Technical Report NREL/TP-5600-49603 September 2010

1

Technical Report

NREL/TP-5600-49603

September 2010

Fall 2010 Composite Data Products

ARRA Material Handling Equipment

Quarter 3 of 2010

Composite Data Products

Final Version September 30, 2010

Jennifer Kurtz, Keith Wipke, Sam Sprik, and Todd Ramsden

2

NOTICE

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J. Kurtz, K. Wipke, S. Sprik, T. Ramsden

September 30th

, 2010

Fall 2010 Composite Data ProductsARRA Material Handling Equipment

CDPARRA-MHE-01Fuel Cell MHE Systems Deployed

National Renewable Energy Laboratory Innovation for Our Energy Future

2010 Q1 2010 Q20

20

40

60

80

100

120

140

160

180

200

220

14

122

35

49

122136

206

Cu

mu

lati

ve U

nit

s D

eplo

yed

Fuel Cell Units Deployed - ARRA

Class IIIClass IIClass I

NREL cdparra_mhe_01

Created: Sep-22-10 5:07 PM

CDPARRA-MHE-02Fuel Cell Operation Hours


0

2

4

6

8

10

12

14

16

18

010

020

030

040

050

060

070

080

090

010

0011

0012

0013

0014

0015

0016

0017

0018

0019

0020

0021

0022

00

>220

0

% F

uel

Cel

l S

tack

s

Cumulative Fuel Cell Operation Hours - ARRA

65.9% FC Stacks > 1000 Hours

Min Fleet Average = 599 fuel cell hours

Max Fleet Average = 1338 fuel cell hours

NREL cdparra_mhe_02

Created: Sep-22-10 5:28 PM Fuel Cell Operation Hours

CDPARRA-MHE-03Fueling Events by Quarter


2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q20

2000

4000

6000

8000

10000

12000

14000Fueling Events By Quarter - ARRA

Nu

mb

er o

f F

ills

Cumulative Fuelings = 13,329

NREL cdparra_mhe_03


CDPARRA-MHE-04Hydrogen Dispensed by Quarter


2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q20

1000

2000

3000

4000

5000

6000Hydrogen Dispensed to Material Handling Equipment By Quarter - ARRA

Hyd

rog

en D

isp

ense

d [

kg]

Cumulative Hydrogen Dispensed = 6,198 kg

NREL cdparra_mhe_04


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

100

200

300

400

500

600

700

800Refueling Time of Day - ARRA

Time of Day [hours]

Nu

mb

er o

f R

efu

elin

gs

NREL cdparra_mhe_05


CDPARRA-MHE-06Histogram of Fueling Times


0 1 2 3 4 5 6 7 8 9 100

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

Time (min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling TimesARRA

13,329 Events Average = 1.93 min

NREL cdparra_mhe_06

Created: Sep-22-10 6:40 PM Fill data for class 1, 2, and 3 trucks

CDPARRA-MHE-07Tank Pressure Level at Fueling


Tank Pressure At Fill: ARRA

FE

28%

NREL cdparra_mhe_07


1. Some refueling events not recorded/detected due to data noise or incompleteness.2. The outer arc is set at 40% total refuelings.3. Full Pressure is either 3600 psi or 5000 psi.

Total refuelings1 = 4106Median Tank Pressure (At Fill) = 17%

CDPARRA-MHE-08Operation Time between Fueling


0 2 4 6 8 10 120

100

200

300

400

500

600

700

Average of 4.1 op hours between fills

Operating Time Between Fuelings - ARRA

Operating Hours Between Fuelings1,2

Co

un

t

NREL cdparra_mhe_08

Created: Sep-30-10 3:39 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.

CDPARRA-MHE-09Histogram of Fueling Rates


0 0.2 0.4 0.6 0.8 1 1.20

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling RatesARRA

13,329 Events Average = 0.27 kg/min

NREL cdparra_mhe_09


CDPARRA-MHE-10Histogram of Fueling Amounts


0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

200

400

600

800

1000

1200

1400

1600

1800

2000

Amount Fueled (kg)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling AmountsARRA

Average = 0.47 kg

NREL cdparra_mhe_10


CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter


2010 Q1 2010 Q20

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

To

tal O

per

atio

n H

ou

rs

Fuel Cell Operation Hours by Quarter - ARRA

52613

96433Total Hours = 149,046

NREL cdparra_mhe_11


CDPARRA-MHE-12Fuel Cell System Maintenance by Category


10%

13%

14%

23%

24%

Number of EventsTotal Events = 789

73% were unscheduled

9%

17%

13%

28%

20%

Labor HoursTotal Hours = 1165

69% were unscheduled

Controls, Electronics, Sensors

Preventative maintenance

Thermal management

Energy Storage System

Fuel System

Other

Electrical

Operator Error

Air System

FC Stack

Scheduled equip upgrade

Air system

NREL cdparra_mhe_12


Forklift Maintenance By Category - ARRA

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


0 20 40 60 80 100 120 140 160 180 200

Air systemScheduled equip upgrade

FC StackAir System

Operator ErrorElectrical

OtherFuel System

Energy Storage SystemThermal management

Preventative maintenanceControls, Electronics, Sensors

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

Number of Events

Total Events = 78971% were unscheduled Scheduled

Unscheduled

0 50 100 150 200 250 300 350

Air systemScheduled equip upgrade

FC StackAir System

Operator ErrorElectrical

OtherFuel System

Energy Storage SystemThermal management

Preventative maintenanceControls, Electronics, Sensors

Number of Labor Hours by Category

Hours

Total Hours = 116568% were unscheduled Scheduled

Unscheduled

NREL cdparra_mhe_13

Created: Sep-30-10 11:45 AM

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


10Q1 10Q20

1

2

3

4

5

6Average FC Maintenance Events

Ave

rag

e #

of

Eve

nts

per

Sys

tem

10Q1 10Q20

1

2

3

4

5

6Average FC Maintenance Hours

Ave

rag

e H

ou

rs p

er S

yste

m

Operator Error (Unscheduled)UnscheduledScheduled

NREL cdparra_mhe_14


Average Fuel Cell System Quarterly Maintenance - ARRA

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

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


0 10 20 30 40 50 60 70 80 90 100 1100

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


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

30

% 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


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


6321 kg Hydrogen Dispensed

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

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


A B C0

1

2

3

4

5

6

7

8

9

10

Fleet

Ho

urs

Average Daily Fuel Cell Operation Hours per Fleet - ARRA

25th and 75th PercentileMedian

NREL cdparra_mhe_23


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

25

30

Average Daily Fuel Cell Operation Hours

% F

uel

Cel

l Sys

tem

s

Average Daily Fuel Cell Operation Hours per System - ARRA

50.4% Fuel Cell Systems Average 5-7 Hours Daily

NREL cdparra_mhe_24


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


2010 Q1 2010 Q20

1

2

3

4

5

6

Nu

mb

er o

f R

epo

rts

Fuel Cell System Safety Reports by Quarter - ARRA

Incident2

Near Miss1

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)

Technical Report NREL/TP-5600-49603 September 2010

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