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Real-World Hydrogen Technology Validation. ICHS 2011: T5 #217 S. Sprik, J. Kurtz, K. Wipke, T. Ramsden, C. Ainscough, L. Eudy, G. Saur September 12-14, 2011. Contents. NREL Hydrogen Technology Validation Overview of Tech Val Projects - PowerPoint PPT Presentation
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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.
Real-World HydrogenTechnology Validation
ICHS 2011: T5 #217
S. Sprik, J. Kurtz, K. Wipke, T. Ramsden, C. Ainscough, L. Eudy, G. Saur
September 12-14, 2011
NATIONAL RENEWABLE ENERGY LABORATORY
Contents
2
NREL Hydrogen Technology Validation
Overview of Tech Val Projects
Selected Composite Data Products (CDPs) including Safety and Maintenance
NATIONAL RENEWABLE ENERGY LABORATORY
NREL Tech Val – Who We Are, What We Do
Within NREL’s Hydrogen Technologies and Systems Center, the Technology Validation group works on confirming that technical targets have been achieved for components and systems under “Real World” conditions.
CollectionAnalysisCollaborationReporting on Real World
Operation Data from the Field and State of the Art Performance Data from the Lab
NATIONAL RENEWABLE ENERGY LABORATORY
Energy Systems Integration Facility - ESIF
Rendering courtesy of Smith Group
(This is a rendering. Building completion expected in 2012)
NATIONAL RENEWABLE ENERGY LABORATORY
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, & collaboration2) Results published via NREL Tech Val website, conferences, and reports
Data Flow Supports both DOE/Public as Well as Fuel Cell Developers
Results
Internal analysis completed quarterly
Bundled data (operation & maintenance/safety) delivered to NREL quarterly
NATIONAL RENEWABLE ENERGY LABORATORY
•Code developed at NREL •Started out just for fuel cell cars and their infrastructure•Added other applications as they came along•Allows for batch processing•Select which analyses to perform and which projects to go into a CDP•Updated continuously
Analysis Tool
NATIONAL RENEWABLE ENERGY LABORATORY
0
100
200
300
400
500
600
700
FCB FCEV MHE BU
Num
ber o
f Sys
tem
s
HSDC - Fuel Cell Systems
ExpectedOperatingRetired
NREL cdp_comb_01Created: 04/06/2011 9:16 AM
Technology ValidationDemonstrations are essential for validating the performance of technologies in integrated systems, under real-world conditions.
8
NATIONAL RENEWABLE ENERGY LABORATORY
Cross Application Usage
49,272
114,290
450,251
218
Hours614,031
Total Hours:
547,653
2,872,533
MilesTotal Miles:3,420,186 4,541
28,230
75,364
Hydrogen Fills
Total H2 Fills:108,135
96,286
90,865
39,477
32
Hydrogen Amount
Total H2 kgs:226,660
NREL cdp_comb_02Created: 04/13/2011 4:27 PM
NATIONAL RENEWABLE ENERGY LABORATORY
Fueling Rates by Application
NATIONAL RENEWABLE ENERGY LABORATORY
Funding from DOE
FC Learning Demo
NATIONAL RENEWABLE ENERGY LABORATORY
FCEV Learning Demonstration Teams
12
Teams through end of 2009
Teams through 2011
NATIONAL RENEWABLE ENERGY LABORATORY
Two Sets of CDPs Through 2009Q4 After 2009Q4
80 Spring 2010 Results
•Most comprehensive set we ever published•Includes durability, range, fuel economy•Covers data from all 4 Learning Demo teams + CHIP project over 5-year period•Majority of these are now static, serving as a historical record of Gen 1 & Gen 2 comparisons.
