Next Generation Hydrogen Station Composite Data Products: All Stations (Retail and Non-Retail Combined)

Data through Quarter 4 of 2016 Sam Sprik, Jennifer Kurtz, Chris Ainscough, Genevieve Saur, and Michael Peters May 10, 2017

NREL/PR-5400-68554

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• Air Liquide • Air Products • California Air Resources Board • California Energy Commission • California State University Los

Angeles • First Element • Gas Technology Institute • Linde • H2 Frontier • Proton OnSite • Shell • IPHE and HySUT

Hydrogen Station Project Partners

3

Deploy

Analysis Categories

Energy

Cost Safety

Reliability

Utilization

Quality

Performance

Deployment

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CDP-INFR-10 Cumulative Number of Stations

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CDP-INFR-11 Hydrogen Stations by Type

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CDP-INFR-27 Hydrogen Station Timeline

Safety

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• Alarms not communicated • Breakaway leak • Check compressor oil filter • Check integrity of delivered equipment • Compressor leaking at startup normal? • Does isolated leak need to shut down station? • Electrical glitch • Estop activated after hearing escaping gas-nitrogen • Estop activated when nozzle stuck on car • Estop activated without cause • Estop flooded prevented restart • False alarm - No Fire • Fill and leak check together caused shutdown - false

leak alarm • Filter to catch scrap from material processing • Forgot to turn back on after maintenance • Freezing and thawing caused moisture in

communication connector • Frozen cooling block - defrost • HTO sensor fault

Safety (and Maintenance) Learnings From Safety Reports Template

• Heat trace short caused false fire alarm • Heavy rain triggered fire alarm • Hose vent failure - nozzle stuck on car • Loose wire intermittent problems • Loud popping could be relief valve • Mass balance alarm bug • Mass balance alarm caused by high ambient

temperature • Power Issue - 3 Phase • Predict service life better • Proper installation prevents leaks • Rain on sensor causing alarm • Regular inspection of compressor valves • Regular leak checks • Regular station inspection • Reset • Spider web obscuring sensor • Thermocouple failure shutdown station • Vibration from normal activity shutdown

dispenser • Vibration isolation

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CDP-INFR-31 Safety Reports Primary Factors

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CDP-INFR-32 Safety Reports by Equipment Involved

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CDP-INFR-33 Safety Reports by Quarter

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CDP-INFR-34 Safety Reports by Event Description

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CDP-INFR-48 Mean Fills per Hydrogen Leak

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CDP-INFR-54 Mean Hydrogen Dispensed per Hydrogen Leak

Maintenance and Reliability

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CDP-INFR-21 Maintenance by Equipment Type

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CDP-INFR-22 Maintenance Labor Hours per Event

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CDP-INFR-23 Equipment Category Repair Time

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CDP-INFR-24 Failure Modes for Top Equipment Categories

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CDP-INFR-26 Compressor Monthly Maintenance

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CDP-INFR-28 Maintenance Labor Hours by Month

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CDP-INFR-30 Maintenance Costs Over Time

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CDP-INFR-49 Mean Fills Between Failures

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CDP-INFR-50 Reliability Growth by Fills

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CDP-INFR-51 Mean Amount Dispensed Between Failures

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CDP-INFR-52 Reliability Growth by Amount Dispensed

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CDP-INFR-59 Historical Failure Rate by Fills

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CDP-INFR-60 Historical Failure Rate by Amount Dispensed

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CDP-INFR-62 Mean Fills per Hydrogen Leak Over Time

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CDP-INFR-63 Mean Hydrogen Dispensed per Leak Over Time

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CDP-INFR-64 Maintenance Causes and Effects: Safety (Entire)

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CDP-INFR-65 Maintenance Causes and Effects: Safety (Sensor)

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CDP-INFR-66 Maintenance Causes and Effects: Safety (Software)

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CDP-INFR-67 Maintenance Causes and Effects: Dispenser (Entire)

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CDP-INFR-68 Maintenance Causes and Effects: Dispenser (Valve)

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CDP-INFR-69 Maintenance Causes and Effects: Dispenser (Software)

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CDP-INFR-70 Maintenance Causes and Effects: Compressor (Entire)

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CDP-INFR-71 Maintenance Causes and Effects: Compressor (Valve)

