arra material handling equipment composite data products data through quarter 4 of 2012

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

ARRA Material Handling Equipment Composite Data Products

Data Through Quarter 4 of 2012

J. Kurtz, S. Sprik, C. Ainscough, G. Saur, M. Post, M. Peters, and T. Ramsden

Technical Report NREL/TP-5600-58612May 2013

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.

Available electronically at http://www.osti.gov/bridgeAvailable for a processing fee to U.S. Department of Energyand its contractors, in paper, from:U.S. Department of EnergyOffice of Scientific and Technical InformationP.O. Box 62Oak Ridge, TN 37831-0062phone: 865.576.8401fax: 865.576.5728email: mailto:[email protected]

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.

3

CDPARRA-MHE-01Fuel Cell 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

136

206 206

308

402

467

504 504 504 504 504 504

Cu

mu

lati

ve S

yste

ms

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

Class IIIClass IIClass IRetired Class II

NREL cdparra_mhe_01

Created: Apr-01-13 3:18 PM | Data Range: 2010Q1-2012Q4

4

CDPARRA-MHE-02Fuel 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

50

>825

0

% F

uel

Cel

l S

yste

ms

Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2012Q4

25% of FC Systems > 6,120 Hours

FC SystemRetired FC SystemFleet Average FC System Hours

NREL cdparra_mhe_02

Created: Apr-01-13 3:18 PM | Data Range: 2010Q1-2012Q4 Fuel Cell Operation Hours

5

CDPARRA-MHE-03Fueling Events by Quarter

0

5

10

15

20

25

30

35

2009Q1

2009Q2

2009Q3

2009Q4

2010Q1

2010Q2

2010Q3

2010Q4

2011Q1

2011Q2

2011Q3

2011Q4

2012Q1

2012Q2

2012Q3

2012Q4

Fueling Events By Quarter - ARRA

Nu

mb

er o

f F

ills

[1,0

00]

Cumulative Fuelings = 246,997

0

10

20

30

40

50

60

70

80

90

Cu

mu

lati

ve F

uel

ing

s [1

,000

]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_03


6

CDPARRA-MHE-04Hydrogen Dispensed by Quarter

0

5

10

15

20

25

30

2009Q1

2009Q2

2009Q3

2009Q4

2010Q1

2010Q2

2010Q3

2010Q4

2011Q1

2011Q2

2011Q3

2011Q4

2012Q1

2012Q2

2012Q3

2012Q4

Hydrogen Dispensed By Quarter - ARRA

Hyd

rog

en D

isp

ense

d [

1,00

0 kg

]

Cumulative Hydrogen Dispensed = 187,426 kg

0

5

10

15

20

25

30

35

40

45

50

Cu

mu

lati

ve A

mo

un

t [1

,000

kg

]

All Sites By QuarterCumulative By Site

NREL cdparra_mhe_04


7

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

1000

2000

3000

4000

5000

6000

7000

8000

9000Refueling Time of Day - ARRA

Time of Day [hours]

Nu

mb

er o

f R

efu

elin

gs

NREL cdparra_mhe_05


8

CDPARRA-MHE-06Histogram of Fueling Times

0 1 2 3 4 5 6 7 8 9 100

5

10

15

20

25

Time (min)

Nu

mb

er o

f F

uel

ing

Eve

nts

[1,

000]

Histogram of Fueling TimesARRA Combined Fleet

220,979 Events Average = 2.28 min

Range of0

1

2

3

4

5

Site Averages

Ave

rag

e F

uel

ing

Tim

es (

min

)NREL cdparra_mhe_06

Created: Apr-01-13 3:35 PM | Data Range: 2010Q1-2012Q4 Fill data for class 1, 2, and 3 trucks

9

CDPARRA-MHE-07Tank Pressure Level at Fueling

Tank Pressure At Fill: ARRA

FE

23%

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 = 89,585Median Tank Pressure (At Fill) = 26%

10

CDPARRA-MHE-08Operation Time between Fueling

0 2 4 6 8 10 120

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

Average: 4.6 hours

Operating Time Between Fuelings - ARRACombined Fleet

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: Apr-01-13 3:41 PM | Data Range: 2010Q1-2012Q4 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.

