ARRA Material Handling Equipment Composite Data Products Data through Quarter 4 of 2013
ARRA MHE Composite Data Products for Data Through 2011 Q4
description
Transcript of ARRA MHE Composite Data Products for Data Through 2011 Q4
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.
ARRA MHE Composite Data Products for Data Through 2011 Q4
Jennifer Kurtz, Keith Wipke, Sam Sprik, Todd Ramsden, Chris Ainscough, Genevieve Saur
April 04, 2012
2
CDPARRA-MHE-01Fuel Cell MHE Systems Deployed
2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40
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
136
206 206
308
402
467
504 504
Cu
mu
lati
ve S
yste
ms
Dep
loye
d
Fuel Cell Units Deployed - ARRA
Class IIIClass IIClass I
NREL cdparra_mhe_01
Created: Apr-04-12 5:16 PM
3
CDPARRA-MHE-02Fuel Cell System Operation Hours
0
1
2
3
4
5
6
7
8
9
10
02004006008001000
12001400
16001800
20002200
24002600
28003000
32003400
36003800
40004200
44004600
48005000
52005400
56005800
60006200
>6200
% F
uel
Cel
l S
yste
ms
Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2011Q4
25% of FC Systems > 4,860 Hours
FC SystemRetired FC SystemFleet Average FC System Hours
NREL cdparra_mhe_02
Created: Mar-12-12 4:41 PM Fuel Cell Operation Hours
4
CDPARRA-MHE-03Fueling Events by Quarter
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q4 2011Q1 2011Q2 2011Q3 2011Q40
5
10
15
20
25
30
35Fueling Events By Quarter - ARRA
Nu
mb
er o
f F
ills
[100
0]
Cumulative Fuelings = 148,251
0
10
20
30
40
50
60
Cu
mu
lati
ve F
uel
ing
s [1
000]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_03
Created: Mar-14-12 4:21 PM
5
CDPARRA-MHE-04Hydrogen Dispensed by Quarter
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q4 2011Q1 2011Q2 2011Q3 2011Q40
5
10
15
20
25
30
35Hydrogen Dispensed By Quarter - ARRA
Hyd
rog
en D
isp
ense
d [
1000
kg
]
Cumulative Hydrogen Dispensed = 104,916 kg
0
5
10
15
20
25
30
35
Cu
mu
lati
ve A
mo
un
t [1
000
kg]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_04
Created: Mar-14-12 4:23 PM
6
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
6000Refueling Time of Day - ARRA
Time of Day [hours]
Nu
mb
er o
f R
efu
elin
gs
NREL cdparra_mhe_05
Created: Mar-14-12 4:52 PM
7
CDPARRA-MHE-06Histogram of Fueling Times
0 1 2 3 4 5 6 7 8 9 100
2000
4000
6000
8000
10000
12000
14000
16000
18000
Time (min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling TimesARRA Combined Fleet Through 2011Q4
140,959 Events Average = 2.18 min
Range of0
1
2
3
4
5
Site Averages
Ave
rag
e F
uel
ing
Tim
esNREL cdparra_mhe_06
Created: Mar-14-12 4:26 PM Fill data for class 1, 2, and 3 trucks
8
CDPARRA-MHE-07Tank Pressure Level at Fueling
Tank Pressure At Fill: ARRA
FE
23%
NREL cdparra_mhe_07
Created: Mar-15-12 12:45 PM
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 = 62,062Median Tank Pressure (At Fill) = 26%
9
CDPARRA-MHE-08Operation Time between Fueling
0 2 4 6 8 10 120
500
1000
1500
2000
2500
3000
Average: 4.8 hours
Operating Time Between Fuelings - ARRACombined Fleet Through 2011Q4
Operating Hours Between Fuelings1,2
Co
un
t
Range of0
2
4
6
8
10
Site Averages
Ave
rag
e O
p H
rs b
etw
een
Fu
elin
gs
NREL cdparra_mhe_08
Created: Mar-15-12 12:46 PM 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.
