arra material handling equipment composite data products: data

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 This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

ARRA Material Handling Equipment Composite Data Products Data through Quarter 4 of 2013

J. Kurtz, S. Sprik, and M. Peters

Technical Report NREL/TP-5400-62130 June 2014

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.

This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.

Available electronically at http://www.osti.gov/scitech

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) photo by Pat Corkery, NREL 16416, photo from SunEdison, NREL 17423, photo by Pat Corkery, NREL 16560, photo by Dennis Schroeder, NREL 17613, photo by Dean Armstrong, NREL 17436, photo by Pat Corkery, NREL 17721.

Printed on paper containing at least 50% wastepaper, including 10% post consumer waste.

http://www.osti.gov/scitech

mailto:[email protected]

mailto:[email protected]

http://www.ntis.gov/help/ordermethods.aspx

3

CDPARRA-MHE-01 Fuel Cell Material Handling Equipment (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

100

146

258

100

146

258

136

206 206

308

402

467

504 504 504 504 504 504 504 504 504 504

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

2013

Q3

2013

Q4

Class IIIClass IIClass IRetired Class II

NREL cdparra_mhe_01

Created: Apr-03-14 5:43 PM | Data Range: 2009Q4-2013Q4

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 2013Q4

25% of FC Systems > 6,870 HoursMax Stack Hours = 16,610Average Stack Hours = 4,710

FC SystemRetired FC SystemFleet Average FC System Hours

NREL cdparra_mhe_02

Created: Apr-14-14 11:25 PM | Data Range: 2009Q4-2013Q4 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

2013Q32013Q4

Fueling Events By Quarter - ARRAN

umbe

r of F

ills

[1,0

00]

Cumulative Fuelings = 329,834

0

10

20

30

40

50

60

70

80

90

100

Cum

ulat

ive

Fuel

ings

[1,0

00]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_03


6

CDPARRA-MHE-04 Hydrogen Dispensed by Quarter

0

5

10

15

20

25

30

2009Q12009Q2

2009Q32009Q4

2010Q12010Q2

2010Q32010Q4

2011Q12011Q2

2011Q32011Q4

2012Q12012Q2

2012Q32012Q4

2013Q12013Q2

2013Q32013Q4

Hydrogen Dispensed By Quarter - ARRAH

ydro

gen

Dis

pens

ed [1

,000

kg]

Cumulative Hydrogen Dispensed = 275,520 kg

0

10

20

30

40

50

60

70

Cum

ulat

ive

Am

ount

[1,0

00 k

g]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_04


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

2000

4000

6000

8000

10000

12000Refueling Time of Day - ARRA

Time of Day [hours]

Num

ber o

f Ref

uelin

gs

NREL cdparra_mhe_05


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

35

Time (min)

Num

ber o

f Fue

ling

Even

ts [1

,000

]Histogram of Fueling Times

ARRA Combined Fleet

284,649 Events Average = 2.30 min

Range of0

1

2

3

4

5

Site Averages

Ave

rage

Fue

ling

Tim

es (m

in)

NREL cdparra_mhe_06

Created: Apr-03-14 8:17 AM | Data Range: 2009Q1-2013Q4 Fill data for class 1, 2, and 3 trucks

9

CDPARRA-MHE-07 Tank Pressure Level at Fueling

Tank Pressure At Fill: ARRA

FE

24%

NREL cdparra_mhe_07


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 = 112,539Median Tank Pressure (At Fill) = 25%

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: Apr-01-14 7:16 PM | Data Range: 2009Q4-2013Q4 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

284,649 Events Average = 0.35 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: Apr-02-14 4:25 PM | Data Range: 2009Q1-2013Q4 Fill data for class 1, 2, and 3 trucks

12

CDPARRA-MHE-10 Histogram of Fueling Amounts

0 0.5 1 1.5 20

5

10

15

20

25

Amount Fueled (kg)

Num

ber o

f Fue

ling

Even

ts [1

,000

]Histogram of Fueling Amounts

ARRA Combined Fleet

Average = 0.70 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: Apr-03-14 8:34 AM | Data Range: 2009Q1-2013Q4 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

2013

Q3

2013

Q4

Tota

l Ope

ratio

n H

ours

[1,0

00]

Fuel Cell Operation Hours by Quarter - ARRA

Total Hours = 2,005,680

0

100

200

300

400

500

600

700

Cum

ulat

ive

Flee

t Hou

rs [1

000]