11

CDPARRA-MHE-09Histogram of Fueling Rates

0 0.2 0.4 0.6 0.8 1 1.20

5

10

15

20

25

Avg Fuel Rate (kg/min)

Nu

mb

er o

f F

uel

ing

Eve

nts

[1,

000]

Histogram of Fueling RatesARRA Combined Fleet

220,979 Events Average = 0.32 kg/min

Range of0

0.2

0.4

0.6

0.8

1

Site Averages

Ave

rag

e F

uel

ing

Rat

es (

kg/m

in)

NREL cdparra_mhe_09


12

CDPARRA-MHE-10Histogram of Fueling Amounts

0 0.5 1 1.5 20

2

4

6

8

10

12

14

16

18

20

Amount Fueled (kg)

Nu

mb

er o

f F

uel

ing

Eve

nts

[1,

000]

Histogram of Fueling AmountsARRA Combined Fleet

Average = 0.64 kg

Range of0

0.5

1

1.5

2

Site Averages

Ave

rag

e F

uel

ing

Am

ou

nts

(kg

)

NREL cdparra_mhe_10


13

CDPARRA-MHE-11Fuel 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

To

tal

Op

erat

ion

Ho

urs

[1,

000]

Fuel Cell Operation Hours by Quarter - ARRA

Total Hours = 1,445,558

0

50

100

150

200

250

300

350

400

450

500

Cu

mu

lati

ve F

leet

Ho

urs

[10

00]

All FleetsIndividual Fleet

NREL cdparra_mhe_11

Created: Apr-02-13 10:22 AM | Data Range: 2009Q4-2012Q4

14

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

35

40

45

% 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

15

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


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


17

CDP-MHE-18Infrastructure Maintenance by Category

5%5%

7%

7%

12%

13% 15%

35%

Total Events = 1,4251

71% unscheduled

entiresystem

46

misc 136

multiplesystems

227

classified

events1 1016

Event Count

6%

7%

17%

14%

50%

Total Hours = 8,19467% unscheduled

hydrogen compressor

control electronics

dispenser

feedwater system

air system

electrical

valves

reformer

NREL cdp_mhe_18


Infrastructure Maintenance By Equipment Type

MISC includes the following failure modes: actuators, safety, seal, storage,unspecified, software, thermal management, fuel system, fittings&piping,

sensors, other

18

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

0 50 100 150 200 250 300 350 400

MISC

SENSORS

REFORMER

VALVES

ELECTRICAL

AIR SYSTEM

FEEDWATER SYSTEM

DISPENSER

CONTROL ELECTRONICS

ENTIRE SYSTEM

HYDROGEN COMPRESSOR

Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category

Number of Events

Total Events = 1,42571% were unscheduled

Scheduled

Total

0 500 1000 1500 2000 2500 3000

MISC

FITTINGS&PIPING

MULTIPLE SYSTEMS

SENSORS

VALVES

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ENTIRE SYSTEM

HYDROGEN COMPRESSOR

Number of Labor Hours by Category

Hours

Total Hours = 8,19466% were unscheduled Scheduled

Total

NREL cdp_mhe_19


MISC includes the following categories:ACTUATORS

SAFETYSEAL

STORAGEOTHER

UNSPECIFIEDSOFTWARE

THERMAL MANAGEMENTFUEL SYSTEM

FITTINGS&PIPINGMULTIPLE SYSTEMS

19

CDP-MHE-20Infrastructure Maintenance by Quarter

0

2

4

6

8

10

12

14

16

18

20Maintenance Events

Ave

rag

e #

of

Eve

nts

Per

Th

ou

san

d F

ills

09Q

109

Q2

09Q

309

Q4

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

12Q

112

Q2

12Q

312

Q4

0

20

40

60

80

100

120

140Maintenance Hours

Ave

rag

e H

ou

rs P

er T

ho

usa

nd

Fill

s

09Q

109

Q2

09Q

309

Q4

10Q

110

Q2

10Q

310

Q4

11Q

111

Q2

11Q

311

Q4

12Q

112

Q2

12Q

312

Q4

ScheduledUnscheduledOperator

NREL cdp_mhe_20


Average Infrastructure Site Quarterly Maintenance

20

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


186,963 kg Hydrogen Dispensed

21

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

22

CDPARRA-MHE-23Average 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

Ho

urs

Average Daily Fuel Cell Operation Hours per System - ARRA

25th and 75th PercentileMedian

NREL cdparra_mhe_23


23

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

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

5

10

15

Hours of Operation Per Day1

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 Day1

Fu

el C

ell S

yste

ms

[%]