10
CDPARRA-MHE-09Histogram of Fueling Rates
0 0.2 0.4 0.6 0.8 1 1.20
2000
4000
6000
8000
10000
12000
14000
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesARRA Combined Fleet Through 2011Q4
140,959 Events Average = 0.31 kg/min
Range of0
0.2
0.4
0.6
0.8
Site Averages
Ave
rag
e F
uel
ing
Rat
es
NREL cdparra_mhe_09
Created: Mar-14-12 4:32 PM Fill data for class 1, 2, and 3 trucks
11
CDPARRA-MHE-10Histogram of Fueling Amounts
0 0.5 1 1.5 20
2000
4000
6000
8000
10000
12000
14000
16000
18000
Amount Fueled (kg)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling AmountsARRA Combined Fleet Through 2011Q4
Average = 0.59 kg
Range of0
0.2
0.4
0.6
0.8
1
1.2
1.4
Site Averages
Ave
rag
e F
uel
ing
Am
ou
nts
NREL cdparra_mhe_10
Created: Mar-14-12 4:38 PM Fill data for class 1, 2, and 3 trucks
12
CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter
2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40
50
100
150
200
250
To
tal O
per
atio
n H
ou
rs [
1,00
0]
Fuel Cell Operation Hours by Quarter - ARRA
Total Hours = 959,887
0
50
100
150
200
250
300
350
Cu
mu
lati
ve F
leet
Ho
urs
[10
00]
All FleetsIndividual Fleet
NREL cdparra_mhe_11
Created: Mar-28-12 2:47 PM
13
CDPARRA-MHE-12Fuel Cell System Maintenance by Category
11%
11%
12%
14%15%
16%
21%
Classified Events = 2,5741
74% unscheduled
multiplesystems
25
misc 483
entiresystem
611
classified
events1 2574
Event Count
14%
8%
19%
9% 6%
19%
24%
Total Hours = 4,84779% unscheduled
thermal management
fuel system
software
sensors
energy storage system
control electronics
air system
NREL cdparra_mhe_12
Created: Mar-27-12 8:07 AM
Fuel Cell System Maintenance By Category - ARRA
MISC includes the following failure modes: 'software', actuators, dispenser, userinterface, seal, fittings&piping, valves, fc stack, electrical, other
14
CDPARRA-MHE-13Fuel Cell System Scheduled and Unscheduled Maintenance by Category
0 100 200 300 400 500 600 700
MISC
ELECTRICAL
AIR SYSTEM
CONTROL ELECTRONICS
ENERGY STORAGE SYSTEM
SENSORS
SOFTWARE
FUEL SYSTEM
THERMAL MANAGEMENT
ENTIRE SYSTEM
Fuel Cell System Maintenance Scheduled vs. Unscheduled - ARRANumber of Maintenance Events by Category
Number of Events
Total Events = 3,69374% were unscheduled
ScheduledTotal
0 100 200 300 400 500 600 700 800 900
MISC
SOFTWARE
CONTROL ELECTRONICS
SENSORS
ELECTRICAL
AIR SYSTEM
ENERGY STORAGE SYSTEM
FUEL SYSTEM
ENTIRE SYSTEM
THERMAL MANAGEMENT
Number of Labor Hours by Category
Hours
Total Hours = 4,84779% were unscheduled Scheduled
Total
NREL cdparra_mhe_13
Created: Mar-26-12 4:20 PM
MISC includes the following categories:'SOFTWARE'ACTUATORSDISPENSER
USER INTERFACESEAL
MULTIPLE SYSTEMSFITTINGS&PIPING
VALVESFC STACK
OTHER
15
CDPARRA-MHE-14Average Fuel Cell System Maintenance by Quarter
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2Maintenance Events
Ave
rag
e #
of
Eve
nts
Per
Veh
icle
10Q
110
Q2
10Q
310
Q4
11Q
111
Q2
11Q
311
Q4
0
0.5
1
1.5
2
2.5
3Maintenance Hours
Ave
rag
e H
ou
rs P
er V
ehic
le
10Q
110
Q2
10Q
310
Q4
11Q
111
Q2
11Q
311
Q4
ScheduledUnscheduledOperator
NREL cdparra_mhe_14
Created: Mar-26-12 4:21 PM
Average Maintenance Per Unit by Quarter - ARRA
16
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
% 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
Created: Mar-09-12 11:09 AM
1
1) 100% max fuel cell voltage is approximately open-circuit voltage
17
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
Created: Mar-09-12 11:09 AM
18
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
Created: Mar-09-12 11:10 AM
19
CDP-MHE-18Infrastructure Maintenance by Category
7%
7%
8%
8%
11%
12%
19%
28%
Classified Events = 6461
77% unscheduled
multiplesystems
8
misc 102
entiresystem
127
classified
events1 646
Event Count
6%
9%
9%
5%
17%
48%
Total Hours = 4,75070% unscheduled
hydrogen compressor
feedwater system
dispenser
electrical
reformer
valves
sensors
air system
