Upload
others
View
0
Download
0
Embed Size (px)
Citation preview
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Contract No. DE-AC36-08GO28308
ARRA Material Handling Equipment Composite Data Products Data through Quarter 2 of 2013
J. Kurtz, S. Sprik, C. Ainscough, G. Saur, M. Post, and M. Peters
Technical Report NREL/TP-5400-60795 November 2013
This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.
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 Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/help/ordermethods.aspx
Cover Photos: (left to right) PIX 16416, PIX 17423, PIX 16560, PIX 17613, PIX 17436, PIX 17721 Printed on paper containing at least 50% wastepaper, including 10% post consumer waste.
3
CDPARRA-MHE-01 Fuel Cell MHE Systems Deployed
0
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
100
146
258
100
146
258
100
146
258
100
146
258
100
146
258
100
146
258
136
206 206
308
402
467
504 504 504 504 504 504 504 504
Cum
ulat
ive
Syst
ems
Dep
loye
d
Fuel Cell Units Deployed - ARRA
2010
Q1
2010
Q2
2010
Q3
2010
Q4
2011
Q1
2011
Q2
2011
Q3
2011
Q4
2012
Q1
2012
Q2
2012
Q3
2012
Q4
2013
Q1
2013
Q2
Class IIIClass IIClass IRetired Class II
NREL cdparra_mhe_01
Created: Sep-27-13 3:34 PM | Data Range: 2010Q1-2013Q2
4
CDPARRA-MHE-02 Fuel Cell System Operation Hours
0
1
2
3
4
5
6
025
050
075
010
0012
5015
0017
5020
0022
5025
0027
5030
0032
5035
0037
5040
0042
5045
0047
5050
0052
5055
0057
5060
0062
5065
0067
5070
0072
5075
0077
5080
0082
5085
0087
50>8
750
% F
uel C
ell S
yste
ms
Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2013Q2
25% of FC Systems > 6,870 HoursMax Stack Hours = 16,610Average Stack Hours = 4,720
FC SystemRetired FC SystemFleet Average FC System Hours
NREL cdparra_mhe_02
Created: Sep-30-13 8:19 AM | Data Range: 2009Q4-2013Q2 Fuel Cell Operation Hours
5
CDPARRA-MHE-03 Fueling Events by Quarter
0
5
10
15
20
25
30
35
2009Q12009Q2
2009Q32009Q4
2010Q12010Q2
2010Q32010Q4
2011Q12011Q2
2011Q32011Q4
2012Q12012Q2
2012Q32012Q4
2013Q12013Q2
Fueling Events By Quarter - ARRAN
umbe
r of F
ills
[1,0
00]
Cumulative Fuelings = 291,114
0
10
20
30
40
50
60
70
80
90
Cum
ulat
ive
Fuel
ings
[1,0
00]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_03
Created: Sep-27-13 3:59 PM | Data Range: 2009Q4-2013Q2
6
CDPARRA-MHE-04 Hydrogen Dispensed by Quarter
0
5
10
15
20
25
30
2009Q12009Q2
2009Q32009Q4
2010Q12010Q2
2010Q32010Q4
2011Q12011Q2
2011Q32011Q4
2012Q12012Q2
2012Q32012Q4
2013Q12013Q2
Hydrogen Dispensed By Quarter - ARRAH
ydro
gen
Dis
pens
ed [1
,000
kg]
Cumulative Hydrogen Dispensed = 232,551 kg
0
10
20
30
40
50
60
Cum
ulat
ive
Am
ount
[1,0
00 k
g]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_04
Created: Sep-27-13 4:04 PM | Data Range: 2009Q4-2013Q2
7
CDPARRA-MHE-05 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
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000Refueling Time of Day - ARRA
Time of Day [hours]
Num
ber o
f Ref
uelin
gs
NREL cdparra_mhe_05
