Testbed Fabrication &
Test6/30/09 3/30/11 80% The first test stand is built
and leak test is underway.The second test stand frame is built. BOP components and temperature control components must still be specified and purchased.
4 Parallel Testbed Fabrication & Test
6/30/09 3/30/11 95% Components are identified and undergoing testing. System testing is underway.
5 Reliability Analysis 6/30/11 20% Tested components are under analysis
6 Failure Analysis 6/30/117 Consulting 6/30/118 Project Management &
Reporting4/30/11 6/1/09 99% The Hydrogen Safety Plan
was returned to Stark State and is under review for update.
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Reliability data generated for pressure sensors, tubing and hydrogen circulating pump
Students have been trained in construction, programming, operation, data acquisition and automated control of testbeds
Testing of Pressure Hydrogen Safety Plan implemented to ensure safe operation of the testbeds with hydrogen
• Continue to test components and document reliability
• Commission third testbed
• Continue to evaluate failure modes of tested components
Technical Accomplishments & Progress
7Fuel Cell BoP Reliability Testbeds
Technical Accomplishments and Progress
Fuel Cell Testbeds
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LC-BV1
LC-BV2
LC-BV3
LC-BV4
LC-BV5
LC-BV6
P
LC-P3
T
LC-T4
Compressed Air
N2
H2
3REG
1REG
2REG LC-HTR2
P
LC-P4
P
TEST
System Relief
Regulator
Pressure Relief Valve,
Sample Cylinder
Trace Heater
PAnalog Pressure Gauge
T Thermocouple
Powered bellows valve Drain
Needle Valve
Liquid Drain
PEM BOP RELIABILITY TEST STAND: 27 MAY 09
LIFE CYCLE TEST PARAMETERS:Pressure……………..50 psia target, 15 – 100 psi function by designTemperature………...80ºC target, 20 – 80ºC max function by designRelative Humidity…..95%RH target, 5 – 95%RH function by design
ALL DEVICES FM APPROVED, OR EQUIVALENT FOR H2 SERVICE
½” 316L SS TUBE, 100 ft., est
LC-H1
Humidity indicator, analog out
Equipment Legend
T
LC-T6-C
DUT
P T
P T
F
Bypass
T
(3)
(3)
LVDT
LVDT
Accelerometer(quantity)
BLOWER LOOP
LIFE CYCLE TEST
DYNAMIC RESPONSE TEST SYSTEM:
Purpose to test baseline performance before and after life cycle. Has added / reduced test features, i.e., LVDT, not heat, no humidity. Integrated pressure decay test.
T
LC-T3-C
LC-A1
T
LC-T7
P
LC-P1
T
LC-T1
P
LC-P2
T
LC-T2
F
LC-F1
LLC-HTR1
LC-BWR-1
T
LC-RV1
SILENCER
Plug Valve
DUT Blower
2PV
PT
LC-HTR3
LV-NV1
LIFE CYCLE TEST DEVICES:Analog and digital output to NI Hardware, 4-20 mA, 0-5V, 0-10V, RS-232Thermocouple, K-Type%RH detectors, Vaisala, 5 – 95% RH, 95% - 100% RHHeaters, Heat trace, 1000 W, 110 VACStainless control valves, 316SS option to controlStainless tubing, ½” OD, 316SSHigh Purity RegulatorsSample Cylinders, StainlessH2, N2, Air input streamsSilenced exhausts
Recirculate Nitrogen
LC-NV2
LC-PV2
LC-PV1 LC-PV3
TEST
LC-BAV1 T
LC-T5
LC-PV4
LC-PV5
LC-REG1
CNV1
CNV2
CNV3
1REG 1REG
LC-PV4
LC-PV6
LC-PV7
LC-PV8 LC-PV9
Testbed Design - Hydrogen Recycle
Life Cycle TestLong Term Testing
Dynamic Response TestPre- and Post- Test
Assessment
Technical Accomplishments and Progress
Test Bed Designed for Multiple Test Modes
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Dynamic Response Test System → Pressure Test
Pres
sure
Tes
tUs
er In
terfa
ceUs
er In
terfa
ce
Configure I/OLogging Rate Select Chart
Pressure = x sec Pressure vs. time
Configure Pressure Behavior
Pressure MAX = x sec
Temperature = x secLVDT = x sec
Pressure MIN = x sec
Pressure HOLD = x secNumber of Steps = xNumber of Repetitions = x
Initialize Pressure at zero
Set Pressure
Set Pressure increment = (Pmax
– Pmin)/steps
Set Number of Rep’s
Set Hold Time at each step
Command to close Isolation Valving
New pressure?
