ARRA Fuel Cell Deployment and Operation (Presentation) · FC Operation Summary 0 2 4 6 8 10 12 14 16 18 0 80 90 00 % Fuel Cell Stacks Cumulative Fuel Cell Operation Hours - ARRA 65.9%

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 Fuel Cell Deployment and Operation

FC Seminar

COM34-4

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

10/20/2010

NREL/PR-5600-49764

Innovation for Our Energy Future

Contents

Overview of ARRA Fuel Cell Project

NREL Data Analysis Objectives

Deployment CDPs

Backup Power CDPs

Material Handling Technical CDPs

Summary


American Recovery and Reinvestment Act (ARRA) Fuel Cell Early Market Project

COMPANY AWARD APPLICATION

Delphi Automotive $2.4 M Auxiliary Power

FedEx Freight East $1.3 M Specialty Vehicle

GENCO $6.1 M Specialty Vehicle

Jadoo Power $2.2 M Backup Power

MTI MicroFuel Cells $3.0 M Portable

Nuvera Fuel Cells $1.1 M Specialty Vehicle

Plug Power, Inc. (1) $3.4 M CHP

Plug Power, Inc. (2) $2.7 M Backup Power

Univ. of N. Florida $2.5 M Portable

ReliOn Inc. $8.5 M Backup Power

Sprint Comm. $7.3 M Backup Power

Sysco of Houston $1.2 M Specialty Vehicle

Project ObjectiveDeploy ~1,000 fuel cells to

accelerate the commercialization and deployment of fuel cells

and fuel cell manufacturing, installation, maintenance,

and support services

12 awards with >$40 million ARRA & ~$53 million cost share


CDPs

DDPs

Composite Data Products (CDPs) •Aggregated data across multiple systems,

sites, and teams• Publish analysis results without revealing

proprietary data every 6 months2

Detailed Data Products (DDPs) •Individual data analyses

• Identify individual contribution to CDPs• Only shared with partner who supplied

data every 6 months1

1) Data exchange may happen more frequently based on data, analysis, & collaboration

2) Results published via NREL Tech Val website, conferences, and reports

HSDC Data Flow

Results

Internal analysis completed quarterly

Bundled data (operation & maintenance/safety)

delivered to NREL quarterly


NREL Data Analysis Objectives – ARRA Demonstrations

•Independent technology assessment; focused on fuel cell system and hydrogen infrastructure: performance, operation, and safety.•Leverage data processing and analysis capabilities developed from the fuel cell vehicle Learning Demonstration project and DoD Forklift Demo. •Establish a baseline of real-world fuel cell operation and maintenance data and identify technical/market barriers.•Support market growth through analyses relevant to the value proposition and reporting on technology status to fuel cell and hydrogen communities and stakeholders


2009 Q4 2010 Q1 2010 Q20

50

100

150

200

250

300D

eliv

ered

Qua

ntity

Calendar Quarter

DOE ARRA1 Funded Early Fuel Cell Markets: Delivered Units

APUBackup PowerMaterial Handling EquipmentStationary

Created: Aug-30-10 5:15 PM 1) American Recovery and Reinvestment Act

Delivered Fuel Cell Units & Deployment Sites

211

ARRA Forklift SiteARRA Backup SiteARRA Stationary SiteARRA APU

Some site locations TBD


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

200

400

600

800

1000

1200

1400

Projected Operation Quantities

In O

pera

tion

Qua

ntity

Calendar Quarter

DOE ARRA1 Funded Early Fuel Cell Markets: Units in Operation

APUBackup PowerMaterial Handling EquipmentStationary

Created: Aug-30-10 5:15 PM 1) American Recovery and Reinvestment Act

Fuel Cell Units in OperationCurrent and Projected Quantities

1000

211


Deployment & Operation Data

FC Backup Power

8

High level summary of operation

First cycle of CDPs (IA A & ARRA Sites)

Trends still developing

Many additional analyses planned for future

CDP cycles


Backup Power Sites

Backup Power Deployments

1-10

11-20

21-30

31-40

41-50

51-60

61-70

71-80

81-90

91-100

>100

NREL cdp_bu_03Created: Sep-28-10 5:58 PM

State kW Capacity SitesCalifornia 20 1

South Carolina 50 1Utah 20 3

Site Capacity (line height proporational to installed site kW capacity)

