spring 2011 composite data products arra material handling equipment

NREL is a national laboratory of the U.S. Department of Energy, Office of EnergyEfficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Contract No. DE-AC36-08GO28308

Spring 2011 Composite Data ProductsARRA Material Handling Equipment

J. Kurtz, K. Wipke, S. Sprik, T. Ramsden, C. Ainscough, G. Saur

Technical Report NREL/TP-5600-51577April 2011

NOTICEThis 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.

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Available for sale to the public, in paper, from:U.S. Department of CommerceNational Technical Information Service5285 Port Royal RoadSpringfield, VA 22161phone: 800.553.6847fax: 703.605.6900email: [email protected] ordering: http://www.ntis.gov/help/ordermethods.aspx

Cover Photos: (left to right) PIX 16416, PIX 17423, PIX 16560, PIX 17613, PIX 17436, PIX 17721

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

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.

Spring 2011 Composite Data ProductsARRA Material Handling Equipment

Jennifer Kurtz, Keith Wipke, Sam Sprik, Todd Ramsden, Chris Ainscough, Genevieve Saur

April 6th, 2011

TP-5600-51577

NATIONAL RENEWABLE ENERGY LABORATORY

CDPARRA-MHE-01Fuel Cell MHE Systems Deployed

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

Cu

mu

lati

ve S

yste

ms

1,2 D

eplo

yed

Fuel Cell Units Deployed - ARRA

Class IIIClass IIClass I

NREL cdparra_mhe_01

Created: Mar-10-11 2:18 PM


CDPARRA-MHE-02Fuel Cell System Operation Hours

0

2

4

6

8

10

12

0 200 400 600 8001000

12001400

16001800

20002200

24002600

28003000

>3000

% F

uel

Cel

l S

yste

ms

Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2010Q4

25% of FC Systems > 2360 Hours

FC SystemFleet Average FC System Hours

NREL cdparra_mhe_02

Created: Mar-09-11 6:49 PM Fuel Cell Operation Hours


CDPARRA-MHE-03Fueling Events by Quarter

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40

2000

4000

6000

8000

10000

12000

14000

16000

Fueling Events By Quarter - ARRA

Nu

mb

er o

f F

ills

Cumulative Fuelings = 38,863

0

5

10

15

20

25

Cu

mu

lati

ve F

uel

ing

s [1

000]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_03



CDPARRA-MHE-04Hydrogen Dispensed by Quarter

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40

1000

2000

3000

4000

5000

6000

7000

8000Hydrogen Dispensed By Quarter - ARRA

Hyd

rog

en D

isp

ense

d [

kg]

Cumulative Hydrogen Dispensed = 18,597 kg

0

1

2

3

4

5

6

7

8

9

10

Cu

mu

lati

ve A

mo

un

t [1

000

kg]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_04



CDPARRA-MHE-05Refueling 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

200

400

600

800

1000

1200

1400

1600Refueling Time of Day - ARRA

Time of Day [hours]

Nu

mb

er o

f R

efu

elin

gs

NREL cdparra_mhe_05

Created: Mar-03-11 9:22 AM


CDPARRA-MHE-06Histogram of Fueling Times

0 1 2 3 4 5 6 7 8 9 100

1000

2000

3000

4000

5000

6000

Time (min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling TimesARRA Combined Fleet Through 2010Q4

38,795 Events Average = 1.83 min

NREL cdparra_mhe_06

Created: Mar-23-11 3:38 PM Fill data for class 1, 2, and 3 trucks


CDPARRA-MHE-07Tank Pressure Level at Fueling

Tank Pressure At Fill: ARRA

FE16

%

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 = 10100Median Tank Pressure (At Fill) = 27%


CDPARRA-MHE-08Operation Time between Fueling

0 2 4 6 8 10 120

200

400

600

800

1000

1200

Average: 5.0 hours

Operating Time Between Fuelings - ARRACombined Fleet Through 2010Q4

Operating Hours Between Fuelings1,2

Co

un

t

Range of0

2

4

6

8

Site Averages

Ave

rag

e O

p H

rs b

etw

een

Fu

elin

gs

NREL cdparra_mhe_08

Created: Mar-22-11 10:26 AM Excludes Data > 12 hours

1) 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.