23 Results
• 5 new CDPs, and updated 18 previously published CDPs with data from last 12 months
• Results on most recent durability, range, fuel economy, not yet possible to publish until more data accumulated (end of 2011)
• Covers data from 2 Learning Demo OEMs + CHIP project
• Emphasized changes observed between older data and the newer data
Spring 2011
NATIONAL RENEWABLE ENERGY LABORATORY
Technology Validation FCEVThe Learning Demonstration has Exceeded Technical Goals
for Driving Range and Fuel Cell Durability
DOE Vehicle/Infrastructure Demonstration Four teams in 50/50 cost-shared projects with
DOE Fuel Cell Technologies Program
• 155 fuel cell vehicles and 25 fueling stations demonstrated• More than 3 million miles traveled• More than 147,000 kg of hydrogen produced or dispensed*• Analysis by NREL shows:
• Efficiency: 53 – 59% (>2x higher than gasoline internal combustion engines)
• Range: ~196 – 254 miles • Fuel Cell System Durability:
~ 2,500 hrs (~75,000 miles at 30 mph avg. speed)
*includes hydrogen not used in the Program’s demonstration vehicles
14
NATIONAL RENEWABLE ENERGY LABORATORY
Status: Out of 25 Project Stations, 13 Are Still Operational (3/5 outside of DOE project)
Mar-31-2011
2 Online3 Future
54 Online15 Future
6 Online
SF Bay Area
DC to New York
4 Online
Detroit Area
Los Angeles Area
17 Online11 Future
3 mile radius
6 mile radius
6
9
9
0
5
10
15
20
25
Num
ber o
f Sta
tions
Reporting Period
Cumulative Stations
Continuing Outside of Project
Retired Stations
Current Project Stations
NREL cdp_fcev_31Created Mar-14-11 9:52 AM
9
6
9
**
** Funded by state of CA or others, outside of this project
* CDP station status is as of 12/31/10
NATIONAL RENEWABLE ENERGY LABORATORY
Vehicle Deployment Over Time
4
83
45
23
-
20
40
60
80
100
120
140
160
180
Cum
ulat
ive
Vehi
cles
Dep
loye
d/R
etire
d1
Vehicle Deployment by On-Board Hydrogen Storage Type
700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired
(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL(2) Two project teams concluded in Fall/Winter 2009Created Mar-10-11 3:37 PM
155
NREL cdp_fcev_25
(2)
NATIONAL RENEWABLE ENERGY LABORATORY
Number of Stations Over Time
6
9
9
0
5
10
15
20
25
Num
ber o
f Sta
tions
Reporting Period
Cumulative Stations
Continuing Outside of Project
Retired Stations
Current Project Stations
NREL cdp_fcev_31Created Mar-14-11 9:52 AM
NATIONAL RENEWABLE ENERGY LABORATORY
Station Types in FCEV Learning Demo
0
1
2
3
4
5
6
7
8
9
10
11
Delivered Compressed H2
Natural Gas On-Site Reforming
On-Site Electrolysis Delivered Liquid H2
# of
Sta
tions
Station Type
Learning Demonstration Hydrogen Stations By Type
Operating Outside of ProjectOperating Within ProjectHistorical 2005-2009
NREL cdp_fcev_32Created Mar-10-11 4:18 PM
*
*Some project teams concluded Fall/Winter 2009. Markers show the cumulative stations operated during the 2005-2009 period
NATIONAL RENEWABLE ENERGY LABORATORY
Safety Reports for FCEV Learning Demo
0
1
2
3
Num
ber o
f Rep
orts
Safety Reports - Vehicle Operation
Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment
Created: Feb-18-11 2:32 PMNREL cdp_fcev_09
Created: Feb-18-11 2:32 PMNREL cdp_fcev_09
13 events•4 traffic accidents•4 leaks during fueling
NATIONAL RENEWABLE ENERGY LABORATORY
Definitions for Safety ReportingAn incident is defined as an event that results in any of the following:
• 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 defined as:
• An event that, under slightly different circumstances, could have become an incident
• An unplanned hydrogen release insufficient to sustain a flame
NATIONAL RENEWABLE ENERGY LABORATORY
Safety Reports for FCEV Infrastructure
0
10
20
30
40
50
Num
ber o
f Rep
orts
Type of Infrastructure Safety Reports by Quarter Through 2010 Q4
IncidentNear MissNon-EventAvg # Reports/Station
NREL cdp_fcev_36Created: Mar-14-11 11:18 AM
Reporting PeriodAn 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
5 incidents
NATIONAL RENEWABLE ENERGY LABORATORY
Safety Reports by Type
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Seve
rity
Total Infrastructure Safety Reports by Severityand Report Type Through 2009 Q4
Alarms OnlyAutomatic System ShutdownElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionManual System ShutdownNon-H2 ReleaseSite Power OutageStructural IssueSystem Trouble, not Alarm
NREL CDP20Created: Mar-11-10 2:45 PM
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
Equipment malfunctionsSignificant H2 Release
Leaks
NATIONAL RENEWABLE ENERGY LABORATORY
Safety Reports Primary Factors
0 50 100 150 200 250 300
Non-Event
Near Miss
Incident
Number of Reports
Seve
rity
Primary Factors of Infrastructure Safety ReportsThrough 2009 Q4
Calibration/Settings/ Software ControlsDesign FlawElectrical Power to SiteEnvironment (Weather, Power Disruption, Other)False AlarmInadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel ErrorSystem Manually Shutdown
NREL CDP37Created: Mar-11-10 2:45 PM
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
Controls issue2 operator error2 design flaws
NATIONAL RENEWABLE ENERGY LABORATORY
Funding from DOE-ARRA, DLA
Backup Power, Material Handling Equipment
NATIONAL RENEWABLE ENERGY LABORATORY
Early Market Locations
FC Unit Locations - Early Market Applications
0
25
50
75
100
125
Material Handling Equipment (13 Sites and 618 FC Units)Backup Power (90 Sites and 219 FC Units)Stationary (2 Sites and 12 FC Units)APU (1 Sites and 1 FC Units)Bus (1 Sites and 1 FC Units)
NREL cdp_em_03Created: Feb-09-11 10:26 AM
Number of FCUnits in
State/Site
NATIONAL RENEWABLE ENERGY LABORATORY
Early Market Applications
NATIONAL RENEWABLE ENERGY LABORATORY
Summary of FC MHE Operation - ARRA
27
*Through December 2010
FCMHE operating at end user facilities, accumulating many hours and hydrogen fills safely, and already showing productivity improvements.
Sites 5 CDPARRA-MHE-#
Units in Operation(60 Class 1, 76 Class 2, 172 Class 3)
308* 01
Hours Accumulated 307,433 hrs* 11
FC Systems > 2360 hrs 25%* 02
Hydrogen Dispensed 18,597 kg* 04
Hydrogen Fills 38,863* 03
Average Fill Amount 0.48 kg/fill* 10
Average Fill Time 1.8 min/fill* 06
NATIONAL RENEWABLE ENERGY LABORATORY
0
10
20
30
40
50
60
70
80
Star
ts
Starts by Month
07/09
08/09
09/09
10/09
11/09
12/09
01/10
02/10
03/10
04/10
05/10
06/10
07/10
08/10
09/10
10/10
11/10
12/10
Calendar Month
408 of 409 Starts Successful (99.8%)59% Conditioning Starts
StartsConditioning1 StartSuccessful Start
0
20
40
Rep
ortin
g FC
Sys
tem
s
NREL cdp_bu_04Created: Mar-16-11 12:59 PM 1) FC system conditioning is an automated operation for regular
system checks; activitated after long periods of no operation.