Created: Sep-27-13 4:10 PM | Data Range: 2009Q4-2013Q2
8
CDPARRA-MHE-06 Histogram of Fueling Times
0 1 2 3 4 5 6 7 8 9 100
5
10
15
20
25
30
Time (min)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Times
ARRA Combined Fleet
255,493 Events Average = 2.31 min
Range of0
1
2
3
4
5
Site Averages
Ave
rage
Fue
ling
Tim
es (m
in)
NREL cdparra_mhe_06
Created: Sep-26-13 5:13 PM | Data Range: 2009Q4-2013Q2 Fill data for class 1, 2, and 3 trucks
9
CDPARRA-MHE-07 Tank Pressure Level at Fueling
Tank Pressure At Fill: ARRA
FE
23%
NREL cdparra_mhe_07
Created: Sep-27-13 3:40 PM | Data Range: 2010Q1-2013Q2
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 = 101,349Median Tank Pressure (At Fill) = 26%
10
CDPARRA-MHE-08 Operation Time Between Fueling
0 2 4 6 8 10 120
1000
2000
3000
4000
5000
6000
7000
Average: 4.4 hours
Operating Time Between Fuelings - ARRACombined Fleet
Operating Hours Between Fuelings1,2
Cou
nt
Range of0
2
4
6
8
Site Averages
Ave
rage
Op
Hrs
bet
wee
n Fu
elin
gsNREL cdparra_mhe_08
Created: Sep-26-13 8:51 AM | Data Range: 2009Q4-2013Q2 Excludes Data > 12 hours1) 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.
11
CDPARRA-MHE-09 Histogram of Fueling Rates
0 0.2 0.4 0.6 0.8 1 1.20
5
10
15
20
25
30
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Rates
ARRA Combined Fleet
255,493 Events Average = 0.33 kg/min
Range of0
0.2
0.4
0.6
0.8
1
Site Averages
Ave
rage
Fue
ling
Rat
es (k
g/m
in)
NREL cdparra_mhe_09
Created: Sep-28-13 12:00 PM | Data Range: 2009Q4-2013Q2 Fill data for class 1, 2, and 3 trucks
12
CDPARRA-MHE-10 Histogram of Fueling Amounts
0 0.5 1 1.5 20
2
4
6
8
10
12
14
16
18
20
Amount Fueled (kg)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Amounts
ARRA Combined Fleet
Average = 0.68 kg
Range of0
0.5
1
1.5
2
Site Averages
Ave
rage
Fue
ling
Am
ount
s (k
g)
NREL cdparra_mhe_10
Created: Sep-28-13 12:10 PM | Data Range: 2009Q4-2013Q2 Fill data for class 1, 2, and 3 trucks
13
CDPARRA-MHE-11 Fuel Cell Operation Hours by Quarter
0
50
100
150
200
250
2010
Q1
2010
Q2
2010
Q3
2010
Q4
2011
Q1
2011
Q2
2011
Q3
2011
Q4
2012
Q1
2012
Q2
2012
Q3
2012
Q4
2013
Q1
2013
Q2
Tota
l Ope
ratio
n H
ours
[1,0
00]
Fuel Cell Operation Hours by Quarter - ARRA
Total Hours = 1,859,616
0
100
200
300
400
500
600
700
Cum
ulat
ive
Flee
t Hou
rs [1
000]
All FleetsIndividual Fleet
NREL cdparra_mhe_11
Created: Sep-30-13 9:55 AM | Data Range: 2009Q4-2013Q2
14
CDPARRA-MHE-15 Operating 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
45
% Rated Max Fuel Cell Voltage
% F
uel C
ell O
pera
ting
Tim
e
Operating Time at Fuel Cell Voltage Levels - ARRA
NREL cdparra_mhe_15
Created: Sep-30-13 9:58 AM | Data Range: 2009Q4-2013Q2
1
1) 100% max fuel cell voltage is approximately open-circuit voltage
15
CDPARRA-MHE-16 Operating 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 C
ell O
pera
ting
Tim
e
Operating Time at Fuel Cell Current Levels - ARRA
NREL cdparra_mhe_16
Created: Sep-30-13 9:58 AM | Data Range: 2009Q4-2013Q2
16
