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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. Technical Report NREL/TP-5600-49603 September 2010. NOTICE - PowerPoint PPT Presentation
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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
This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United
States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes
any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or
process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific
commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute
or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views
and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any
agency thereof.
Available electronically at http://www.osti.gov/bridge
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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
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-22-10 5:55 PM
CDPARRA-MHE-04Hydrogen Dispensed by Quarter
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-30-10 3:39 PM
CDPARRA-MHE-05Refueling Time of Day
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-22-10 6:12 PM
CDPARRA-MHE-06Histogram of Fueling Times
National Renewable Energy Laboratory Innovation for Our Energy Future
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
National Renewable Energy Laboratory Innovation for Our Energy Future
Tank Pressure At Fill: ARRA
FE
28%
NREL cdparra_mhe_07
Created: Sep-22-10 6:18 PM
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-22-10 6:41 PM Fill data for class 1, 2, and 3 trucks
CDPARRA-MHE-10Histogram of Fueling Amounts
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-22-10 6:41 PM Fill data for class 1, 2, and 3 trucks
CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-23-10 3:37 PM
CDPARRA-MHE-12Fuel Cell System Maintenance by Category
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-22-10 7:00 PM
Forklift Maintenance By Category - ARRA
CDPARRA-MHE-13Fuel Cell System Scheduled and Unscheduled Maintenance by Category
National Renewable Energy Laboratory Innovation for Our Energy Future
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-30-10 3:27 PM
Average Fuel Cell System Quarterly Maintenance - ARRA
CDPARRA-MHE-15Operating Time at Fuel Cell Voltage Levels
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-30-10 12:03 PM
1
1) 100% max fuel cell voltage is approximately open-circuit voltage
CDPARRA-MHE-16Operating Time at Fuel Cell Current Levels
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-23-10 4:39 PM
CDPARRA-MHE-17Operating Time at Fuel Cell Power Levels
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-23-10 4:39 PM
CDPARRA-MHE-21Average Daily Hydrogen Dispensed by Location
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-30-10 3:29 PM
6321 kg Hydrogen Dispensed
CDPARRA-MHE-22Average Daily Dispensing Operations by Site
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-23-10 5:03 PM
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
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-09-10 7:37 PM
CDPARRA-MHE-24Average Daily Fuel Cell Operation Hours per System
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-09-10 5:51 PM
CDPARRA-MHE-26Fuel Cell System Safety Reports by Quarter
National Renewable Energy Laboratory Innovation for Our Energy Future
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
Created: Sep-23-10 3:07 PM
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)
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