Summary of Backup Power System Operation
* Through December 201028
Sites 85 CDP-BU-#
Deployed Systems 189* 01
Total Successful Starts 408 (99.8%)* 04
Total Run Time 218 hours* 05
Total Hydrogen 32.3 kg* 06
Key Performance Metrics
ReliabilityLow Emissions
Low NoiseEase of Use
Remote Monitoring
NATIONAL RENEWABLE ENERGY LABORATORY
ARRA Deployment
2010 Q1 2010 Q2 2010 Q3 2010 Q40
50
100
150
200
250
300
350
400
14
122
35
40
131
35
40
131
60
76
172
136
206 206
308
Cum
ulat
ive
Syst
ems1,
2 Dep
loye
dFuel Cell Units Deployed - ARRA
Class IIIClass IIClass I
NREL cdparra_mhe_01
Created: Mar-10-11 2:18 PM
>750
NATIONAL RENEWABLE ENERGY LABORATORY
Fuel Cell Deployments for DLA
2009 Q1 2009 Q2 2009 Q3 2009 Q4 2010 Q1 2010 Q2 2010 Q3 2010 Q40
10
20
30
40
50
60
70
80
90
100
110
40 40 40
60 60 60 60 60
Cum
ulat
ive
Syst
ems
1,2 D
eplo
yed
Fuel Cell Units Deployed - DLA
Class IIIClass IIClass I
NREL cdpdla_mhe_01
Created: Mar-24-11 10:54 AM
~75
NATIONAL RENEWABLE ENERGY LABORATORY
Fueling by Quarter for ARRA
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40
2000
4000
6000
8000
10000
12000
14000
16000Fueling Events By Quarter - ARRA
Num
ber o
f Fill
s
Cumulative Fuelings = 38,863
0
5
10
15
20
25
Cum
ulat
ive
Fuel
ings
[100
0]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_03
Created: Mar-21-11 3:29 PM
NATIONAL RENEWABLE ENERGY LABORATORY
Fueling by Quarter for DLA
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40
500
1000
1500
2000
2500
3000
3500
Hydrogen Dispensed to Material Handling Equipment By Quarter - DLAH
ydro
gen
Dis
pens
ed [k
g]
Cumulative Hydrogen Dispensed = 20,880 kg
0
2
4
6
8
10
12
14
16
18
20
Cum
ulat
ive
Am
ount
[100
0 kg
]
All Sites By QuarterCumulative By Site
NREL cdpdla_mhe_04
Created: Mar-25-11 10:18 AM
NATIONAL RENEWABLE ENERGY LABORATORY
MHE Infrastructure Maintenance By Category
9%
10%
13%23%
31%
Number of EventsTotal Events = 363
87% were unscheduled
8%
8%
10%
13% 35%
20%
Labor HoursTotal Hours = 2427
87% were unscheduledH2 production unit
compressor
preventative maintenance
dispenser
system control & safety
valves & piping
MISC
NREL cdp_mhe_18Created: Mar-18-11 9:20 AM
Infrastructure Maintenance By CategoryAll Sites Thru 2010Q4
MISC includes the following categories:Data collection
electricalother
storage
NATIONAL RENEWABLE ENERGY LABORATORY
ARRA FC System maintenance
10%10%
11%
12%
14%
Number of EventsTotal Events = 1149
83% were unscheduled
6%
9%
11%11%
22%
6%
13%
Labor HoursTotal Hours = 1676
87% were unscheduled
THERMAL MANAGEMENT
SENSORS
ENERGY STORAGE SYSTEM
PREVENTATIVE MAINTENANCE
ELECTRICAL
FUEL SYSTEM
CONTROL ELECTRONICS
UPGRADE
SOFTWARE
OTHER
AIR SYSTEM
MISC
NREL cdparra_mhe_12
Created: Mar-30-11 4:58 PM
Fuel Cell System Maintenance By Category - ARRAAll ARRA Sites Thru 2010Q4
MISC includes the following categories:FC STACK
MANUFACTURING DEFECTVALVES
ACTUATORSSERVICE
OPERATOR PROTOCOL
NATIONAL RENEWABLE ENERGY LABORATORY
DLA FC System Maintenance by Category
8%
9%11%
16%
20%
Number of EventsTotal Events = 1432
76% were unscheduled
4%
7% 10%
13%
5%
15%
9%
Labor HoursTotal Hours = 3459
75% were unscheduled
ENERGY STORAGE SYSTEM
PREVENTATIVE MAINTENANCE
OPERATOR PROTOCOL
OTHER
UPGRADE
THERMAL MANAGEMENT
CONTROL ELECTRONICS
FUEL SYSTEM
SENSORS
ELECTRICAL
MISC
NREL cdpdla_mhe_12
Created: Mar-24-11 10:50 AM
Fuel Cell System Maintenance By Category - DLAAll DLA Sites Thru 2010Q4
MISC includes the following categories:VALVESSERVICESAFETY
SOFTWAREAIR SYSTEMFC STACK
NATIONAL RENEWABLE ENERGY LABORATORY
MHE Infrastructure Safety Reports