CDPARRA-MHE-09Histogram of Fueling Rates

0 0.2 0.4 0.6 0.8 1 1.20

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

Avg Fuel Rate (kg/min)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling RatesARRA Combined Fleet Through 2010Q4

38,795 Events Average = 0.33 kg/min

Range of0

0.1

0.2

0.3

0.4

0.5

Site Averages

Ave

rag

e F

uel

ing

Rat

es

NREL cdparra_mhe_09

Created: Mar-24-11 9:50 AM Fill data for class 1, 2, and 3 trucks


CDPARRA-MHE-10Histogram of Fueling Amounts

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

1000

2000

3000

4000

5000

6000

Amount Fueled (kg)

Nu

mb

er o

f F

uel

ing

Eve

nts

Histogram of Fueling AmountsARRA Combined Fleet Through 2010Q4

Average = 0.48 kg

NREL cdparra_mhe_10

Created: Mar-23-11 3:35 PM Fill data for class 1, 2, and 3 trucks


CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter

2010 Q1 2010 Q2 2010 Q3 2010 Q40

20000

40000

60000

80000

100000

120000

To

tal O

per

atio

n H

ou

rs

Fuel Cell Operation Hours by Quarter - ARRA

Total Hours = 307,433

0

20

40

60

80

100

120

140

160

180

Cu

mu

lati

ve F

leet

Ho

urs

[10

00]

All FleetsIndividual Fleet

NREL cdparra_mhe_11



CDPARRA-MHE-12Fuel Cell System Maintenance by Category

10%10%

11%

12%

14%

Number of EventsTotal Events = 1149

83% were unscheduled

6%

9%

11%11%

22%

6%

13%

Labor HoursTotal Hours = 1676


THERMAL MANAGEMENT

SENSORS

ENERGY STORAGE SYSTEM

PREVENTATIVE MAINTENANCE

ELECTRICAL

FUEL SYSTEM

CONTROL ELECTRONICS

UPGRADE

SOFTWARE

OTHER

AIR SYSTEM

MISC

NREL cdparra_mhe_12


Fuel Cell System Maintenance By Category - ARRAAll ARRA Sites Thru 2010Q4

MISC includes the following categories:FC STACK

MANUFACTURING DEFECTVALVES

ACTUATORSSERVICE

OPERATOR PROTOCOL


CDPARRA-MHE-13Fuel Cell System Scheduled and Unscheduled Maintenance by Category

0 20 40 60 80 100 120 140 160

MISCAIR SYSTEM

OTHERSOFTWARE

UPGRADECONTROL ELECTRONICS

FUEL SYSTEMELECTRICAL

PREVENTATIVE MAINTENANCEENERGY STORAGE SYSTEM

SENSORSTHERMAL MANAGEMENT

Fuel Cell System Maintenance Scheduled vs. Unscheduled - ARRANumber of Maintenance Events by Category