NREL cdp_mhe_18
Created: Mar-14-12 4:24 PM
Infrastructure Maintenance By Equipment Type
MISC includes the following failure modes: actuators, safety, seal, thermal management,unspecified, software, fuel system, fittings&piping, control electronics, other
20
CDP-MHE-19Infrastructure Scheduled & Unscheduled Maintenance by Category
0 20 40 60 80 100 120 140 160 180 200
MISC
CONTROL ELECTRONICS
AIR SYSTEM
SENSORS
VALVES
REFORMER
ELECTRICAL
DISPENSER
FEEDWATER SYSTEM
ENTIRE SYSTEM
HYDROGEN COMPRESSOR
Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category
Number of Events
Total Events = 88377% were unscheduled
ScheduledTotal
0 200 400 600 800 1000 1200 1400 1600
MISC
CONTROL ELECTRONICS
FEEDWATER SYSTEM
REFORMER
FITTINGS&PIPING
AIR SYSTEM
SENSORS
VALVES
DISPENSER
ENTIRE SYSTEM
HYDROGEN COMPRESSOR
Number of Labor Hours by Category
Hours
Total Hours = 4,75070% were unscheduled Scheduled
Total
NREL cdp_mhe_19
Created: Mar-14-12 4:24 PM
MISC includes the following categories:ACTUATORS
SAFETYOTHERSEAL
THERMAL MANAGEMENTUNSPECIFIED
MULTIPLE SYSTEMSSOFTWARE
FUEL SYSTEMFITTINGS&PIPING
21
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
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
ScheduledUnscheduledOperator
NREL cdp_mhe_20
Created: Mar-14-12 4:25 PM
Average Infrastructure Site Quarterly Maintenance
22
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
Created: Mar-14-12 3:58 PM
99,650 kg Hydrogen Dispensed
23
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
Created: Mar-15-12 12:51 PM
Average Daily Dispensing Operations by Site - ARRA
Shaded areas represent the min and max site average hydrogen use and fill frequency
24
CDPARRA-MHE-23Average Daily Fuel Cell Operation Hours per Fleet
A B C D E F G H I J0
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
Created: Mar-12-12 4:59 PM
25
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
20
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
5
10
15
Average Hours of Operation Per Day1
Fu
el C
ell S
yste
ms
[%]
Average Daily Fuel Cell System Operation Hours
66.1% Fuel Cell SystemsAverage > 6 Hours Daily
NREL cdparra_mhe_24
Created: Mar-28-12 3:09 PM 1) Excludes 0 hour operation days
26
CDP-MHE-25Infrastructure Safety Reports by Quarter
2009 Q1 2009 Q2 2009 Q3 2009 Q4 2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40
5
10
15
20
25
30
Eve
nts
Rep
ort
ed
0
14
28
43
57
71
85Infrastructure Safety Reports By Quarter
Hu
nd
red
s o
f F
ills
Per
Rep
ort
Incident2
Near Miss1
Hundreds of Fills Per Safety Report
NREL cdp_mhe_25
Created: Mar-14-12 4:37 PM
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: 131,474
Total Reports: 73Lifetime kg H
2 Dispensed per Report: 1,801
27
CDPARRA-MHE-26Fuel Cell System Safety Reports by Quarter
2010 Q1 2010 Q2 2010 Q3 2010 Q4 2011 Q1 2011 Q2 2011 Q3 2011 Q40
5
10
15
20
25
30
35
40
45
50
55
60
Eve
nts
Rep
ort
ed
0
5
9
14
18
23
28
32
37
41
46
50
55Fuel Cell System Safety Reports by Quarter - ARRA
Sta
ck H
ou
rs P
er R
epo
rt [
1,00
0]
Incident2
Near Miss1
Stack Hours Per Report [1,000]
NREL cdparra_mhe_26
Created: Mar-26-12 4:21 PM
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 Stack Hours: 973,006Total Reports: 217Lifetime Stack Hours per Report: 4,484
28
CDPARRA-MHE-27Fuel Cell System Safety Reports by Severity and Type
0 50 100 150 200 250
Incident
Near Miss
Number of Reports
Sev
erit
y
Fuel Cell System Safety Reports by Severity - ARRA and Report Type 2011Q4
Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionNon-H2 FireOperator ProtocolOther 1 (user defined)
NREL cdparra_mhe_27
Created: Mar-27-12 9:20 AM
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
29
CDP-MHE-28Fuel Cell System Reliability Growth by Site for Quarter
0
0.5
1
1.5
2
2.5
3
Sh
ape
Par
amet
er (
)1
Overall Site Reliability Growth: MHE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.