Average Daily Fuel Cell System Operation Hours

51.3% Fuel Cell SystemsAverage > 6 Hours Daily

NREL cdparra_mhe_24

Created: Apr-01-13 4:04 PM | Data Range: 2010Q1-2012Q4 1) Excludes 0 hour operation days

24

CDP-MHE-25Infrastructure Safety Reports by Quarter

0

5

10

15

20

25

30

Eve

nts

Rep

ort

ed

0

24

48

73

97

121

145Infrastructure Safety Reports By Quarter

Hu

nd

red

s o

f F

ills

Per

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

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: 213,978

Total Reports: 82Lifetime kg H

2 Dispensed per Report: 2,609

25

CDPARRA-MHE-35Refuel Events 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


26

CDP-MHE-41Infrastructure Safety Categories

0 10 20 30 40 50 60 70

Incident

Near Miss

Number of Reports

Sev

erit

y

Infrastructure Safety Reports by Severity - All Sites and Report Type

Number of Fueling Events: 294,118Number of Safety Reports: 82Fuelings Per Report: 3,587

Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Minor, YES IgnitionH2 Release - Significant, NO IgnitionNon-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-42Amount of Hydrogen Dispensed by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

5

10

15

20

Dis

pen

sed

Hyd

rog

en [

% o

f to

tal]

Day of Week

Dispensed Hydrogen per Day of Week

0

30

60

90

120

108 kg/day avg

Dai

ly A

vera

ge

[kg

]

All SitesIndividual Site

NREL cdparra_mhe_42


28

CDP-MHE-44Infrastructure 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

5

10

15

20

25

30

Labor Hours Per Event

Fre

qu

ency

(%

of

tota

l)

Breakdown of Maintenance Event Labor Hours: Infrastructure

NREL cdp_mhe_44

0

20

40

60

80

100

Sites

Eve

nt

Lab

or

(hrs

)

Maximum and Mean Event Labor Hoursfor each site.

MeanMax

NREL cdp_mhe_44


>24

50% of repairs require less than the mean of 7.2 hours of labor.Median labor hours: 7.1

29

CDPARRA-MHE-45Infrastructure Reliability Growth

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Sh

ape

Par

amet

er (

)1

Overall Site Infrastructure Reliability Growth: ARRA

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

Ins

tan

tan

eou

s M

TB

F

Instantaneous MTBF (Days)

sites

NREL cdparra_mhe_45


Sites sorted by Increasing Age(Calendar Days)

Fa

ilure

Ra

te In

cre

asi

ng

Fa

ilure

Ra

te D

ecr

ea

sin

g

Instantaneous MTBF improved for 2 of 6 sites for the last 20% of events.

51%2

-53%2

107%2

-47%2

-25%2

-57%2

30

CDP-MHE-46Infrastructure Equipment Category of Safety Events

5%

19%

22%

44%

By Number of ReportsTotal Near Miss Reports = 63

6%6%

88%

By Number of IncidentsTotal Incidents = 16hydrogen compressor

fittings & piping

dispenser

seal

valves

reformer

Misc

NREL cdp_mhe_46


Safety Reports By Equipment Category: Infrastructure

MISC includes the following categories:FUEL SYSTEM

OTHER

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-47Infrastructure Maintenance by Mode

5%

5%

6%

7%

7%

8%8%

10%

14%

14%


71% unscheduled

upgrade 54

misc 266

preventativemaintenance

353

classified

events1 752

Event Count

6%

11%

6%

11%

12%

9%

17%

12%


data error

replace failed parts

flow low

out of calibration

inspect trouble alarm or report

pressure high

hydrogen leak

pressure low

fluid leak_non_hydrogen

metal fatigue

temperature high

flow high

excessive noise

failed closed

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, voltage

low, cleanup device failed, electrical short, maintenance error, networkmalfunction, fluid leak non-hydrogen, broken wire, manufacturing defect,

ambient temperature too low, drive off, power outage, unspecifiedelectronics failure, failed open, software bug, lightning strike, moisture

infiltration, operator protocol, other

32

CDP-MHE-48Infrastructure Mean Time Between Failures

0 25 50 75 100 125 150 1750

1

2

3

4

5

6

7

8

9

10

Site MTBF1 (Days)