CDPARRA-MHE-17 Operating 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 C
ell O
pera
ting
Tim
e
Operating Time at Fuel Cell Power Levels - ARRA
NREL cdparra_mhe_17
Created: Sep-30-13 9:59 AM | Data Range: 2009Q4-2013Q2
17
CDP-MHE-18 Infrastructure Maintenance by Category
5%6%
9%
11%
14%
16%
40%
Total Events = 1,6971
69% unscheduled
entiresystem 75
misc 205
multiplesystems 278
classifiedevents1 1139
Event Count
5%
8%
13%
17%
54%
Total Hours = 9,92866% unscheduled
hydrogen compressor
dispenser
control electronics
feedwater system
air system
electrical
valves
NREL cdp_mhe_18
Created: Sep-26-13 5:50 PM | Data Range: 2009Q1-2013Q2
Infrastructure Maintenance By Equipment Type
MISC includes the following failure modes: actuators, seal, storage,unspecified, thermal management, safety, software, fuel system,
fittings&piping, reformer, sensors, other
18
CDP-MHE-19 Infrastructure Scheduled and Unscheduled Maintenance by Category
0 50 100 150 200 250 300 350 400 450 500
MISCSENSORS
VALVESELECTRICAL
MULTIPLE SYSTEMSAIR SYSTEM
FEEDWATER SYSTEMCONTROL ELECTRONICS
DISPENSERENTIRE SYSTEM
HYDROGEN COMPRESSOR
Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category
Number of Events
Total Events = 1,69770% were unscheduled
ScheduledTotal
0 500 1000 1500 2000 2500 3000 3500 4000
MISC
MULTIPLE SYSTEMS
SENSORS
VALVES
AIR SYSTEM
CONTROL ELECTRONICS
DISPENSER
ENTIRE SYSTEM
HYDROGEN COMPRESSOR
Number of Labor Hours by Category
Hours
Total Hours = 9,92866% were unscheduled Scheduled
Total
NREL cdp_mhe_19
Created: Sep-27-13 10:21 AM | Data Range: 2009Q1-2013Q2
MISC includes the following categories:ACTUATORS
SEALSTORAGE
UNSPECIFIEDOTHER
THERMAL MANAGEMENTSAFETY
SOFTWAREFUEL SYSTEM
FITTINGS&PIPINGREFORMER
19
CDP-MHE-20 Infrastructure Maintenance by Quarter
0
2
4
6
8
10
12
14
16
18
20Maintenance Events
Ave
rage
# o
f Eve
nts
Per T
hous
and
Fills
09Q1
09Q2
09Q3
09Q4
10Q1
10Q2
10Q3
10Q4
11Q1
11Q2
11Q3
11Q4
12Q1
12Q2
12Q3
12Q4
13Q1
13Q2
0
20
40
60
80
100
120
140Maintenance Hours
Ave
rage
Hou
rs P
er T
hous
and
Fills
09Q1
09Q2
09Q3
09Q4
10Q1
10Q2
10Q3
10Q4
11Q1
11Q2
11Q3
11Q4
12Q1
12Q2
12Q3
12Q4
13Q1
13Q2
ScheduledUnscheduledOperator
NREL cdp_mhe_20
Created: Sep-30-13 9:57 AM | Data Range: 2009Q1-2013Q2
Average Infrastructure Site Quarterly Maintenance
20
CDPARRA-MHE-21 Average 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
Created: Sep-26-13 8:52 AM | Data Range: 2010Q1-2013Q2
232,038 kg Hydrogen Dispensed
21
CDPARRA-MHE-22 Average 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/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
NREL cdparra_mhe_22
Created: Sep-27-13 11:24 AM | Data Range: 2010Q1-2013Q2
Average Daily Dispensing Operations by Site - ARRA
Shaded areas represent the min and max site average hydrogen use and fill frequency
22
CDPARRA-MHE-23 Average Daily Fuel Cell Operation Hours per Fleet
A B C D E F G H I J K L0
2
4
6
8
10
12
Fleet
Hou
rs
Average Daily Fuel Cell Operation Hours per System - ARRA
25th and 75th PercentileMedian
NREL cdparra_mhe_23
