fuel cell balance of plant reliability testbed · •start – aug 2008 •finish – july 2011...

Fuel Cell Balance of Plant Reliability Testbed

PI: Susan ShearerPresenters:

Rob Shutler - Lockheed Martin MS2&

Educational Project Coordinator: Vern Sproat, PE - Stark State College

10 May 2011Project ID #: FC075

This presentation does not contain any proprietary, confidential, or otherwise restricted information

• Start – Aug 2008• Finish – July 2011• 75% Complete

Timeline

• Total project funding– DOE $787,200– Contractor 196,800

Budget

• Technology Validation: Project will generate a reliability database for candidate PEM fuel cell BOP components

• Education: Project will enhance the education of technical workforce trained in PEM fuel cell system technology

Barriers

• Stark State College: Project Lead and location of 2 testbeds built by students

• Lockheed Martin: Location of 1 of 3 testbeds and design

Partners

Overview

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3

Relevance

Balance of Plant (BOP) – Evaluation of components for use in hydrogen fuel cell systems and workforce development

– Reliability

– Durability as defined by Mean Time Between Failure (MTBF)

– Hands on workforce / technician training for maintaining fuel cell systems and documentation of component capability

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• Develop testbeds to address the challenge to the fuel cell industry for the durability and reliability of components that comprise the complete system - Balance of Plant (BOP).

• Develop test plan to address the candidate BOP components and basic testbed design for long-term operation.

• Collaborate with component manufacturers to develop and enhance final product performance.

• Develop statistical models for extremely small sample sizes while incorporating manufacturer validation data for future evaluation of candidate components.

• Conduct real-time, in-situ analysis of critical components’ key parameters to monitor system reliability.

• Utilize testbeds to enhance the education of the technical workforce trained in PEM fuel cell system technology.

Approach

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Approach / ProgressTask # Project Milestones

Task Completion DateProgress Notes

Original Planned

Revised Planned

ActualPercent

Complete

1 Test Bed Design 3/31/09 3/31/09 100%2 Renovation of College Facility 3/31/09 9/30/09 9/31/09 100%3 College Testbed Fabrication &

Test6/30/09 3/30/11 80% The first test stand is built

and leak test is underway.The second test stand frame is built. BOP components and temperature control components must still be specified and purchased.

4 Parallel Testbed Fabrication & Test

6/30/09 3/30/11 95% Components are identified and undergoing testing. System testing is underway.

5 Reliability Analysis 6/30/11 20% Tested components are under analysis

6 Failure Analysis 6/30/117 Consulting 6/30/118 Project Management &

Reporting4/30/11 6/1/09 99% The Hydrogen Safety Plan

was returned to Stark State and is under review for update.

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Reliability data generated for pressure sensors, tubing and hydrogen circulating pump

Students have been trained in construction, programming, operation, data acquisition and automated control of testbeds

Testing of Pressure Hydrogen Safety Plan implemented to ensure safe operation of the testbeds with hydrogen

• Continue to test components and document reliability

• Commission third testbed

• Continue to evaluate failure modes of tested components

Technical Accomplishments & Progress

7Fuel Cell BoP Reliability Testbeds

Technical Accomplishments and Progress

Fuel Cell Testbeds

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LC-BV1

LC-BV2

LC-BV3

LC-BV4

LC-BV5

LC-BV6

P

LC-P3

T

LC-T4

Compressed Air

N2

H2

3REG

1REG

2REG LC-HTR2

P

LC-P4

P

TEST

System Relief

Regulator

Pressure Relief Valve,

Sample Cylinder

Trace Heater

PAnalog Pressure Gauge

T Thermocouple

Powered bellows valve Drain

Needle Valve

Liquid Drain

PEM BOP RELIABILITY TEST STAND: 27 MAY 09

LIFE CYCLE TEST PARAMETERS:Pressure……………..50 psia target, 15 – 100 psi function by designTemperature………...80ºC target, 20 – 80ºC max function by designRelative Humidity…..95%RH target, 5 – 95%RH function by design

