NYCT OPERATINGEXPERIENCE

WITH HYBRID TRANSIT BUSES

Gary LaBouff

Director, Research & Development

May, 2006

Overview of NYCT Bus Operations

NYCT Bus Operations (2005)

Annual Bus Customers 740,586,160 Average Weekday Ridership 2,361,299 Total Buses in Fleet 4,512 # of Bus Routes 243 # of Bus Stops 12,693 # Of Total Employees 14,061 Annual Mileage 119,495,228 Gallons of Fuel Consumed

Diesel

41,116,861 CNG

7,156,336

NYCT Bus Fleet

End of Year

Type 2003 2004 2005 2006

Transit Buses40' Two Stroke Diesel 580 167 0 040' Four Stroke Diesel 2,655 2,531 2,504 2,36560' Four Stroke Diesel 420 630 630 63040' Four Stroke CNG 221 481 481 48140' Diesel Hybrid 10 141 335 474

Coaches45' Four Stroke Diesel 570 572 572 572

Totals 4,456 4,522 4,522 4,522

1. Reduce Bus Fleet Emissions- Achieve levels below current U.S. mandates

2. Improve Service- Improve equipment reliability

- Achieve quieter operation

3. Reduce the Cost of Operations

- Improve fuel economy

- Reduce maintenance costs

- Avoid infrastructure costs

NYCT Goals

The Clean Fuel Solution - Hybrid Electric

Hybrid Electric buses combine a diesel engine and electric drive components

Improved performance

Significant emissions reduction

Increased fuel economy

Smooth and quiet operation

Avoids the infrastructure costs of CNG - no special fuel handling is required

BAE/Orion VII Hybrid System

Lead Acid Battery Packs

DieselEngine

Generator

ElectricTraction Motor

PowerElectronics

Lead-Acid Batteries

Diesel Engine

Generator

Power Electronics (PCS)

Traction Motor

NYCT Hybrid Bus Programs

NYCT Hybrid Bus Programs - Overview

Successful prototype in 1996 (Orion/GE)

Pilot fleet of 10 Orion VI/BAE hybrid buses began revenue service in 1998

125 Production Orion VII/BAE Gen. I hybrid buses ordered - pilot bus in 2003, production deliveries in 2004

200 Production Orion VII/BAE Gen. II hybrid buses ordered - pilot bus in 2004, production deliveries in 2005

500 Additional Orion VII/BAE Gen. II+ ordered, (216 NYCT,284 MTA BUS) - Delivery by 6/07.

Revenue Service Experience - Orion VI

Hybrid buses in service since Sept. 1998

Met standard performance specs

Approx. 700,000 revenue miles

Drivers and customers like the buses

Brake life approximately doubled

Very positive - for a brand new technology, have exceeded expectations

Orion VII/BAE Hybrid Buses - Gen. I First of 125 into service in February, 2004

As of 1 April 2006:

125 Buses in service

Approx. 5.5 million revenue service miles to date

Two depots; Bronx & Queens

Used interchangeably with standard buses

Fuel economy and emissions better than Orion VI hybrid buses

Orion VII/BAE Hybrid Buses - Gen. I Design Improvements over Orion VI

Active Control of Generator

Variable engine speed

Improved Traction Motor

Planetary gear reduction

Redesigned bearing system

Redesigned Packaging

Particulate Filter with Active Control

Improved Diagnostic System

Improved Re-gen Control for Smoother Braking

Orion VII/BAE Hybrid Buses - Gen. II

First of 200 into service in December, 2004

As of 1 April 2006:

200 Buses in service

Over 3.5 million revenue service miles

Two depots, Brooklyn and Manhattan

Smoother and quieter than Generation I

Orion VII/BAE Hybrid Buses - Gen. II Design Improvements over Orion VII Gen. I

New Generator - Flywheel Mounted - (currently being redesigned)

New Design Coolant/Lube Pumps

Oil Cooled Propulsion Control System

Improved Accessibility

Software Upgrade

Updated engine - EGR with common rail fuel system

Orion VII Hybrid Bus Revenue Miles

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

Cum

ulat

ive

Mile

s

NYCT Fleets Composite Fuel Economy

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

Standard Diesel (No EGR)

Standard Diesel(EGR)

CNG NYCT Orion VIHybrid

NYCT Orion VIIHybrid

MPG

Emissions Comparison

Dynamometer Results - CBD Cycle

Reference:

Orion VII Transit Bus Equipped with BAE Systems HybriDrive TM Propulsion System (MY2004): Emissions and Fuel

Economy Test Report' Environment Canata Technology Centre, ERMD Final Report #04-18, September 2004.