2.% change in instantaneous MTBF
3. Some sites are no longer active. Final results are shown for those sites.
Entire historyLast 20% of eventsFirst 120 Days
NREL cdp_mhe_28
Created: Mar-27-12 8:59 AM
Instantaneous MTBF improved for the last
20% of events for 10 of 16 fleets.3
Fleets Sorted by Increasing Age (Average Hours Per Vehicle)
Fa
ilure
Ra
te In
cre
asi
ng
Fa
ilure
Ra
te D
ecr
ea
sin
g
81%2
51%2
-18%2-53%2
27%2
-69%292%2
143%2
209%2
39%2
-2%2
16%2
5%2
76%2
-27%2 -24%2
30
CDP-MHE-29Fuel Cell System Reliability Growth by Top 4 Categories
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
ENERGY STORAGE SYSTEM
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
THERMAL MANAGEMENT
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
FUEL SYSTEM
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
CONTROL ELECTRONICS
Failure Rate Increasing
Failure Rate Decreasing
Fleet
NREL cdp_mhe_29
Created: Mar-27-12 9:02 AM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164 These represent the top four equipment failure categories from all combined data.
31
CDP-MHE-30Fuel Cell System Mean Time Between Failure
0 500 1000 1500 2000 2500 3000 3500 4000 4500 50000
10
20
30
40
Unit MTBF1 (Hours)
Per
cen
t o
f U
nit
s
Unit MTBF by Operating Hours
17%
17%
18%20%
27%19%
15%
16% 16%
19%
15%26%
28%
26%
19% 13%
13%
13%
13% 13%
13%
13%
13%
AIR SYSTEMCONTROL ELECTRONICSELECTRICALENERGY STORAGE SYSTEMFUEL SYSTEMSENSORSSOFTWARETHERMAL MANAGEMENT
NREL cdp_mhe_30
Created: Mar-26-12 4:17 PM
1Mean Time Between Failure
Class 1 Class 2 Class 3
Equipment Categories for Units with MTBF<=250 hours.2
2 Categories representing <10% of the total are not shown
32
CDP-MHE-31Fuel Cell System Mean Time Between Scheduled Maintenance
0 1000 2000 3000 4000 5000 60000
10
20
30
Unit MTBSM1 (Hours)
Per
cen
t o
f U
nit
s
Unit MTBSM by Operating Hours
0 1000 2000 3000 4000 5000 60000
10
20
Unit MTBPM2 (Hours)
Per
cen
t o
f U
nit
s
Individual Unit MTBPM2 All Sites
0 1000 2000 3000 4000 5000 60000
10
20
Unit MTBU3 (Hours)
Per
cen
t o
f U
nit
s
Individual Unit MTBU3 All Sites
NREL cdp_mhe_31
Created: Mar-26-12 4:18 PM
1. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades
2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade
33
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
12000
14000
7,476
5,646
Max of Site Projections512,823
Ave of Site Projections55,157
Ho
urs
Operation Hours and Projected Hours to 10% Voltage Drop(2-4)
NREL cdp_mhe_32
Created: Mar-28-12 3:32 PM
(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.