Co

un

t o

f S

ites

Site MTBF (Calendar Days In Operation): Infrastructure

NREL cdp_mhe_48


1. Cumulative Mean Time Between Failure

33

CDP-MHE-49Infrastructure Mean Time Between Scheduled Maintenance

0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 4250

1

2

3

4

5

6

7

8

9

10

Site MTBSM1 (Days)

Co

un

t o

f S

ites

Site MTBSM by Calendar Days In Operation: Infrastructure

0 50 100 150 200 250 300 350 4000123456789

10

Site MTBPM2 (Days)C

ou

nt

of

Sit

es

Individual Site MTBPM2 All Sites

0 25 50 75 100 125 150 175 200 2250

1

2

3

4

5

Site MTBU3 (Days)

Co

un

t o

f S

ites

Individual Site MTBU3 All Sites

NREL cdp_mhe_49


1. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades

2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade

34

CDP-MHE-50Infrastructure Reliability Growth by Category

0

0.5

1

1.5

2

2.5

3

3.5

4

Calendar Days In Operation

Sh

ape

Par

amet

er (

)*

ELECTRICAL

Failure Rate Increasing

Failure Rate Decreasing

Site

0

0.5

1

1.5

2

2.5

3

3.5

4


Sh

ape

Par

amet

er (

)*

VALVES



Site

0

0.5

1

1.5

2

2.5

3

3.5

4


Sh

ape

Par

amet

er (

)*

HYDROGEN COMPRESSOR



Site

0

0.5

1

1.5

2

2.5

3

3.5

4


Sh

ape

Par

amet

er (

)*

AIR SYSTEM



Site

NREL cdp_mhe_50

Created: Apr-02-13 9:48 AM | Data Range: 2009Q1-2012Q4 *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164 These represent the top four equipment failure categories from all combined data.

35

CDP-MHE-51Infrastructure Hydrogen Leaks by Equipment Type

6%

6%

6%

18%

24%

39%

Total Events = 521

100% unscheduled

misc 1

classified1

events51

Event Count

6%

7%

24%

23%

35%

Total Hours = 469100% unscheduled

hydrogen compressor

dispenser

fittings&piping

valves

seal

reformer

storage

NREL cdp_mhe_51


Hydrogen Leaks By Equipment Category: Infrastructure

36

CDP-MHE-52Infrastructure Failures by Mode

0 50 100 150 200 250 300 350

HYDROGEN COMPRESSOR

CONTROL ELECTRONICS

DISPENSER

AIR SYSTEM

Event Count

50%*

23%*

19%*

8%*

DATA ERROR

DRIVE OFF

EXCESSIVE NOISE

FAILED CLOSED

HYDROGEN LEAK

INSPECT TROUBLE ALARM OR REPORT

LIGHTNING STRIKE

METAL FATIGUE

MOISTURE INFILTRATION

OPERATOR PROTOCOL

OUT OF CALIBRATION

PRESSURE LOW

REPLACE FAILED PARTS

MISC

0 500 1000 1500 2000 2500

HYDROGEN COMPRESSOR

CONTROL ELECTRONICS

DISPENSER

AIR SYSTEM

Labor Hours

56%*

17%*

19%*

8%*

NREL cdp_mhe_52


Failure Modes for Top Four Infrastructure Equipment Categories

* Percentage of total events or hours, reference CDP 66.

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

high, flow low, fluid leak non-hydrogen, fluid leak non_hydrogen, fluidleak_non_hydrogen, inspect trouble alarm or report, maintenance error, manufacturing

defect, metal fatigue, moisture infiltration, network malfunction, operator protocol, other,power outage, pressure high, pressure low, replace failed parts, software bug,temperature high, unspecified electronics failure, vandalism, voltage low, other

37

CDP-MHE-55Infrastructure Mean Time Between Safety Events

0 25 50 75 100 125 150 175 200 225 250 275 300 325 3500

1

2

3

4

5

Site MTBSE1 (Calendar Days in Operation)

Co

un

t o

f S

ites

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)