New Pressure Increment?
New No. Of Rep’s?
New Hold Time?
Command Pressure
Y
N
Command Increment
Y
N
Command Increment
Y
N
Command Increment
Y
Read Pressure In1. Master2. DUT
Go to pressure step 1 Hold pressure Hold time for x
sec
Hold pressure Go to pressure step 2
Hold time for x sec
Hold pressure Go to pressure step n
Hold time for x sec
Repetition for n cycles
Total Rep’s complete?
N
Command prompt“Test Complete” Record name/date
Run / Stop
Runtime
Max Pressure
Min Pressure
Number of Steps
Number of Repetitions
DUT ID#
DUT Administrative
notes
ChartHold Time
Pressure
Time →
P(min)
P(max)
P1
P2
Pfinal
Hold
Close isolation Valve
REPETITION 1 REPETITION 2
STEP
Method Store Method Recall
{
{
“Run” next test?
Y
Insert administrative file
data
RUN
TEST PURPOSE:1.) RESPONSE TIME2.) PRESSURE DECAY LEAK3.) TRANSDUCER EFFECTS (accuracy, linearity, repeatability, short term reproducibility, hysteresis, bias, zero offset)
Zoom / Scale feature
Stop
Logic processes for testbed development
Technical Accomplishments and Progress
Testbed Design - Hydrogen Recycle
Testbed Logic Process Diagrams
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Testbeds LabVIEW Programming
Technical Accomplishments and Progress
Student Constructed Operator Interface
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Reliability is the ability of an item to perform the required function, under stated conditions, for a period of time.
Candidate BOP Components
COTS - Commercial off-the-shelf components
• High-production products such as piping, fittings, etc. where past history is available.
– Use Weibull and Weibayes Analysis for those components with previous history. This procedure incorporates test and field data (vendor reliability and quality analysis) to demonstrate the component product meets the reliability target at the desired confidence level.
• Low production units with no manufacturer reliability data.
– End-of-life component data and Forensic Failure Analysis will be the most important test data.
Reliability Testbed
Pumps
Valves
Fittings
Heater
Heat Exchanger
PEM Fuel Cell BOP Dynamics
Mechanical Chemical Purity
Heat GenerationFatigue
Leak IntegrityFlow Capacity
Cycle LifeThermal cycles
Make-upThermal cycle
Cycle Life
Fouling
Fatigue
Chemical compatibility
Hydrogen –Embrittlement
Oxidation
Particle generation by erosion
Particle generation by actuation, wear
out, elastomer leach contaminants
Low-level trace elements leach
Whittling of elements, particle
shedding
Particle shedding, Elastomer leach contaminants
Particle shedding, Elastomer leach
contaminants, Low-level trace elements
leach
Transducer Effects
Controller tuning, accuracy
Controller tuning, accuracy
Controller tuning, accuracy
Linearity, hysteresis, accuracy, repeatability, reproducibility, drift, bias
Meters / Analyzers
Technical Accomplishments and Progress
Analysis Method for Test Components
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Pressure Sensors
Component Absolute PSI Error Price $ Dimensions Ranking
Brand A Yes 0-50 0.25% 87 1.12 1
Brand B NO 0-50 0.25% 87 1.12 2
Brand C Available 0-50 1% 69 2.6 3
Brand D NO 0-50 0.25% 134 1.12 4
Brand E Yes 0-60 0.25% 435 4.3 5
Brand F NO 0-50 0.50% 150 2.91 6
Brand G Yes 0-50 0.25% 360 3.27 7
Brand H NO 0-50 1% 79 3.3 8
Brand I Yes 0-50 ±0.15% FS 525 3.825 9
Brand J Yes 0-60 (0-4 bar) 0.175% > 0.4 bar 3.68+connector 10
Brand K Yes 0-50 0.5%FS 495 3.1+ connector 11
Brand L Yes 0-50 0.5%FS 301 4.17 inches 12
Brand M Yes 0-50 0.25% FS 600 4.13+connector 13
Brand N Yes 0-50 0.4% of RO 580 4.8 inches 14
Several Hard and Soft Sensor Failures Have Been Documented
Trade Study for low cost, high reliability, compact sensors
Evaluation Test Data for Devices
Under Test
Technical Accomplishments and Progress
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Hydrogen Recirculation Pump
Search for Low Cost, Low Power, Low Weight Component
• Hydrogen recycle pump chosen for COTS Capability
• Recycle pump search identified the following issues:
– Reliability of limited production components
– Materials compatibility, special order necessary for 316 SS with sealed operation
– Development costs required for specialized hydrogen blower
• Pump chosen: Parker Univane™
– Rated off-the-shelf for hydrogen operation and operation conditions - $8K
• Issue: Product line has been discontinued
• Substituting COTS blower with lesser capability
Technical Accomplishments and Progress
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Fuel Cell Tubing
• Alternate Tubing Choice– Performance tubing with greater
resistance to permeation Zeus® Perme-Shield™ high-purity PFA. Perme-Shield demonstrates exceptional barrier properties and significantly defends against gas permeation and chemical leaching through the tubing walls used in wet chemical processing.