34
CDP-MHE-33 Fuel Cell Stack Voltage Durability as a Function of Voltage Drop Levels
10 15 20 25 300
5000
10000
15000Fuel Cell Stack Durability as a Function of Voltage Drop4
% Voltage Drop
Pro
ject
ed H
ou
rs2,
3
25th/75th Percentile Projections3
Average of Fleet Projections1,5
Max of Fleet Projections1,5
NREL cdp_mhe_33
Created: Mar-28-12 3:33 PM
1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life criteria.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 projected hours vary based on the percentage of voltage degradation, but the projected hours do not imply that all stacks will (or do) operate to these voltage degradation levels.5) Each site has one voltage projection value that is the weighted average of the site's fuel cell stack projections.
35
CDP-MHE-34 Fuel Cell Stack Power Degradation over Time
0
20
40
60
80
100
120
0 200 400 600 800 1000120014001600180020002200240026002800300032003400360038004000
Stack Op Hour Segments2
% P
ow
er1
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
Created: Mar-28-12 3:34 PM
Median power differencefrom 0 hour segment to3800 hour segment = -6.49%
36
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
Created: Mar-09-12 5:36 PM
37
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
100
200
300
400
Average of 3.2 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 2.4 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
Created: Mar-15-12 12:47 PM
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
38
CDP-MHE-38Histogram of Fuel Cell Stack Voltage Degradation
0 1500 3000 4500 6000 7500 9000 10500 12000 13500 15000 >150000
10
20Fuel Cell Stacks Projected Hours to 10% Voltage Degradation
5,51
7
FC
Sta
cks
[%]
Projected Hours to 10% Voltage Degradation 1,3
Time 0 Fit (In Service)
Time 0 Fit (Retired or Not in Service)2
Weighted Average (Fleet)
NREL cdp_mhe_38
Created: Mar-28-12 3:35 PM
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.
39
CDP-MHE-39Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation
0 1000 2000 3000 4000 5000 6000 7000 8000
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation
Pro
ject
ed H
ou
rs1
,2,4
Operation Hours
projected hrs = operation hrs
FC System
FC System (Limited)2
FC System (Retired)3
Unity Line
NREL cdp_mhe_39
Created: Mar-28-12 3:36 PM
15% of stacks arebelow the unity lineand have operatedpast 10% voltagedegradation.
On average, thesestacks haveoperated for 2,480hours.
Stacks above theunity line have notoperated past 10%voltage degradation.
1) Indicates the projected hours to a 10% voltage degradation based upon curve fitting data from operation hour 0.2) Projected hours limited based on demonstrated hours.3) Stacks retired due to low-performance or catastrophic failure.4) Each projection has uncertainty based on the confidence intervals of the fit.
40
CDPARRA-MHE-40Site Summary
0 200 400 600 800 10000
10
20
30
40
50
60
70
80
90
100
110
120
130
140
Facility Size (thousand sq.ft.)
To
tal U
nit
s a
t S
ite
Units Deployed vs Facility Size
GreenfieldRetrofitFutureDelivered - LiquidOn-Site Reforming
NREL cdparra_mhe_40
Created: Mar-28-12 5:09 PM
504 Units 8 Sites
Class IClass IIClass IIIHeight proportional to units deployed.
MHE Deployment - ARRA
Marker size proportional to number of units.
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
41
CDP-MHE-41Infrastructure Safety Categories
0 10 20 30 40 50 60
Incident
Near Miss
Number of Reports
Sev
erit
y
Infrastructure Safety Reports by Severity - All Sites and Report Type 2011Q4
Alarms OnlyElectrical IssueEquipment MalfunctionH2 Release - Minor, NO IgnitionH2 Release - Minor, YES IgnitionH2 Release - Significant, NO IgnitionNon-H2 ReleaseOperator ProtocolStructural Issue
NREL cdp_mhe_41
Created: Mar-14-12 12:25 PM
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
42
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
35
70
105
140
128 kg/day avg
Dai
ly A
vera
ge
[kg
]
All SitesIndividual Site
NREL cdparra_mhe_42
Created: Mar-09-12 5:41 PM
43
CDPARRA-MHE-43MHE 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
10
20
30
40
50
60
70
Labor Hours Per Event
Fre
qu
ency
(%
of
tota
l)
Maintenance Labor Hours Breakdown: ARRA MHE
NREL cdparra_mhe_43
1 2 30
10
20
30
40
Class
Max
imu
m E
ven
t H
ou
rs
Maximum Event Labor Hoursfor each fleet, by Class
0
1
2
3
Med
ian
Eve
nt
Ho
urs
Median Event Labor Hoursfor each fleet, by Class
NREL cdparra_mhe_43
Created: Mar-26-12 4:21 PM
>24
63% of repairs require less than the mean of 1.7 hours of labor.Median labor hours: 1.0
1Mean:
2.2
2Mean:
1.8
3Mean:
1.4Class
44
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
1 2 3 4 5 6 7 8 9 0
20
40
60
80
100
Site
Eve
nt
Lab
or
(hrs
)
Maximum and Mean Event Labor Hoursfor each site.