ALL DEVICES FM APPROVED, OR EQUIVALENT FOR H2 SERVICE

½” 316L SS TUBE, 100 ft., est

LC-H1

Humidity indicator, analog out

Equipment Legend

T

LC-T6-C

DUT

P T

P T

F

Bypass

T

(3)

(3)

LVDT

LVDT

Accelerometer(quantity)

BLOWER LOOP

LIFE CYCLE TEST

DYNAMIC RESPONSE TEST SYSTEM:

Purpose to test baseline performance before and after life cycle. Has added / reduced test features, i.e., LVDT, not heat, no humidity. Integrated pressure decay test.

T

LC-T3-C

LC-A1

T

LC-T7

P

LC-P1

T

LC-T1

P

LC-P2

T

LC-T2

F

LC-F1

LLC-HTR1

LC-BWR-1

T

LC-RV1

SILENCER

Plug Valve

DUT Blower

2PV

PT

LC-HTR3

LV-NV1

LIFE CYCLE TEST DEVICES:Analog and digital output to NI Hardware, 4-20 mA, 0-5V, 0-10V, RS-232Thermocouple, K-Type%RH detectors, Vaisala, 5 – 95% RH, 95% - 100% RHHeaters, Heat trace, 1000 W, 110 VACStainless control valves, 316SS option to controlStainless tubing, ½” OD, 316SSHigh Purity RegulatorsSample Cylinders, StainlessH2, N2, Air input streamsSilenced exhausts

Recirculate Nitrogen

LC-NV2

LC-PV2

LC-PV1 LC-PV3

TEST

LC-BAV1 T

LC-T5

LC-PV4

LC-PV5

LC-REG1

CNV1

CNV2

CNV3

1REG 1REG

LC-PV4

LC-PV6

LC-PV7

LC-PV8 LC-PV9

Testbed Design - Hydrogen Recycle

Life Cycle TestLong Term Testing

Dynamic Response TestPre- and Post- Test

Assessment


Test Bed Designed for Multiple Test Modes

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Dynamic Response Test System → Pressure Test

Pres

sure

Tes

tUs

er In

terfa

ceUs

er In

terfa

ce

Configure I/OLogging Rate Select Chart

Pressure = x sec Pressure vs. time

Configure Pressure Behavior

Pressure MAX = x sec

Temperature = x secLVDT = x sec

Pressure MIN = x sec

Pressure HOLD = x secNumber of Steps = xNumber of Repetitions = x

Initialize Pressure at zero

Set Pressure

Set Pressure increment = (Pmax

– Pmin)/steps

Set Number of Rep’s

Set Hold Time at each step

Command to close Isolation Valving

New pressure?

New Pressure Increment?

New No. Of Rep’s?

New Hold Time?

Command Pressure

Y

N

Command Increment

Y

N

Command Increment

Y

N

Command Increment

Y

Read Pressure In1. Master2. DUT

Go to pressure step 1 Hold pressure Hold time for x

sec

Hold pressure Go to pressure step 2

Hold time for x sec

Hold pressure Go to pressure step n

Hold time for x sec

Repetition for n cycles

Total Rep’s complete?

N

Command prompt“Test Complete” Record name/date

Run / Stop

Runtime

Max Pressure

Min Pressure

Number of Steps

Number of Repetitions

DUT ID#

DUT Administrative

notes

ChartHold Time

Pressure

Time →

P(min)

P(max)

P1

P2

Pfinal

Hold

Close isolation Valve

REPETITION 1 REPETITION 2

STEP

Method Store Method Recall

{

{

“Run” next test?