All FleetsIndividual Fleet

NREL cdparra_mhe_11


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


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

% 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


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


17

CDP-MHE-18 Infrastructure Maintenance by Category

6%

8%

9%

17%

17%

38%

Total Events = 1,8721

70% unscheduled

entiresystem 75

misc 232

multiplesystems 283

classifiedevents1 1282

Event Count

7%

16%

19%

51%

Total Hours = 11,04468% unscheduled

hydrogen compressor

dispenser

control electronics

feedwater system

air system

electrical

valves

NREL cdp_mhe_18


Infrastructure Maintenance By Equipment Type

MISC includes the following failure modes: actuators, seal, unspecified,thermal management, energy storage system, storage, 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 = 1,87270% were unscheduled

ScheduledTotal

0 500 1000 1500 2000 2500 3000 3500 4000

MISCFITTINGS&PIPING

MULTIPLE SYSTEMSSENSORS

VALVESAIR SYSTEM

CONTROL ELECTRONICSDISPENSER

ENTIRE SYSTEMHYDROGEN COMPRESSOR

Number of Labor Hours by Category

Hours

Total Hours = 11,04467% were unscheduled Scheduled

Total

NREL cdp_mhe_19


MISC includes the following categories:ACTUATORS

SEALUNSPECIFIED

THERMAL MANAGEMENTOTHER

ENERGY STORAGE SYSTEMSTORAGESAFETY

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

13Q3

13Q4

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

13Q3

13Q4

ScheduledUnscheduledOperator

NREL cdp_mhe_20


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


274,874 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


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


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

47.0% Fuel Cell SystemsAverage > 6 Hours Daily

NREL cdparra_mhe_24

Created: Apr-14-14 11:25 PM | Data Range: 2009Q4-2013Q4 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

2013

Q3

2013

Q4

Incident2

Near Miss1

Hundreds of Fills Per Safety Report

NREL cdp_mhe_25


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: 302,072Total Reports: 107Lifetime kg H2 Dispensed per Report: 2,823

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


26

CDP-MHE-41 Infrastructure Safety Categories

0 10 20 30 40 50 60 70 80 90

Incident

Near Miss

Number of Reports

Seve

rity

Infrastructure Safety Reports by Severity - All Sites and Report Type

Number of Fueling Events: 376,955Number of Safety Reports: 107Fuelings Per Report: 3,523

Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Minor, YES IgnitionH2 Release - Significant, NO IgnitionH� Release - No accumulationNon-H2 ReleaseOperator ProtocolStructural Issue

NREL cdp_mhe_41


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

82 kg/day avg

Dai

ly A

vera

ge [k

g]

All SitesIndividual Site

NREL cdparra_mhe_42


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

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


>24

49% 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

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 cdp_mhe_45


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 3 of 6 sites for the last 20% of events.

-69%2

152%2

13%2 -44%220%2 -58%2

30

CDP-MHE-46 Infrastructure Equipment Category of Safety Events

19%

23%

45%

By Number of ReportsNear Miss Reports = 75

91%

By Number of IncidentsIncidents = 23hydrogen compressor

dispenser

fittings & piping

seal

valves

reformer

Misc

NREL cdp_mhe_46


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%

7%

7%

7%

7%7%

8%

11%

14%

14%


70% unscheduled

upgrade 72

misc 339

preventativemaintenance 482


Event Count

10%

7%

8%

13%7%

13%

11%

17%


replace failed partsdata errorinspect trouble alarm or reportflow lowout of calibrationmetal fatiguesoftware bugpressure lowpressure highhydrogen leaktemperature highfluid leak_non_hydrogenflow high

NREL cdp_mhe_47


Infrastructure Maintenance By Mode

MISC includes the following failure modes: animal damage, cavitation,debris infiltration, false alarm, fluid leak non_hydrogen, vandalism, cleanup

device failed, electrical short, maintenance error, network malfunction,voltage low, fluid leak non-hydrogen, broken wire, manufacturing defect,

ambient temperature too low, frozen, unspecified electronics failure, failedopen, power outage, lightning strike, drive off, moisture infiltration,

operator protocol, failed closed, excessive noise, other

32

CDP-MHE-48 Infrastructure Mean Time Between Failures

0 25 50 75 100 125 150 175 200 225 250 2750

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: Apr-09-14 1:51 PM | Data Range: 2009Q1-2013Q41. Cumulative Mean Time Between Failure

33

CDP-MHE-49 Infrastructure Mean Time Between Scheduled Maintenance

0 25 50 75 100 125 150 175 200 225 250 2750

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 50 100 150 200 2500123456789

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: Apr-14-14 10:59 AM | Data Range: 2009Q1-2013Q41. 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