MeanMax
NREL cdp_mhe_44
Created: Mar-09-12 2:04 PM
>24
51% of repairs require less than the mean of 7.6 hours of labor.Median labor hours: 7.0
45
CDP-MHE-45Infrastructure Reliability Growth
0
0.5
1
1.5
2
2.5
3
3.5
4
Sh
ape
Par
amet
er (
)1
Overall Site Infrastructure Reliability Growth
1 2 3 4 5 6 7 8 9 10
1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.
2.% change in instantaneous MTBF
3. Some sites are no longer active. Final results are shown for those sites.
Entire historyLast 20% of eventsFirst 120 Days
NREL cdp_mhe_45
Created: Mar-13-12 5:50 PM
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 7 of 10 sites for the last 20% of events.3
68%2
-23%2
0%2
0%2
56%2
31%2
16%29%2 86%2
45%2
46
CDP-MHE-46Infrastructure Equipment Category of Safety Events
5%
14%
21%
48%
By Number of ReportsTotal Near Miss Reports = 56
7%
7%
86%
By Number of IncidentsTotal Incidents = 14hydrogen compressor
fittings & piping
dispenser
seal
valves
reformer
Misc
NREL cdp_mhe_46
Created: Mar-14-12 2:38 PM
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
47
CDP-MHE-47Infrastructure Maintenance by Mode
6%
7%
7%
7%
7%
8%8%
9%
10%
11%
15%
Classified Events = 4911
77% unscheduled
upgrade 42
preventativemaintenance
157
misc 193
classified
events1 491
Event Count
5%
10%
5%
11%
18%
9%
10%
17%
6%
Total Hours = 4,75070% unscheduled
flow low
pressure high
hydrogen leak
pressure low
out of calibration
metal fatigue
fluid leak_non_hydrogen
temperature high
inspect trouble alarm or report
flow high
excessive noise
failed closed
data error
NREL cdp_mhe_47
Created: Mar-09-12 2:04 PM
Infrastructure Maintenance By Mode
MISC includes the following failure modes: animal damage, cavitation, debris infiltration,electrical short, power outage, vandalism, voltage low, manufacturing defect, software
bug, cleanup device failed, maintenance error, network malfunction, broken wire, ambienttemperature too low, drive off, failed open, replace failed parts, moisture infiltration,
operator protocol, other
48
CDP-MHE-48Infrastructure Mean Time Between Failures
0 5 10 15 20 25 30 350
1
2
3
4
5
Site MTBF1 (Days)
Co
un
t o
f S
ites
Site MTBF (Calendar Days In Operation): Infrastructure
NREL cdp_mhe_48
Created: Mar-28-12 5:02 PM
1. Cumulative Mean Time Between Failure
49
CDP-MHE-49Infrastructure Mean Time Between Scheduled Maintenance
0 5 10 15 20 25 30 35 40 450
1
2
3
4
5
Site MTBSM1 (Days)
Co
un
t o
f S
ites
Site MTBSM by Calendar Days In Operation: Infrastructure
0 20 40 60 800
1
2
3
4
5
Site MTBPM2 (Days)
Co
un
t o
f S
ites
Individual Site MTBPM2 All Sites
0 20 40 60 80 100 1200
1
2
3
4
5
Site MTBU3 (Days)
Co
un
t o
f S
ites
Individual Site MTBU3 All Sites
NREL cdp_mhe_49
Created: Mar-28-12 4:57 PM
1. Cumulative Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades
2Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade
50
CDP-MHE-50Infrastructure Reliability Growth by Category
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
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
4.5
5
Calendar Days In Operation
Sh
ape
Par
amet
er (
)*
HYDROGEN COMPRESSOR
Failure Rate Increasing
Failure Rate Decreasing
Site
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Calendar Days In Operation
Sh
ape
Par
amet
er (
)*
VALVES
Failure Rate Increasing
Failure Rate Decreasing
Site
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Calendar Days In Operation
Sh
ape
Par
amet
er (
)*
AIR SYSTEM
Failure Rate Increasing
Failure Rate Decreasing
Site
NREL cdp_mhe_50
Created: Mar-12-12 6:23 PM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164 These represent the top four equipment failure categories from all combined data.