Created: Sep-30-13 9:59 AM | Data Range: 2009Q4-2013Q2
23
CDPARRA-MHE-24 Average 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 of
Ope
ratio
n [%
]
Fuel Cell System Operation Hours Per Day
0 1 2 3 4 5 6 7 8 9 10 11 120
2
4
6
8
10
Average Hours of Operation Per Day1
Fuel
Cel
l Sys
tem
s [%
]
Average Daily Fuel Cell System Operation Hours
49.8% Fuel Cell SystemsAverage > 6 Hours Daily
NREL cdparra_mhe_24
Created: Sep-30-13 9:59 AM | Data Range: 2009Q4-2013Q2 1) Excludes 0 hour operation days
24
CDP-MHE-25 Infrastructure Safety Reports by Quarter
0
5
10
15
20
25
30
Even
ts R
epor
ted
0
51
102
153
203
254
305Infrastructure Safety Reports By Quarter
Hun
dred
s of
Fill
s Pe
r Rep
ort
2009
Q1
2009
Q2
2009
Q3
2009
Q4
2010
Q1
2010
Q2
2010
Q3
2010
Q4
2011
Q1
2011
Q2
2011
Q3
2011
Q4
2012
Q1
2012
Q2
2012
Q3
2012
Q4
2013
Q1
2013
Q2
Incident2
Near Miss1
Hundreds of Fills Per Safety Report
NREL cdp_mhe_25
Created: Sep-30-13 9:58 AM | Data Range: 2009Q1-2013Q2
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: 259,103Total Reports: 90Lifetime kg H2 Dispensed per Report: 2,879
25
CDPARRA-MHE-35 Refuel Events by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
25Refueling by Day of Week
% o
f Fill
s in
a D
ay
DayNREL cdparra_mhe_35
Created: Sep-26-13 9:13 AM | Data Range: 2009Q4-2013Q2
26
CDP-MHE-41 Infrastructure Safety Categories
0 10 20 30 40 50 60 70 80
Incident
Near Miss
Number of Reports
Seve
rity
Infrastructure Safety Reports by Severity - All Sites and Report Type
Number of Fueling Events: 245,112Number of Safety Reports: 95Fuelings Per Report: 2,580
Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Minor, YES IgnitionH2 Release - Significant, NO IgnitionNon-H2 ReleaseOperator ProtocolStructural Issue
NREL cdp_mhe_41
Created: Sep-27-13 10:32 AM | Data Range: 2009Q1-2013Q2
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
27
CDPARRA-MHE-42 Amount of Hydrogen Dispensed by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
Dis
pens
ed H
ydro
gen
[% o
f tot
al]
Day of Week
Dispensed Hydrogen per Day of Week
0
25
50
75
100
86 kg/day avg
Dai
ly A
vera
ge [k
g]
All SitesIndividual Site
NREL cdparra_mhe_42
Created: Sep-26-13 9:08 AM | Data Range: 2009Q4-2013Q2
28
CDP-MHE-44 Infrastructure 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
2
4
6
8
10
12
14
16
18
20
22
24
26
Labor Hours Per Event
Freq
uenc
y (%
of t
otal
)
Breakdown of Maintenance Event Labor Hours: Infrastructure
NREL cdp_mhe_44
0
20
40
60
80
100
Sites
Even
t Lab
or (h
rs)
Maximum and Mean Event Labor Hoursfor each site.
MeanMax
NREL cdp_mhe_44
Created: Sep-26-13 9:47 AM | Data Range: 2009Q1-2013Q2
>24
50% of repairs require less than the mean of 7.0 hours of labor.Median labor hours: 7.0
29
CDPARRA-MHE-45 Infrastructure Reliability Growth
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Shap
e Pa
ram
eter
( β)1
Overall Site Infrastructure Reliability Growth: ARRA
1 2 3 4 5 6
1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.