Number of Events

Total Events = 114983% were unscheduled Scheduled

Unscheduled

0 50 100 150 200 250 300 350 400

MISC

FC STACK

SOFTWARE

CONTROL ELECTRONICS

SENSORS

AIR SYSTEM

FUEL SYSTEM

PREVENTATIVE MAINTENANCE

ELECTRICAL

THERMAL MANAGEMENT


Number of Labor Hours by Category

Hours

Total Hours = 167687% were unscheduled Scheduled

Unscheduled

NREL cdparra_mhe_13


MISC includes the following categories:FC STACK

MANUFACTURING DEFECTVALVES

ACTUATORSSERVICE

OPERATOR PROTOCOL


CDPARRA-MHE-14Average Fuel Cell System Maintenance by Quarter

0

50

100

150

200

250

300

350

400

450Maintenance Events

# o

f E

ven

ts

10Q

1

10Q

2

10Q

3

10Q

4

0

100

200

300

400

500

600

700

Maintenance Hours

Ho

urs

10Q

1

10Q

2

10Q

3

10Q

4

ScheduledUnscheduledOperator

NREL cdparra_mhe_14


Average Fuel Cell System Quarterly Maintenance -ARRA


CDPARRA-MHE-15Operating Time at Fuel Cell Voltage Levels

0 10 20 30 40 50 60 70 80 90 100 >1000

5

10

15

20

25

30

% Rated Max Fuel Cell Voltage

% F

uel

Cel

l Op

erat

ing

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


CDPARRA-MHE-16Operating Time at Fuel Cell Current Levels

0 10 20 30 40 50 60 70 80 90 1000

5

10

15

20

25

30

% Rated Max Fuel Cell Current

% F

uel

Cel

l Op

erat

ing

Tim

e

Operating Time at Fuel Cell Current Levels - ARRA

NREL cdparra_mhe_16



CDPARRA-MHE-17Operating 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

Cel

l Op

erat

ing

Tim

e

Operating Time at Fuel Cell Power Levels - ARRA

NREL cdparra_mhe_17



CDP-MHE-18Infrastructure Maintenance by Category

9%

10%

13%23%

31%

Number of EventsTotal Events = 363


8%

8%

10%

13% 35%

20%

Labor HoursTotal Hours = 2427


H2 production unit

compressor

preventative maintenance

dispenser

system control & safety

valves & piping

MISC

NREL cdp_mhe_18


Infrastructure Maintenance By CategoryAll Sites Thru 2010Q4

MISC includes the following categories:Data collection

electricalother

storage


CDP-MHE-19Infrastructure Scheduled & Unscheduled Maintenance by Category

0 20 40 60 80 100 120

MISC

valves & piping


dispenser


compressor

H2 production unit

Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category

Number of Events

Total Events = 36387% were unscheduled Scheduled

Unscheduled

0 100 200 300 400 500 600 700 800 900

MISC

valves & piping


dispenser


H2 production unit

compressor

Number of Labor Hours by Category

Hours

Total Hours = 242787% were unscheduled Scheduled

Unscheduled

NREL cdp_mhe_19


MISC includes the following categories:Data collection

electricalother

storage


CDP-MHE-20Infrastructure Maintenance by Quarter

0

50

100

150Maintenance Events

# o

f E

ven

ts

10Q

1

10Q

2

10Q

3

10Q

4

0

100

200

300

400

500

600

700

Maintenance Hours

Ho

urs

10Q

1

10Q

2

10Q

3

10Q

4

ScheduledUnscheduled

NREL cdp_mhe_20


Average Infrastructure Site Quarterly Maintenance


CDPARRA-MHE-21Average 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


18597 kg Hydrogen Dispensed


CDPARRA-MHE-22Average 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/s

yste

m

Fill Frequency0

20

40

60

80

100

Avg

Dai

ly f

ills

Fill Frequency0

0.5

1

1.5

Avg

Dai

ly f

ills/

syst

em

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


CDPARRA-MHE-23Average Daily Fuel Cell Operation Hours per Fleet

A B C D E0

1

2

3

4

5

6

7

8

9

10

Fleet

Ho

urs

Average Daily Fuel Cell Operation Hours per System - ARRA

25th and 75th PercentileMedian

NREL cdparra_mhe_23



CDPARRA-MHE-24Average Daily Fuel Cell Operation Hours per System

0 1 2 3 4 5 6 7 8 9 10 11 120

2

4

6

8

10

Hours of Operation Per Day

Day

s o

f O

per

atio

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 Day

Fu

el C

ell S

yste

ms

[%]

Average Daily Fuel Cell System Operation Hours

48.7% Fuel Cell SystemsAverage > 6 Hours Daily

NREL cdparra_mhe_24



CDP-MHE-25Infrastructure Safety Reports by Quarter

2010 Q1 2010 Q2 2010 Q3 2010 Q40

5

10

15

20

25

30

Nu

mb

er o

f R

epo

rts

Infrastructure Safety Reports By Quarter

Incident2

Near Miss1

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)


CDPARRA-MHE-26Fuel Cell System Safety Reports by Quarter

2010 Q1 2010 Q2 2010 Q3 2010 Q40

5

10

15

20

25

30

35

40

45

50

Nu

mb

er o

f R

epo

rts

Fuel Cell System Safety Reports by Quarter - ARRA

Incident2

Near Miss1

NREL cdparra_mhe_26


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)


CDPARRA-MHE-27Fuel Cell System Safety Reports by Severity and Type

0 10 20 30 40 50 60

Incident

Near Miss

Number of Reports

Sev

erit

y

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


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


CDP-MHE-28Fuel Cell System Reliability Growth by Site for Quarter


CDP-MHE-29Fuel Cell System Reliability Growth by Top 4 Categories

0

0.5

1

1.5

2

2.5

3

Average Vehicle Operating Hours

Sh

ape

Par

amet

er (

)*


Failure Rate Increasing

Failure Rate Decreasing

Fleet

0

0.5

1

1.5

2

2.5

3


Sh

ape

Par

amet

er (

)*

THERMAL MANAGEMENT



Fleet

0

0.5

1

1.5

2

2.5

3


Sh

ape

Par

amet

er (

)*

OPERATOR PROTOCOL



Fleet

0

0.5

1

1.5

2

2.5

3


Sh

ape

Par

amet

er (

)*

SENSORS



Fleet

NREL cdp_mhe_29

Created: Apr-05-11 4:40 PM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164