Number ofSites in State

2009 Q3 2009 Q4 2010 Q1 2010 Q20

5

10

15

20

25

10

14 14

24

Backup Units Deployed

Uni

ts D

eplo

yed

NREL cdp-BU-01Created: Aug-12-10 2:04 PM

Units Deployed 24

Sites 5

Total Capacity 90 kW


Backup Power Starts and Run Time

07/09 08/09 09/09 10/09 11/09 12/09 01/10 02/10 03/10 04/10 05/10 06/100

5

10

15

20

25

30

Star

ts

Calendar Month

Starts by Month

199 of 201 Starts Successful (99%)

StartsConditioning1 StartSuccessful Start

NREL cdp_bu_04Created: Oct-08-10 1:40 PM

1) FC system conditioning is an automated operation for regularsystem checks; activitated after long periods of no operation.

07/09 08/09 09/09 10/09 11/09 12/09 01/10 02/10 03/10 04/10 05/10 06/100

5

10

15

20

25

30

Cal

cula

ted

Run

time

[hou

rs]

Calendar Month

Run Hours by Month

88 Total Runtime Hours

Run HoursConditioning1 Hours


1) FC system conditioning is an automated operation for regularsystem checks that are run after long periods of no operation.

Total Starts (Thru June 2010) 201

Total Successful Starts 199 (99%)

Total Run Time 88 hours

Total Hydrogen 12.4 kg

07/09 08/09 09/09 10/09 11/09 12/09 01/10 02/10 03/10 04/10 05/10 06/100

2

4

6

8

10

12

14

16

18

20

Hyd

roge

n kg

s C

onsu

med

Calendar Month

Cumulative Hydrogen Consumed by Month

12.4 kgs Total Consumed H24,873 scf Total Consumed H2



Deployment & Operation Data

FC Material Handling Equipment

11

High level summary of operation

First cycle of CDPs

Trends still developing

Many additional analyses planned for future

CDP cycles


FCMHE Fall 2010 CDPs

Analysis Topics

Units Deployed, Operation Hours,

Refueling, Maintenance, Safety, FC Performance, Site

Usage

ARRA FCHMHE CDPs

22

ARRA & DLA Infrastructure CDPs

4Data Files Analyzed

23,307 (1.7GB)


MHE FC Units & Sites

2010 Q1 2010 Q20

20

40

60

80

100

120

140

160

180

200

220

14

122

35

49

122136

206

Cum

ulat

ive

Uni

ts D

eplo

yed

Fuel Cell Units Deployed - ARRA

Class IIIClass IIClass I

NREL cdparra_mhe_01Created: Sep-22-10 5:07 PM

Sites 4

Operational MHE Units/Site 14 35 59 98

Operating Shifts/Site 29 hrs

38 hrs

28-10 hrs

2 9 hrs

Facility Square Footage (1,000) 1,000 75 90 580

FC Units/MHE Unit 1.0 1.0 1.0 1.0

ARRA Forklift SiteDoD Forklift Site


FC Operation Summary

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>2

200

% F

uel C

ell S

tack

s

Cumulative Fuel Cell Operation Hours - ARRA

65.9% FC Stacks > 1000 HoursMin Fleet Average = 599 fuel cell hoursMax Fleet Average = 1338 fuel cell hours

NREL cdparra_mhe_02Created: Sep-22-10 5:28 PM Fuel Cell Operation Hours

149,046 Total Hours Accumulated 66% FC Stacks > 1000 hours

2010 Q1 2010 Q20

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

Tota

l Ope

ratio

n H

ours

Fuel Cell Operation Hours by Quarter - ARRA

52613

96433Total Hours = 149,046



FC Daily Operation

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 C

ell S

yste

ms

Average Daily Fuel Cell Operation Hours per System - ARRA

50.4% Fuel Cell Systems Average 5-7 Hours Daily



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

1000

2000

3000

4000

5000

6000Hydrogen Dispensed to Material Handling Equipment By Quarter - ARRA

Hyd

roge

n D

ispe

nsed

[kg]

Cumulative Hydrogen Dispensed = 6,198 kg


Hydrogen Fill Event Summary

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

2000

4000

6000

8000

10000

12000

14000Fueling Events By Quarter - ARRA

Num

ber o

f Fill

s

Cumulative Fuelings = 13,329


Total Hydrogen Dispensed 6,198 kg

Total Hydrogen Fill Events 13,329 fills


0 1 2 3 4 5 6 7 8 9 100

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

Time (min)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling TimesARRA

13,329 Events Average = 1.93 min

NREL cdparra_mhe_06Created: Sep-22-10 6:40 PM Fill data for class 1, 2, and 3 trucks