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CDP-INFR-72 Maintenance Causes and Effects: Compressor (Seal)

Performance

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CDP-INFR-01 Hydrogen Dispensed by Quarter

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CDP-INFR-58 Hydrogen Fills by Quarter

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CDP-INFR-81 Hydrogen Dispensed by Region

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CDP-INFR-02 Histogram of Fueling Rates

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CDP-INFR-03 Histogram of Fueling Times

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CDP-INFR-04 Histogram of Fueling Amounts

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CDP-INFR-08 Time Between Fueling

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CDP-INFR-09 Fueling Final Pressures

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CDP-INFR-12 Fueling Rates 350 bar vs. 700 bar

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CDP-INFR-13 Number of Fueling Events per Hour

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CDP-INFR-14 Hydrogen Dispensed per Hour

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CDP-INFR-15 Number of Fills by Time of Day

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CDP-INFR-16 Fueling Amounts per Time of Day

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CDP-INFR-17 Fueling Rates by Amount Filled

0 0.5 1 1.5 2 2.5 3

Average Fuel Rate [kg/min]

0

500

1000

1500

2000

2500

3000

Num

ber o

f Fue

ling

Even

ts

Histrogram of Fueling Rates by Amounts

0 to 0.5 kg0.5 to 1 kg1 to 2 kg2 to 4 kg4 to 6 kg2020 MYRDD TargetUltimate MYRDD Target

NREL

Created: May-08-17 4:56 P

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CDP-INFR-18 Fueling Amount vs. Time to Fill

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CDP-INFR-56 Fueling Rates by Year

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CDP-INFR-29 Monthly Averages: 700 bar Fills >1 kg with Pre-Cool of -20°C

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CDP-INFR-55 Monthly Averages: All Fills

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CDP-INFR-57 Monthly Averages: 700 bar Fills >1 kg with Pre-Cool of -40°C

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CDP-INFR-77 Fuel Temperature at Receptacle 30 s After Start of Fill

Cost

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CDP-INFR-39 Compressor Operation Cost

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CDP-INFR-40 Station Costs by Daily Capacity

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CDP-INFR-41 Average Station Cost by Category

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CDP-INFR-42 Station Cost

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CDP-INFR-43 Station Cost by Type

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CDP-INFR-73 Monthly Maintenance Costs

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CDP-INFR-53 Maintenance Cost per kg of Hydrogen Dispensed

Utilization

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CDP-INFR-05 Dispensed Hydrogen per Day of Week

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CDP-INFR-06 Station Capacity Utilization

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CDP-INFR-07 Station Usage

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CDP-INFR-19 Hydrogen Dispensed by Month

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CDP-INFR-20 Number of Fills by Month

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CDP-INFR-74 Hydrogen Dispensed by Station Type

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CDP-INFR-44 Station Capacity Utilization Trends by Quarter

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CDP-INFR-45 Station Amount Dispensed by Quarter

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CDP-INFR-46 Days with Fills by Quarter

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CDP-INFR-47 Summary of Station Usage Statistics

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CDP-INFR-80 Daily Fueling Amounts by Station

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CDP-INFR-82 Daily Fueling Amounts by Month

Hydrogen Quality

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CDP-INFR-25 Hydrogen Quality

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CDP-INFR-79 Impurities—Ammonia

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CDP-INFR-79 Impurities—Argon

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CDP-INFR-79 Impurities—Carbon Dioxide

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CDP-INFR-79 Impurities—Carbon Monoxide

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CDP-INFR-79 Impurities—Formaldehyde

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CDP-INFR-79 Impurities—Formic Acid

91

CDP-INFR-79 Impurities—Helium

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CDP-INFR-79 Impurities—Nitrogen

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CDP-INFR-79 Impurities—Oxygen

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CDP-INFR-79 Impurities—Particulate Concentration

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CDP-INFR-79 Impurities—Total Halogenates

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CDP-INFR-79 Impurities—Total Hydrocarbons

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CDP-INFR-79 Impurities—Total Sulfur

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CDP-INFR-79 Impurities—Water

Component Energy

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CDP-INFR-35 Compressor Energy

101

CDP-INFR-36 Electrolyzer Energy

102

CDP-INFR-78 Station Energy per kg Dispensed