Coextrusion: Permeation-
Resistant Cladding
Zeus® PFA Tubing
PFA- Perfluoroalkoxy polymer
Component Comments
316 Stainless Steel Tubing
DI water compatible
Coextrusion PFA Tubing DI water and chemical resistant, corrosion resistant, lightweight
Technical Accomplishments and Progress
PFA Tubing
Lightweight, Chemical Resistant Tubing
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• Pressure decay method used to test feasibility of PFA tubing• In the process of higher temperature and long-term
exposure to PEM environment testing
Technical Accomplishments and Progress
PFA vs. Stainless Steel
PFA Test Data
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Collaborations
Industry Dialogue Parker Swagelok National Instruments Omega Dyne Rockwell Automation Microchip National
Semiconductor Zeus Thomas Buzmatics Newport BELLOFRAM Proportional-air SI Pressure Summit Instruments Blaze Technical
Services
SMC AMREL BALLARD Brisk Heat Fluke H2Scan Keithley Keyence Kikusui Roxtec Vaisala Clippard Omega Ameritrol ATEX BelGAS
Intek Asmeblon Sandia Labs McMaster-Carr Auto Zone Fluidtrol Alicat Ametek Fox Valve EBZ EXAIR Pfizer Airgas Great Lakes NoShock Chevron Phillips
Chemical Company
Mound Technical Solutions
Agilent Neteon Praxair Item America 8020 Rexel Texas Instruments Prosoft Tektronix Comsol Piedmont Plastics OFCC HYGROSENS AMETEK National Semiconductor
Lockheed Martin
Subcontract Initial Testbed Design
Parallel Testbed Construction Failure Analysis
Reliability Analysis
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Educational Institution Dialogue
• Educational Institution Dialogue (cont.)– Early College course
Alternative Energy and Fuel Cells– Engineering & Science Career Field
Technical Fuel Cell Energy– Project Lead the Way, Ohio Fuel Cell
Option– Upward Bound Fuel Cell Course– Support for First Fuel Cell Contest teams – High School Student Science Projects – Ohio Energy Project
• NSF Great Lakes Fuel Cell Education Partnership State Coordinators
– IndianaVincennes UniversityRose Hulman Institute of Technology
– MichiganKettering UniversityLansing Community CollegeMichigan Technical College
– New YorkRensselaer Polytechnic InstituteHudson Valley Community College
– OhioUniversity of AkronStark State CollegeKent State UniversityHocking Technical College
– PennsylvaniaPenn State University
– TennesseeUniversity of Tennessee
Collaborations
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• Identify additional parts to test
• Acquire real-time, in-situ data from the operation of the testbeds
• Address failure analysis and reliability analysis as failures occur
Proposed Future Work
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Testbed 3Proposed Future Work
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Acknowledgements
• Project Director: Susan Shearer, Stark State College [email protected]
• Educational Project Coordinator: Vern Sproat, P.E. Stark State College; [email protected]
• Steven Sinsabaugh, Lockheed Martin Fellow
• Debbie LaHurd, PhD, Lockheed Martin MS2
• Rob Shutler, Lockheed Martin MS2
• Marc Griffin, Lockheed Martin MS2
• DOE Managers:Greg Kleen, Project OfficerKathi Epping, HQ Technology Manager
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Project Summary Relevance: Balance of Plant (BOP): To use hydrogen in fuel cells, a balance must
be engineered for reliability and technician training for fuel cell system.
Approach: Develop BOP testbeds, collaborate with component manufacturers to enhance product performance, and train technical workforce in PEM fuel cell systems.
Technical Accomplishments & Progress: Generation of Test Plan
Students are being trained on the construction and operation of the test bed, and the Hydrogen Safety Plan has been implemented to ensure safe operation of the testbeds with hydrogen.
Technology Transfer/Collaboration: Active partnership with Lockheed Martin and industry dialogue with Parker, Swagelok, National Instruments, Omega Dyne, and others.
Proposed Future Work: Execute Test Plan; construct third reliability testbed with students; begin acquiring real-time, in-situ data; address failure analysis and reliability analysis of BOP components.