Y

Insert administrative file

data

RUN

TEST PURPOSE:1.) RESPONSE TIME2.) PRESSURE DECAY LEAK3.) TRANSDUCER EFFECTS (accuracy, linearity, repeatability, short term reproducibility, hysteresis, bias, zero offset)

Zoom / Scale feature

Stop

Logic processes for testbed development


Testbed Design - Hydrogen Recycle

Testbed Logic Process Diagrams

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Testbeds LabVIEW Programming


Student Constructed Operator Interface

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Reliability is the ability of an item to perform the required function, under stated conditions, for a period of time.

Candidate BOP Components

COTS - Commercial off-the-shelf components

• High-production products such as piping, fittings, etc. where past history is available.

– Use Weibull and Weibayes Analysis for those components with previous history. This procedure incorporates test and field data (vendor reliability and quality analysis) to demonstrate the component product meets the reliability target at the desired confidence level.

• Low production units with no manufacturer reliability data.

– End-of-life component data and Forensic Failure Analysis will be the most important test data.

Reliability Testbed

Pumps

Valves

Fittings

Heater

Heat Exchanger

PEM Fuel Cell BOP Dynamics

Mechanical Chemical Purity

Heat GenerationFatigue

Leak IntegrityFlow Capacity

Cycle LifeThermal cycles

Make-upThermal cycle

Cycle Life

Fouling

Fatigue

Chemical compatibility

Hydrogen –Embrittlement

Oxidation

Particle generation by erosion

Particle generation by actuation, wear

out, elastomer leach contaminants

Low-level trace elements leach

Whittling of elements, particle

shedding

Particle shedding, Elastomer leach contaminants

Particle shedding, Elastomer leach

contaminants, Low-level trace elements

leach

Transducer Effects

Controller tuning, accuracy



Linearity, hysteresis, accuracy, repeatability, reproducibility, drift, bias

Meters / Analyzers


Analysis Method for Test Components

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Pressure Sensors

Component Absolute PSI Error Price $ Dimensions Ranking

Brand A Yes 0-50 0.25% 87 1.12 1

Brand B NO 0-50 0.25% 87 1.12 2

Brand C Available 0-50 1% 69 2.6 3

Brand D NO 0-50 0.25% 134 1.12 4

Brand E Yes 0-60 0.25% 435 4.3 5

Brand F NO 0-50 0.50% 150 2.91 6

Brand G Yes 0-50 0.25% 360 3.27 7

Brand H NO 0-50 1% 79 3.3 8

Brand I Yes 0-50 ±0.15% FS 525 3.825 9

Brand J Yes 0-60 (0-4 bar) 0.175% > 0.4 bar 3.68+connector 10

Brand K Yes 0-50 0.5%FS 495 3.1+ connector 11

Brand L Yes 0-50 0.5%FS 301 4.17 inches 12

Brand M Yes 0-50 0.25% FS 600 4.13+connector 13

Brand N Yes 0-50 0.4% of RO 580 4.8 inches 14

Several Hard and Soft Sensor Failures Have Been Documented

Trade Study for low cost, high reliability, compact sensors

Evaluation Test Data for Devices

Under Test


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Hydrogen Recirculation Pump

Search for Low Cost, Low Power, Low Weight Component

• Hydrogen recycle pump chosen for COTS Capability

• Recycle pump search identified the following issues:

– Reliability of limited production components

– Materials compatibility, special order necessary for 316 SS with sealed operation

– Development costs required for specialized hydrogen blower

• Pump chosen: Parker Univane™

– Rated off-the-shelf for hydrogen operation and operation conditions - $8K

• Issue: Product line has been discontinued

• Substituting COTS blower with lesser capability


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Fuel Cell Tubing

• Alternate Tubing Choice– Performance tubing with greater

resistance to permeation Zeus® Perme-Shield™ high-purity PFA. Perme-Shield demonstrates exceptional barrier properties and significantly defends against gas permeation and chemical leaching through the tubing walls used in wet chemical processing.