0 2 4 6 8 10 12 14 16
Incident
Near Miss
Number of Reports
Seve
rity
Infrastructure Safety Reports by Severity - All Sites and Report Type 2010Q4
Alarms OnlyEquipment MalfunctionH2 Release - Minor, NO IgnitionNon-H2 ReleaseOther 1 (user defined)Structural Issue
NREL cdp_mhe_41
Created: Mar-09-11 2:26 PM
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
Most incidents were dispenser hose break-away
NATIONAL RENEWABLE ENERGY LABORATORY
ARRA FC System Safety Reports
0 10 20 30 40 50 60
Incident
Near Miss
Number of Reports
Seve
rity
Fuel Cell System Safety Reports by Severity - ARRA and Report Type 2010Q4
Electrical IssueH2 Release - Minor, NO IgnitionH2 Release - Significant, NO Ignition
NREL cdparra_mhe_27
Created: Mar-29-11 2:35 PM
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
NATIONAL RENEWABLE ENERGY LABORATORY
DLA FC System Safety Reports
0 5 10 15 20 25
Incident
Near Miss
Number of Reports
Seve
rity
Fuel Cell System Safety Reports by Severity - All Sites and Report Type 2010Q4
H2 Release - Minor, NO IgnitionNon-H2 FireStructural IssueWater discharge
NREL cdpdla_mhe_27
Created: Mar-10-11 11:35 AM
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
Possible static dischargeShort from power washing
NATIONAL RENEWABLE ENERGY LABORATORY
FCMHE 42 CDPs
39
Results include• Units deployed, operation hours, & fuel cell operation trends• Hydrogen fill count, amount, time, & rate • Tank level at fill & downtime from fill• Fuel cell durability & reliability• Fuel cell and infrastructure maintenance events & safety reports
NATIONAL RENEWABLE ENERGY LABORATORY
Funding from DOE and DOT Federal Transit Administration
FC Bus
NATIONAL RENEWABLE ENERGY LABORATORY
Technology Validation FCBFC Buses Are Demonstrating Long Life and Superior Fuel
Economy Compared to their Diesel and CNG Baselines
Traveled: >547,000 milesDispensed: >96,000 kg H2
Fuel economy results: 41% to 132% better than diesel and CNG buses
41
NATIONAL RENEWABLE ENERGY LABORATORY
Bus Safety
•Break-away not functioning as intended•Tanks on top of bus increase height/center of gravity
NATIONAL RENEWABLE ENERGY LABORATORY
Specific Safety Reports
•Car accident•Vibrating machinery (cold)•Fire at a Fueling Station•Breakaways not operating as intended•FL water spill•FL fire power washing•FL evap pad caught on fire
NATIONAL RENEWABLE ENERGY LABORATORY
Lessons learned from Safety Reports
•First responders may need training more often or when new to area•Need to prevent drive-offs with hose still attached•Need systems to prevent incidents or near misses getting worse because of cascading events•Want technology to be transparent to user but there are differences that user needs to be aware of
• Power washing of fuel cell forklift•Routine inspections are necessary to catch problems early•Make sure alarms are appropriate to the event to prevent over reaction.•Redundant checks to make sure maintenance is done properly•Fail-safe systems are working as intended
NATIONAL RENEWABLE ENERGY LABORATORY 45
Preventing drive offs
NATIONAL RENEWABLE ENERGY LABORATORY
New CDPs Coming Soon
In the next round of CDPs (Oct 2011)
Performance More detailed durability CDPs
Safety and Maintenance Hydrogen leaks by equipment category Hydrogen compressor failure modes Mean time between safety events Equipment category of safety events
NATIONAL RENEWABLE ENERGY LABORATORY
Summary
•Safety data collected from teams•Safety data reported in CDPs and available on NREL’s website•Incidents reported to H2Incidents.org when possible•Tech Val has seen a good safety record