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)

Num

ber o

f Fue

ling

Even

ts

Histogram of Fueling AmountsARRA

Average = 0.47 kg

NREL cdparra_mhe_10Created: Sep-22-10 6:41 PM Fill data for class 1, 2, and 3 trucks

Hydrogen Fill Event Rates and Amounts

Average Fill Time 1.9 minutes

Average Fill Amount 0.47 kg


Tank Pressure Level at Fueling

Tank Pressure At Fill: ARRA

FE

28%


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%


Refueling 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]

Num

ber o

f Ref

uelin

gs



Operation 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

Cou

nt

NREL cdparra_mhe_08Created: 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.


Average Daily Site H2 Dispensing

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/sy

stem

Fill Frequency 0

20

40

60

80

100

Avg

Dai

ly fi

lls

Fill Frequency 0

0.5

1

1.5

Avg

Dai

ly fi

lls/s

yste

m


Average Daily Dispensing Operations by Site - ARRA

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


Fuel 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


Forklift Maintenance By Category - ARRA

73% Unscheduled Maintenance Events

38% Events for Controls, Electronics, Sensors or

Thermal Mgmt


Average Fuel Cell System Maintenance by Quarter

10Q1 10Q20

1

2

3

4

5

6Average FC Maintenance Events

Ave

rage

# o

f Eve

nts

per S

yste

m

10Q1 10Q20

1

2

3

4

5

6Average FC Maintenance Hours

Ave

rage

Hou

rs p

er S

yste

m

Operator Error (Unscheduled)UnscheduledScheduled


Average Fuel Cell System Quarterly Maintenance - ARRA


Fuel Cell System Safety Reports by Quarter

2010 Q1 2010 Q20

1

2

3

4

5

6

Num

ber o

f Rep

orts

Fuel Cell System Safety Reports by Quarter - ARRA

Incident2

Near Miss1


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)


Infrastructure Maintenance

0 5 10 15 20 25 30 35 40 45

storageother

electricalvalves & piping

dispenserpreventative maintenance

system control & safetyH2 production unit

compressor

Infrastructure Maintenance Scheduled vs. Unscheduled Number of Maintenance Events by Category

Number of Events

Total Events = 17371% were unscheduled Scheduled

Unscheduled

0 50 100 150 200 250 300 350 400 450

storageother

electricalvalves & piping

dispenserpreventative maintenance

system control & safetyH2 production unit

compressor

Number of Labor Hours by Category

Hours

Total Hours = 159973% were unscheduled Scheduled

Unscheduled

NREL cdp_mhe_19Created: Oct-05-10 3:13 PM

Total Hydrogen Dispensed 19,831 kg

Total Hydrogen Fill Events 36,468 fills

Total FC Hours 251,177 hours

Maintenance Events 173 (71% Unscheduled)

Safety Incidents 0

ARRA & DLA Sites Combined

10Q1 10Q20

5

10

15

20

25

30Average Site Maintenance Events

Ave

rage

# o

f Eve

nts

per S

ite

10Q1 10Q20

20

40

60

80

100

120

140

160Average Site Maintenance Hours

Ave

rage

Hou

rs p

er S

ite

UnscheduledScheduled


Average Infrastructure Site Quarterly Maintenance

2010 Q1 2010 Q20

1

2

3

4

5

Num

ber o

f Rep

orts

Infrastructure Safety Reports By Quarter

Incident2

Near Miss1


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)


Summary

•206 MHE Units in operation at 4 sites with more than 13,300 fills, 6,200 kgs dispensed, and 149,000 hours accumulated without a safety incident.•24 BU Units (90 kW installed capacity) in operation at 5 sites with 199 of 201 Starts successful and 88 total hours run time.•Operation trends unclear because we are in early stage of deployment and analysis•Many more sites coming on-line in the next 6-12 months•Many more planned analyses like fuel cell durability, system reliability, and application value proposition


Contact Information & Website

http://www.nrel.gov/hydrogen/proj_fc_market_demo.html

Jennifer Kurtzjennifer.kurtz nrel.gov

303-275-4061@

Documents

ARRA Fuel Cell Deployment and Operation (Presentation) · FC Operation Summary 0 2 4 6 8 10 12 14 16 18 0 80 90 00 % Fuel Cell Stacks Cumulative Fuel Cell Operation Hours - ARRA 65.9%