2.% change in instantaneous MTBF
Entire historyLast 20% of eventsFirst 120 Days
0
10
20
30
40
50
Calendar Days in Operation
Inst
anta
neou
s M
TBF
Instantaneous MTBF (Days)
sites
NREL cdparra_mhe_45
Created: Sep-28-13 12:47 PM | Data Range: 2010Q1-2013Q2
Sites sorted by Increasing Age(Calendar Days)
Failu
re R
ate
Incr
easi
ngFa
ilure
Rat
e D
ecre
asin
g
Instantaneous MTBF improved for 2 of 6 sites for the last 20% of events.
44%2
-69%2
152%2
-6%2
-25%2-44%2
30
CDP-MHE-46 Infrastructure Equipment Category of Safety Events
18%
20%
48%
By Number of ReportsTotal Near Miss Reports = 71
5%5%
90%
By Number of IncidentsTotal Incidents = 21hydrogen compressor
fittings & piping
dispenser
seal
valves
reformer
Misc
NREL cdp_mhe_46
Created: Sep-26-13 2:14 PM | Data Range: 2009Q1-2013Q2
Safety Reports By Equipment Category: Infrastructure
MISC includes the following categories:STORAGE
FUEL SYSTEMOTHER
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
31
CDP-MHE-47 Infrastructure Maintenance by Mode
5%
6%
6%
7%
8%
8% 9%
12%
13%
14%
Total Events = 1,6971
70% unscheduled
upgrade 66
misc 294
preventativemaintenance 446
classifiedevents1 891
Event Count
5%
6%
10%
8%
15%
15%
16%
11%
Total Hours = 9,92866% unscheduled
data errorreplace failed partsinspect trouble alarm or reportflow lowmetal fatigueout of calibrationhydrogen leakpressure highpressure lowtemperature highfluid leak_non_hydrogenflow highexcessive noise
NREL cdp_mhe_47
Created: Sep-27-13 10:44 AM | Data Range: 2009Q1-2013Q2
Infrastructure Maintenance By Mode
MISC includes the following failure modes: animal damage, cavitation,debris infiltration, false alarm, fluid leak non_hydrogen, vandalism, voltage
low, cleanup device failed, electrical short, maintenance error, networkmalfunction, fluid leak non-hydrogen, broken wire, manufacturing defect,
ambient temperature too low, power outage, unspecified electronicsfailure, failed open, software bug, lightning strike, drive off, moisture
infiltration, operator protocol, failed closed, other
32
CDP-MHE-48 Infrastructure Mean Time Between Failures
0 25 50 75 100 125 150 175 200 225 250 275 3000
1
2
3
4
5
6
7
8
9
10
Site MTBF1 (Days)
Cou
nt o
f Site
s
Site MTBF (Calendar Days In Operation): Infrastructure
NREL cdp_mhe_48
Created: Sep-28-13 12:45 PM | Data Range: 2009Q1-2013Q21. Cumulative Mean Time Between Failure
33
CDP-MHE-49 Infrastructure Mean Time Between Scheduled Maintenance
0 25 50 75 100 125 150 175 200 2250
1
2
3
4
5
6
7
8
9
10
Site MTBSM1 (Days)
Cou
nt o
f Site
s
Site MTBSM by Calendar Days In Operation: Infrastructure
0 50 100 150 2000123456789
10
Site MTBPM2 (Days)C
ount
of S
ites
Individual Site MTBPM2 All Sites
0 25 50 75 100 1250
1
2
3
4
5
Site MTBU3 (Days)
Cou
nt o
f Site
s
Individual Site MTBU3 All Sites
NREL cdp_mhe_49
Created: Sep-26-13 9:47 AM | Data Range: 2009Q1-2013Q21. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades
2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade
34
CDP-MHE-50 Infrastructure Reliability Growth by Category
0
0.5
1
1.5
2
2.5
3
3.5
4
Calendar Days In Operation
Shap
e Pa
ram
eter
( β)*
ELECTRICAL
Failure Rate Increasing
Failure Rate Decreasing
Site
0
0.5
1
1.5
2
2.5
3
3.5
4
Calendar Days In Operation
Shap
e Pa
ram
eter
( β)*
HYDROGEN COMPRESSOR
Failure Rate Increasing
Failure Rate Decreasing
Site
0
0.5
1
1.5
2
2.5
3
3.5
4
Calendar Days In Operation
Shap
e Pa
ram
eter
( β)*
VALVES
Failure Rate Increasing
Failure Rate Decreasing
Site
0
0.5
1
1.5
2
2.5
3
3.5
4
Calendar Days In Operation
Shap
e Pa
ram
eter
( β)*
AIR SYSTEM
Failure Rate Increasing
Failure Rate Decreasing
Site
NREL cdp_mhe_50
Created: Sep-26-13 9:48 AM | Data Range: 2009Q1-2013Q2 *IEC 61164 β*IEC 61164 β*IEC 61164 β*IEC 61164 βThese represent the top four equipment failure categories from all combined data.