NATIONAL RENEWABLE ENERGY LABORATORY
Daimler F-Cell at NREL
48
NREL’s Renewable H2 Station, storingover 250 kg H2 and dispensing at 350 bar
NATIONAL RENEWABLE ENERGY LABORATORY 49
Kia Borrego Fuel Cell at NREL
NATIONAL RENEWABLE ENERGY LABORATORY 50
Ford Hydrogen Shuttle at NREL
NATIONAL RENEWABLE ENERGY LABORATORY 51
Proterra Bus at NREL
NATIONAL RENEWABLE ENERGY LABORATORY 52
Questions and Discussion
Contact: Sam Sprik, National Renewable Energy Lab 303.275.4431 [email protected]
All public Learning Demo, FC Bus, and Early Market papers and presentations are available online at www.nrel.gov/hydrogen/proj_tech_validation.html
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. 53
NATIONAL RENEWABLE ENERGY LABORATORY
FC Durability Target of 2000 Hours Met By Gen 2 Projections (2010)
Gen1 Gen2 Gen1 Gen2 Gen1 Gen20200400600800
1000120014001600180020002200240026002800
2006 Target
2009 Target
Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation
Tim
e (H
ours
)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2
Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection to 10% Voltage Degradation4,5,6
Max ProjectionAvg Projection
NREL CDP01Created: Mar-23-10 10:39 AM
(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% voltage degradation.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and methodology limitations. Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demonstrated op hours.
*
Durability is defined by DOE as projected hours to 10% voltage degradation* Spring 2010
NATIONAL RENEWABLE ENERGY LABORATORY
Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0
50
100
150
200
250
300
Vehi
cle
Ran
ge (m
iles)
Vehicle Range1
2015 Target2009 Target Gen 1 Gen 2
NREL CDP02Created: Mar-10-10 1:18 PM
(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAE J2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.
Vehicle Range Achieved 2009 Target of 250 Miles with Gen 2 Adjusted Fuel Economy
NATIONAL RENEWABLE ENERGY LABORATORY
Factors Affecting Fuel Economy Show Large Spread in Data
0 10 20 30 40 50 60 700
0.2
0.4
0.6
0.8
1
Effect of Average Trip Length on Fuel Economy
1 Fuel
Eco
nom
y [n
orm
aliz
ed]
Trip Length [miles]
Average of Fleet Medians25th to 75th Percentile
NREL cdp_fcev_85Created: Mar-18-11 11:46 AM
(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 miles for calculating median and percentiles.
0 5 10 15 20 25 30 35 40 45 50 550
0.2
0.4
0.6
0.8
1
1.2
Effect of Average Trip Speed on Fuel Economy
1 Fuel
Eco
nom
y [n
orm
aliz
ed]
Avg Trip Speed [miles/hour]
Average of Fleet Medians25th to 75th Percentile
NREL cdp_fcev_84Created: Mar-18-11 11:46 AM
(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 mph for calculating median and percentiles.
Fuel economy relatively insensitive to average trip length, except for very short trips
Factor of 2X observed for fuel economy as a function of average trip speed
NATIONAL RENEWABLE ENERGY LABORATORY
Fuel Cell System Reliability Analysis
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1. The New Weibull Handbook, 5th ed., Robert Abernethy, (2007)2. IEC 61164:2004, Reliability Growth – Statistical Estimation Methods, International Electrotechnical Commission, (2004)
• Failure events (i.e. unscheduled maintenance records) are tracked per unit and per fleet
• Crow-AMSAA analysis method1,2
• Study failure rates (e.g Shape Parameter > 1 is an increasing failure rate)• Highlight common failures per category and unit• Tracks progress and reliability predictions