Coextrusion: Permeation-

Resistant Cladding

Zeus® PFA Tubing

PFA- Perfluoroalkoxy polymer

Component Comments

316 Stainless Steel Tubing

DI water compatible

Coextrusion PFA Tubing DI water and chemical resistant, corrosion resistant, lightweight


PFA Tubing

Lightweight, Chemical Resistant Tubing

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• Pressure decay method used to test feasibility of PFA tubing• In the process of higher temperature and long-term

exposure to PEM environment testing


PFA vs. Stainless Steel

PFA Test Data

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Collaborations

Industry Dialogue Parker Swagelok National Instruments Omega Dyne Rockwell Automation Microchip National

Semiconductor Zeus Thomas Buzmatics Newport BELLOFRAM Proportional-air SI Pressure Summit Instruments Blaze Technical

Services

SMC AMREL BALLARD Brisk Heat Fluke H2Scan Keithley Keyence Kikusui Roxtec Vaisala Clippard Omega Ameritrol ATEX BelGAS

Intek Asmeblon Sandia Labs McMaster-Carr Auto Zone Fluidtrol Alicat Ametek Fox Valve EBZ EXAIR Pfizer Airgas Great Lakes NoShock Chevron Phillips

Chemical Company

Mound Technical Solutions

Agilent Neteon Praxair Item America 8020 Rexel Texas Instruments Prosoft Tektronix Comsol Piedmont Plastics OFCC HYGROSENS AMETEK National Semiconductor

Lockheed Martin

Subcontract Initial Testbed Design

Parallel Testbed Construction Failure Analysis

Reliability Analysis

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Educational Institution Dialogue

• Educational Institution Dialogue (cont.)– Early College course

Alternative Energy and Fuel Cells– Engineering & Science Career Field

Technical Fuel Cell Energy– Project Lead the Way, Ohio Fuel Cell

Option– Upward Bound Fuel Cell Course– Support for First Fuel Cell Contest teams – High School Student Science Projects – Ohio Energy Project

• NSF Great Lakes Fuel Cell Education Partnership State Coordinators

– IndianaVincennes UniversityRose Hulman Institute of Technology

– MichiganKettering UniversityLansing Community CollegeMichigan Technical College

– New YorkRensselaer Polytechnic InstituteHudson Valley Community College

– OhioUniversity of AkronStark State CollegeKent State UniversityHocking Technical College

– PennsylvaniaPenn State University

– TennesseeUniversity of Tennessee

Collaborations

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• Identify additional parts to test

• Acquire real-time, in-situ data from the operation of the testbeds

• Address failure analysis and reliability analysis as failures occur

Proposed Future Work

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Testbed 3Proposed Future Work

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Acknowledgements

• Project Director: Susan Shearer, Stark State College [email protected]

• Educational Project Coordinator: Vern Sproat, P.E. Stark State College; [email protected]

• Steven Sinsabaugh, Lockheed Martin Fellow

• Debbie LaHurd, PhD, Lockheed Martin MS2

• Rob Shutler, Lockheed Martin MS2

• Marc Griffin, Lockheed Martin MS2

• DOE Managers:Greg Kleen, Project OfficerKathi Epping, HQ Technology Manager

mailto:[email protected]�

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Project Summary Relevance: Balance of Plant (BOP): To use hydrogen in fuel cells, a balance must

be engineered for reliability and technician training for fuel cell system.

Approach: Develop BOP testbeds, collaborate with component manufacturers to enhance product performance, and train technical workforce in PEM fuel cell systems.

Technical Accomplishments & Progress: Generation of Test Plan

Students are being trained on the construction and operation of the test bed, and the Hydrogen Safety Plan has been implemented to ensure safe operation of the testbeds with hydrogen.

Technology Transfer/Collaboration: Active partnership with Lockheed Martin and industry dialogue with Parker, Swagelok, National Instruments, Omega Dyne, and others.

Proposed Future Work: Execute Test Plan; construct third reliability testbed with students; begin acquiring real-time, in-situ data; address failure analysis and reliability analysis of BOP components.

fuel cell balance of plant reliability testbed · •start – aug 2008 •finish – july 2011...

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