Shap

e Pa

ram

eter

( β)*

HYDROGEN COMPRESSOR



Site

0

0.5

1

1.5

2

2.5

3

3.5

4


Shap

e Pa

ram

eter

( β)*

VALVES



Site

0

0.5

1

1.5

2

2.5

3

3.5

4


Shap

e Pa

ram

eter

( β)*

DISPENSER



Site

NREL cdp_mhe_50

Created: Apr-09-14 1:51 PM | Data Range: 2009Q1-2013Q4 *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


Hydrogen Leaks By Equipment Category: Infrastructure

36

CDP-MHE-52 Infrastructure Failures by Mode

0 100 200 300 400 500 600

HYDROGEN COMPRESSOR

CONTROL ELECTRONICS

DISPENSER

AIR SYSTEM

Event Count

47%*

22%*

22%*

8%*

DATA ERROR

DRIVE OFF

EXCESSIVE NOISE

HYDROGEN LEAK

INSPECT TROUBLE ALARM OR REPORT

METAL FATIGUE

MOISTURE INFILTRATION

OUT OF CALIBRATION

PRESSURE LOW

REPLACE FAILED PARTS

SOFTWARE BUG

TEMPERATURE HIGH

MISC

SCHEDULED (PREV MAINT, UPGRADES)

0 1000 2000 3000 4000

HYDROGEN COMPRESSOR

CONTROL ELECTRONICS

DISPENSER

AIR SYSTEM

Labor Hours

54%*

17%*

21%*

8%*

NREL cdp_mhe_52

Created: Apr-29-14 8:20 AM | Data Range: 2009Q1-2013Q4

Failure Modes for Top Four Infrastructure Equipment Categories

* Percentage of total events or hours.

MISC includes the following failure modes: ambient temperature too low, broken wire,cavitation, debris infiltration, electrical short, failed closed, false alarm, flow high, flow

low, fluid leak non-hydrogen, fluid leak non_hydrogen, fluid leak_non_hydrogen, inspecttrouble alarm or report, lightning strike, maintenance error, manufacturing defect, metal

fatigue, moisture infiltration, network malfunction, operator protocol, other, power outage,pressure high, replace failed parts, software bug, unspecified electronics failure,

vandalism, voltage low, other

37

CDP-MHE-55 Infrastructure Mean Time Between Safety Events

0 100 200 300 400 500 6000

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

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: Apr-14-14 8:35 PM | Data Range: 2009Q1-2013Q41. 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 = 70%Number of Fills = 158365

Avg Final Pressure = 355 bar% of Fills > 350 bar = 52%Number of Fills = 72582

AverageNominal

NREL cdparra_mhe_62

Created: Apr-02-14 5:09 PM | Data Range: 2009Q1-2013Q4 *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 other26 % of fills have more than 20 minutes between them300306 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

5

6x 104 Final Pressures for Fills with <5 Minutes in Between

# of

Fue

lings

Final Pressure [bar]

Previous FillNext Fill

NREL cdparra_mhe_65

Created: Apr-02-14 5:24 PM | Data Range: 2009Q1-2013Q4 *Time is from end of fill to start of next fill.

40

CDP-MHE-66 Infrastructure Maintenance for Delivered Hydrogen

8%

22%

22%

47%


65% unscheduled

entiresystem 75

misc 171

multiplesystems 277


Event Count

8%

21%

17%

54%


hydrogen compressor

control electronics

dispenser

air system

NREL cdp_mhe_66


Delivered Hydrogen Infrastructure Maintenance By Equipment Type

MISC includes the following failure modes: seal, fuel system, thermalmanagement, electrical, energy storage system, storage, safety, software,

fittings&piping, 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


42

CDPARRA-MHE-68 Fill Counts per Hour

0 5 10 15 20 25 30 35 40 450

5

10

15

Number of Fuelings in an Hour

Freq

uenc

y [%

of t

otal

]

Number of Fuelings Per Hour - ARRA

NREL cdparra_mhe_68


Average: 6.6 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


Average: 4.9 kgs per hourMedian: 3.6 kgs per hourMax: 53.0 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


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 Daily102 kg

Max Daily135 kg

Max Daily177 kg

Max Daily293 kg

Max Daily358 kg

40.8%

Average Daily Utilization1

Maximum Daily Utilization

NREL cdparra_mhe_71


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


47

CDPARRA-MHE-76 Component Repair Time

0123456789

101112

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ELECTRICAL

ENERGY STORAGE SYSTEM

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


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

Jul-2

013

Oct-20

13

% 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


*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


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.

arra material handling equipment composite data products: data

Documents