35
CDP-MHE-51 Infrastructure Hydrogen Leaks by Equipment Type
5%5%
5%
16%
21%
47%
Total Events = 591
100% unscheduled
misc 1
classified1
events58
Event Count
6%6%
21%
21%
42%
Total Hours = 531100% unscheduled
hydrogen compressor
dispenser
fittings&piping
valves
seal
reformer
storage
NREL cdp_mhe_51
Created: Sep-26-13 2:14 PM | Data Range: 2009Q1-2013Q2
Hydrogen Leaks By Equipment Category: Infrastructure
36
CDP-MHE-52 Infrastructure Failures by Mode
0 100 200 300 400
HYDROGEN COMPRESSOR
DISPENSER
CONTROL ELECTRONICS
AIR SYSTEM
Event Count
51%*
20%*
19%*
10%*
DATA ERROR
DRIVE OFF
EXCESSIVE NOISE
FAILED CLOSED
HYDROGEN LEAK
INSPECT TROUBLE ALARM OR REPORT
LIGHTNING STRIKE
METAL FATIGUE
MOISTURE INFILTRATION
OUT OF CALIBRATION
PRESSURE LOW
REPLACE FAILED PARTS
TEMPERATURE HIGH
MISC
0 500 1000 1500 2000 2500 3000 3500
HYDROGEN COMPRESSOR
DISPENSER
CONTROL ELECTRONICS
AIR SYSTEM
Labor Hours
58%*
18%*
14%*
9%*
NREL cdp_mhe_52
Created: Sep-26-13 9:51 AM | Data Range: 2009Q1-2013Q2
Failure Modes for Top Four Infrastructure Equipment Categories
* Percentage of total events or hours, reference CDP 66.
MISC includes the following failure modes: ambient temperature too low, broken wire,cavitation, data error, debris infiltration, electrical short, failed closed, false alarm, flow
high, flow low, fluid leak non-hydrogen, fluid leak non_hydrogen, fluidleak_non_hydrogen, inspect trouble alarm or report, maintenance error, manufacturing
defect, metal fatigue, moisture infiltration, network malfunction, operator protocol, other,power outage, pressure high, pressure low, replace failed parts, software bug,
unspecified electronics failure, vandalism, voltage low, other
37
CDP-MHE-55 Infrastructure Mean Time Between Safety Events
0 25 50 75 100 125 150 175 200 225 250 275 300 325 3500
1
2
3
4
5
6
7
8
9
10
Site MTBSE1 (Calendar Days in Operation)
Cou
nt o
f Site
s
Mean Calendar Days Between Safety Reports (MTBSR): Infrastructure
0 250 500 750 1000 12500
1
2
3
4
5
Site MTBSI2 (Calendar Days in Operation)
Cou
nt o
f Site
s
Mean Calendar Days Between Incidents
0 100 200 300 400 500 6000
1
2
3
4
5
Site MTBSNM3 (Calendar Days in Operation)
Cou
nt o
f Site
s
Mean Calendar Days Between Near Miss
NREL cdp_mhe_55
Created: Sep-27-13 11:31 AM | Data Range: 2009Q1-2013Q21. Cumulative Mean Time Between Safety Report (days)
2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)
38
CDPARRA-MHE-62 Final Pressure of Hydrogen Fills
200 250 300 350 400 4500
2
4
6
8
10
12
14
16
18
20
315
bar*
250 bar Fills (200 to 315 bar) 350 bar Fills ( > 315 bar)
Final Pressure [bar]
% o
f Fue
ling
Even
ts
Fueling Final Pressures
Avg Final Pressure = 255 bar% of Fills > 250 bar = 69%Number of Fills = 149644
Avg Final Pressure = 355 bar% of Fills > 350 bar = 52%Number of Fills = 64138
AverageNominal
NREL cdparra_mhe_62
Created: Sep-26-13 9:26 AM | Data Range: 2009Q4-2013Q2 *The line at 315 bar separates 250 bar fills from 350 bar fills. It is slightly over the allowable 125% of nominal pressure (312.5 bar) from SAE J2601.