Co

un

t o

f S

ites

Mean Calendar Days Between Incidents

0 100 200 300 400 500 6000

1

2

3

4

5

Site MTBSNM3 (Calendar Days in Operation)

Co

un

t o

f S

ites

Mean Calendar Days Between Near Miss

NREL cdp_mhe_55


1. Cumulative Mean Time Between Safety Report (days)

2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)

38

CDPARRA-MHE-62Final 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 F

uel

ing

Eve

nts

Fueling Final Pressures

Avg Final Pressure = 255 bar% of Fills > 250 bar = 70%Number of Fills = 142374

Avg Final Pressure = 355 bar% of Fills > 350 bar = 53%Number of Fills = 53705

AverageNominal

NREL cdparra_mhe_62

Created: Apr-02-13 8:03 AM | Data Range: 2010Q1-2012Q4 *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-65Details of Back-to-Back Fills

<0 0 2 4 6 8 10 12 14 16 18 200

5

10

15

20

25

30

S

imu

ltan

eou

s F

ills

Back-to-Back Fills

36 % of fills are within 0-5 minutes of each other23 % of fills have more than 20 minutes between them228912 Total Fills

Time Between Fuelings* [min]

# o

f F

uel

ing

s [%

of

tota

l]

Histogram of Time Between Fuelings

All Sites CombinedIndividual Sites

200 225 250 275 300 325 350 375 400 425 4500

1

2

3

4

5x 10

4 Final Pressures for Fills with <5 Minutes in Between

# o

f F

uel

ing

s

Final Pressure [bar]

Previous FillNext Fill

NREL cdparra_mhe_65

Created: Apr-02-13 8:12 AM | Data Range: 2010Q1-2012Q4 *Time is from end of fill to start of next fill.

40

CDP-MHE-66Infrastructure Maintenance for Delivered Hydrogen

8%

19%

23%

50%


64% unscheduled

entiresystem

46

misc 124

multiplesystems

221

classified

events1 667

Event Count

8%

19%

17%

56%


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, safety,thermal management, storage, electrical, software, fittings&piping, valves,

sensors, other

41

CDP-MHE-67Infrastructure Maintenance by Month

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec0

20

40

60

80

100

120

140

160

Month

Co

un

t o

f M

ain

ten

ance

Eve

nts

Infrastructure Maintenance by Month

UnscheduledScheduled

NREL cdp_mhe_67


42

CDPARRA-MHE-68Fill Counts per Hours

0 5 10 15 20 25 30 35 40 450

2

4

6

8

10

12

Number of Fuelings in an Hour

Fre

qu

ency

[%

of

tota

l]

Number of Fuelings Per Hour - ARRA

NREL cdparra_mhe_68


Average: 7.3 per hourMedian: 5.0 per hourMax: 39.0 per hour

43

CDPARRA-MHE-69Fill 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]

Fre

qu

ency

[%

of

tota

l]

Hydrogen Dispensed Per Hour - ARRA

NREL cdparra_mhe_69


Average: 4.8 kgs per hourMedian: 3.5 kgs per hourMax: 52.5 kgs per hour

44

CDPARRA-MHE-70Station Usage

1 2 3 4 5 6 7 80

50

100

150

200

250

Station (Sorted By Increasing Max Daily Amount)

Fill

s P

er D

ay

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-71Station 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

acit

y U

tiliz

atio

n2 [

%]

Station Capacity Utilization

Max Daily20 kg

Max Daily25 kg

Max Daily64 kg

Max Daily99 kg

Max Daily102 kg

Max Daily135 kg

Max Daily293 kg

Max Daily358 kg

42.9%

Average Daily Utilization1

Maximum Daily Utilization

NREL cdparra_mhe_71NREL 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-72Component MTBF

0

50

100

150

200

250

AIR S

YSTEM

CONTROL E

LECTRONICS

DISPENSER

FITTIN

GS&PIPIN

G

HYDROGEN COM

PRESSOR

VALVES

MT

BF

(D

ays)

MTBF by Equipment Category: Infrastructure (Delivered H2 Only)

Median SiteLowest Site

NREL cdparra_mhe_72


47

CDP-MHE-97Projected 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

Sta

cks

[%]

In Service

Not 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 through quarter 4 of 2012

Documents