CDP-MHE-30Fuel Cell System Mean Time Between Failure


CDP-MHE-31Fuel Cell System Mean Time Between Scheduled Maintenance

0 1000 2000 3000 4000 5000 60000

2

4

6

8

10

12

14

16

18

20

Unit MTBSM1

% o

f u

nit

s

Individual Unit MTBSM1 All Sites

0 1000 2000 3000 4000 5000 60000

2

4

6

8

10

Unit MTBPM2

% o

f u

nit

s

Individual Unit MTBPM2 All Sites

0 1000 2000 3000 4000 5000 60000

2

4

6

8

10

Unit MTBU3

% o

f u

nit

s

Individual Unit MTBU3 All Sites

NREL cdp_mhe_31

Created: Apr-05-11 1:41 PM

1Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades

2Mean Time Between PreventativeMaintenance

3Mean Time Between Upgrade


CDP-MHE-32 Site Operation Hours and Voltage Durability

Site Max Op Hours(1) Site Ave Op Hours(1)0

2000

4000

6000

8000

10000

4842

3959

Max of Site Projections59519

Ave of Site Projections53002

Ho

urs

Operation Hours and Projected Hours to 10% Voltage Drop(2-4)

NREL cdp_mhe_32


(1) Range bars created using one data point for each fleet. Some stacks have accumulated hours beyond 10% voltage degradation.(2) 10% voltage drop level is a DOE metric for assessing fuel cell performance.(3) Projections using field data and calculated at a high stack current.(4) 10% voltage drop is NOT an indication of an OEM's end-of-life criteria and projections do not address catastrophic stack failure.(5) Each site has one voltage projection value that is the weighted average of the site's fuel cell stack projections.


CDP-MHE-33 Fuel Cell Stack Voltage Durability as a Function of Voltage Drop Levels

10 15 20 25 300

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Fuel Cell Stack Durability as a Function of Voltage Drop4

% Voltage Drop

Pro

ject

ed H

ou

rs2,

3

25th/75th Quartile Projections3,5

Average Fleet Projection1,5

Max Fleet Projection1,5

NREL cdp_mhe_33


(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life cri teria.(2) Projections using field data and calculated at high stack current.(3) 25th and 75th percentiles spans the range of stack projection. The included stacks satisfy a minimum number of operation hours and weighting factor.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) Each site has one voltage projection value that is the weighted average of the sites's fuel cell stack projections.


CDP-MHE-34 Fuel Cell Stack Power Degradation over Time

0

20

40

60

80

100

120

0 200 400 600 800 1000120014001600180020002200240026002800300032003400360038004000Stack Op Hour Segments(2)

% P

ow

er(1

)

Max Fuel Cell Stack Power Degradation Over Operation

1) Normalized by fleet maximum power.2) Each segment point is median FC power (+-100 hrs). Box not drawn if fewer than 3 points in segment.

Data Range25th & 75th PercentilesGroup MedianOutlier

NREL cdp_mhe_34


Median power differencefrom 0 hour segment to3800 hour segment = -12.2%


CDPARRA-MHE-35Dispensed Hydrogen by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

5

10

15

20

25Refueling by Day of Week

% o

f F

ills

in a

Day

DayNREL cdparra_mhe_35



CDPARRA-MHE-37Fuel Cell System Downtime

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 180

20

40

60

80

100

120

Average of 2.3 hours of downtimefrom refueling each month

Refueling Downtime1 (in hours) per Month

Fre

qu

ency

[M

on

ths]

Refueling Downtime Per Material Handling Unit

Fleet Averages

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150

20

40

60

80

Average of 2.5 hours of downtimefrom refueling per 100 hours of operation

Refueling Downtime (in hours) per 100 Operational Hours

Fre

qu

ency

[U

nit

s]

Fleet Averages

NREL cdparra_mhe_37


1 Refueling downtime represents total refueling time from "drive-up" to "drive-away" not only hydrogen gas dispensing time

Note: Some refueling events not recorded/included due to data noise or incompleteness


CDPARRA-MHE-40Site Summary

Forklift Units (I,II,III) 0,26,72 0,14,0 35,0,0 25,0,0 45,14,2 0,36,100 40,0,0 0,25,70Operation

Shifts per Day 2 2 3 1-2 3 2 2 3Hours per Shift 8-10 9.5 8 10 8 8-10 8 8Days per Week 6 N/A N/A 7 7 6 6 6


CDP-MHE-41Infrastructure Safety Categories

0 2 4 6 8 10 12 14 16

Incident

Near Miss

Number of Reports

Sev

erit

y

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


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


CDP-MHE-42Amount of Hydrogen Dispensed by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

2

4

6

8

10

12

14

16

18

20

Dis

pen

sed

Hyd

rog

en [

% o

f to

tal]

Day of Week

Dispensed Hydrogen per Day of Week

0

5

10

15

20

25

30

35

40

45

50

Ave

rag

e kg

All SitesIndividual Site

NREL cdparra_mhe_42


spring 2011 composite data products arra material handling equipment

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