39
CDPARRA-MHE-65 Details of Back-to-Back Fills
<0 0 2 4 6 8 10 12 14 16 18 200
5
10
15
20
25
30
Si
mul
tane
ous
Fills
Back-to-Back Fills
34 % of fills are within 0-5 minutes of each other25 % of fills have more than 20 minutes between them266085 Total Fills
Time Between Fuelings* [min]
# of
Fue
lings
[% o
f tot
al]
Histogram of Time Between Fuelings
All Sites CombinedIndividual Sites
200 225 250 275 300 325 350 375 400 425 4500
1
2
3
4
5x 104 Final Pressures for Fills with <5 Minutes in Between
# of
Fue
lings
Final Pressure [bar]
Previous FillNext Fill
NREL cdparra_mhe_65
Created: Sep-26-13 9:37 AM | Data Range: 2009Q4-2013Q2 *Time is from end of fill to start of next fill.
40
CDP-MHE-66 Infrastructure Maintenance for Delivered Hydrogen
10%
19%
20%
51%
Total Events = 1,3301
63% unscheduled
entiresystem 75
misc 142
multiplesystems 272
classifiedevents1 841
Event Count
9%
14%
18% 58%
Total Hours = 8,81462% unscheduled
hydrogen compressor
dispenser
control electronics
air system
NREL cdp_mhe_66
Created: Sep-26-13 9:47 AM | Data Range: 2009Q1-2013Q2
Delivered Hydrogen Infrastructure Maintenance By Equipment Type
MISC includes the following failure modes: seal, fuel system, thermalmanagement, storage, electrical, fittings&piping, safety, software, valves,
sensors, other
41
CDP-MHE-67 Infrastructure Maintenance by Month
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec0
20
40
60
80
100
120
140
160
180
200
Month
Cou
nt o
f Mai
nten
ance
Eve
nts
Infrastructure Maintenance by Month
UnscheduledScheduled
NREL cdp_mhe_67
Created: Sep-26-13 9:51 AM | Data Range: 2009Q1-2013Q2
42
CDPARRA-MHE-68 Fill Counts per Hour
0 5 10 15 20 25 30 35 40 450
2
4
6
8
10
12
14
Number of Fuelings in an Hour
Freq
uenc
y [%
of t
otal
]
Number of Fuelings Per Hour - ARRA
NREL cdparra_mhe_68
Created: Sep-26-13 9:51 AM | Data Range: 2009Q4-2013Q2
Average: 6.8 per hourMedian: 5.0 per hourMax: 39.0 per hour
43
CDPARRA-MHE-69 Fill Amount per Hour
0 10 20 30 40 50 600
1
2
3
4
5
6
7
8
9
10
Amount Fueled in an Hour [kg]
Freq
uenc
y [%
of t
otal
]
Hydrogen Dispensed Per Hour - ARRA
NREL cdparra_mhe_69
Created: Sep-26-13 10:08 AM | Data Range: 2009Q4-2013Q2
Average: 4.7 kgs per hourMedian: 3.5 kgs per hourMax: 52.5 kgs per hour
44
CDPARRA-MHE-70 Station Usage
1 2 3 4 5 6 7 80
50
100
150
200
250
Station (Sorted By Increasing Max Daily Amount)
Fills
Per
Day
Station Usage
Maximum Daily Fills
Average Daily Fills1
NREL cdparra_mhe_70
Created: Sep-26-13 10:20 AM | Data Range: 2009Q4-2013Q2
1Average daily fills considers only days when at least one fill occurred