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

Conventional Diesel (no EGR, DPF)

Conventional Diesel(EGR, DPF)

Compressed Natural Gas Diesel/Electric Hybrid (EGR, DPF)

g/m

ile

NOx Particulates x 100 CO CO2/1000

EPA Regulated Emission Levels for Heavy Duty On-Highway Engines - PM & NOx

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 1 2 3 4 5 6 7 8 9 10NOx (g/hp-hr)

PM

(g/h

p-hr

)

1988

1990

1991

199419982004

2007-2010

Hybrid Bus Reliability (MDBF)

01

6 Month

Rolling Average

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

Jan-

04

Mar

-04

May

-04

Jul-0

4

Sep

-04

Nov

-04

Jan-

05

Mar

-05

May

-05

Jul-0

5

Sep

-05

Nov

-05

Jan-

06

Mar

-06

MD

BF

(m

iles) 6 Month

Rolling Average

Orion VI Lead Acid Battery Life

For the 36 months of testing ending in February of 2004: 17,000,000 Battery-miles, 5% replaced Replaced batteries did not appear to be ‘end-of-

life’ failures Two buses in service for 40+months with no

failures

Life goal of 3 years appears to be potentially achievable but not realized yet

Changes to software in Orion VII should reduce battery replacements

Hybrid Electric Costs

Life Cycle Costs - HEV vs Standard Current differential in acquisition costs make

justification of HEV’s, based on costs alone, difficult at today’s fuel prices

Current hybrid differential is $125-200K per bus

Series HEV’s in NYCT high density duty cycle can achieve over 30% improvement in fuel economy over standard diesel/transmission systems

This can result in a savings of approx. 50,000 gallons of fuel over a 12 year life of the bus.

If today’s fuel prices double, the savings can negate the initial cost differential.

Fuel Costs - Series HEV vs Std. Propulsion

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

$0 $1 $2 $3 $4 $5

Fuel Cost ($/gal)

Hy

bri

d F

ue

l S

av

ing

s -

12 Y

ea

r L

ife

Baseline: > Standard Diesel 40' Bus > Transit Duty Cycle

2002

2003

2004

2005 Average Fuel Prices

Heavy Urban

Suburban

2006

Life Cycle Costs - HEV vs Standard

Other factors contribute to HEV cost savings

Brake life

Diesel Particulate Filter maintenance HEV system can control regeneration process and

reduce filter problems

Transmission overhaul

Other non-cost factors favor hybrids

Lower noise signature

More flexibility in vehicle energy management Emissions

Lessons Learned from Hybrid Buses

Lessons Learned - Operational

Bus operators and passengers like hybrids

Quiet, smooth operation excellent acceleration/smooth braking “feels” like a standard bus little or no operator training required

Able to be used on all NYCT routes

Bus does not roll back on hills

Lessons Learned - Maintenance More advanced troubleshooting procedures and

tools required

More components and subsystems/interfaces

More wiring and connectors

Long term, reliable, and cost effective energy storage solution still not clear

Lead acid batteries have limited life and can be reliability drivers due to the number required

NiMH still expensive and life unproven

Ultra capacitors, Lithium Ion batteries still in development.

NYCT Hybrid Bus - Future Plans

Evaluate alternative energy storage technologies

Evaluate alternative hybrid system technologies

Continue to develop integrated diagnostic/prognostic systems

Pursue goal of 10,000 hour MDBF for hybrid buses

Move toward all electric accessories

Hybrid Buses - Future Challenges

Component Optimization - HEV allows for the use of other electrically driven system components.

Electric components have inherent advantages:

Remote mounting - better packaging

More efficient

High reliability index

Reduced noise signature

Hybrid Buses - Future Challenges

Opportunities for Electrically Driven Accessories:

Short term Compressors, air and HVAC

Steering

Cooling system

Long Term Wheel motors

ZPE operation

Fuel cell integration

Additional Information

Speaker Contact:

Gary LaBouff, Director - Research & Development

MTA New York City Transit

(718) 566-3535; galabou@nyct.com

Hybrid/CNG/Diesel Emissions Report

www.navc.org/emissionsreport.html

NREL Reports:

www.afdc.doe.gov/resources.html

reports 6369 and 6383