45
CDPARRA-MHE-71 Station Capacity Utilization
1 2 3 4 5 6 7 80
10
20
30
40
50
60
70
80
90
100
Station (Sorted By Increasing Max Daily Amount)
Cap
acity
Util
izat
ion
2 [%]
Station Capacity Utilization
Max Daily20 kg
Max Daily25 kg
Max Daily73 kg
Max Daily99 kg
Max Daily102 kg
Max Daily135 kg
Max Daily293 kg
Max Daily358 kg
40.7%
Average Daily Utilization1
Maximum Daily Utilization
NREL cdparra_mhe_71
Created: Sep-26-13 10:23 AM | Data Range: 2009Q4-2013Q2
1Maximum quarterly utilization considers all days; average daily utilization considers only days when at least one filling occurred2100% represents maximum daily amount dispensed for each individual site
46
CDPARRA-MHE-72 Component Mean Time Between Failures
0
50
100
150
200
250
AIR SYSTEM
CONTROL ELECTRONICS
DISPENSER
FITTINGS&PIPIN
G
HYDROGEN COMPRESSOR
SENSORS
VALVES
MTB
F (D
ays)
MTBF by Equipment Category: Infrastructure (Delivered H2 Only)
Median SiteLowest Site
NREL cdparra_mhe_72
Created: Sep-26-13 10:24 AM | Data Range: 2010Q1-2013Q2
47
CDPARRA-MHE-76 Component Repair Time
0123456789
101112
AIR SYSTEM
CONTROL ELECTRONICS
DISPENSER
ELECTRICAL
ENTIRE SYSTEM
FITTINGS&PIPIN
G
FUEL SYSTEM
HYDROGEN COMPRESSOR
MULTIPLE SYSTEMS
OTHER
SAFETY
SENSORS
SOFTWARE
STORAGE
THERMAL MANAGEMENT
VALVES
Rep
air L
abor
Tim
e (H
ours
)Equipment Category Repair Time: Infrastructure (Delivered H2 Only)
NREL cdparra_mhe_76
Created: Sep-28-13 10:08 AM | Data Range: 2010Q10-2013Q2
75% Percentile
Median
25% Percentile
Mean
48
CDPARRA-MHE-77 Equipment Percentage of Monthly Repair Labor Hours
0
10
20
30
40
50
60
70
80
90
100
Apr-201
0
Jul-2
010
Oct-20
10
Jan-20
11
Apr-201
1
Jul-2
011
Oct-20
11
Jan-20
12
Apr-201
2
Jul-2
012
Oct-20
12
Jan-20
13
Apr-201
3
% o
f Tot
al M
onth
ly M
aint
enan
ce L
abor
Hou
rs
Equipment Percentage of Repair Labor Hours Over Time*
HYDROGEN COMPRESSORCONTROL ELECTRONICSDISPENSERAIR SYSTEMNREL cdparra_mhe_77
Created: Sep-30-13 12:56 PM | Data Range: 2010Q10-2013Q2
*Calculated as a percentageof all maintenance each month; bars maynot total to 100% if other maintenancecategories were present.
49
CDP-MHE-97 Projected Hours to 10% Voltage Degradation
< 10000 hours > 10000 hours 0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%Fuel Cell Stacks Projected Hours to 10% Voltage Degradation
Projected Hours to 10% Voltage Degradation 1,3
FC S
tack
s [%
]
In ServiceNot In Service2
NREL cdp_mhe_97
Created: Sep-28-13 12:46 PM | Data Range: 2009Q1-2013Q2
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.