51
CDP-MHE-51Infrastructure Hydrogen Leaks by Equipment Type
6%
6%
6%
16%
18%
47%
Classified Events = 491
100% unscheduled
misc 0
classified1
events49
Event Count
7%
8%
5%
18%
25%
39%
Total Hours = 442100% unscheduled
hydrogen compressor
fittings&piping
dispenser
valves
seal
reformer
NREL cdp_mhe_51
Created: Mar-14-12 3:11 PM
Hydrogen Leaks By Equipment Category: Infrastructure
52
CDP-MHE-52Infrastructure Compressor Failures by Mode
5%
9%
9%
14%
17%
21%
26%
Classified Events = 1371
98% unscheduled
misc 45
classified1
events137
Event Count
12%
7%
14%
22%
36%
Total Hours = 1,57297% unscheduled
metal fatigue
excessive noise
hydrogen leak
pressure low
temperature high
inspect trouble alarm or report
fluid leak_non_hydrogen
NREL cdp_mhe_52
Created: Mar-09-12 2:07 PM
Hydrogen Compressor Failures By Mode
MISC includes the following failure modes: cavitation, debris infiltration, failed closed,flow high, manufacturing defect, moisture infiltration, operator protocol, preventative
maintenance, maintenance error, upgrade, replace failed parts, other
53
CDPARRA-MHE-53MHE Hydrogen Leaks by Equipment Type
7%
7%
8%
8%
13%
14%
28%
Classified Events = 2081
91% unscheduled
misc 1
classified1
events208
Event Count
7%
5%
13%
28%
30%
Total Hours = 38295% unscheduled
fuel system
air system
thermal management
sensors
entire system
energy storage system
control electronics
valves
software
electrical
fittings&piping
fc stack
seal
multiple systems
NREL cdparra_mhe_53
Created: Mar-26-12 4:22 PM
Hydrogen Leaks By Equipment Category: ARRA MHE
54
CDP-MHE-54MHE Availability
90
91
92
93
94
95
96
97
98
99
100
% A
vaila
bili
ty
MHE Availability - ARRA & DLA1
Jan-1
0
Feb-1
0
Mar
-10
Apr-10
May
-10
Jun-1
0
Jul-1
0
Aug-10
Sep-1
0
Oct-1
0
Nov-10
Dec-1
0
Jan-1
1
Feb-1
1
Mar
-11
Apr-11
May
-11
Jun-1
1
Jul-1
1
Aug-11
Sep-1
1
Oct-1
1
Nov-11
Dec-1
1
MonthlyMean
NREL cdp_mhe_54
Created: Mar-26-12 4:19 PM
1. Availability is calculated as follows: Availability starts at 100% for each vehicle on each calendar day. If the vehicle has a maintenance record on a given day, unavailable hours are subtracted from availability. The number of unavailable hours is calculated according to the following schedule: A. Unavailable hours = 21 hours if maintenance hours is blank or > 6 hours. B. Unavailable hours = if maintenance hours are between 4 and 6 hours. C. Unavailable hours = the actual maintenance hours if it is less than 4 hours. D. If maintenance hours are > 21 , the rules A-C above are applied recursively to any remainder above 21 hours.
Mean Availability: 98 %
55
CDP-MHE-55Infrastructure Mean Time Between Safety Events
0 50 100 150 200 250 300 350 400 450 5000
10
20
30
40
50
Site MTBSE1 (Calendar Days in Operation)
Per
cen
t o
f S
ites
Mean Calendar Days Between Safety Reports (MTBSR): Infrastructure
0 200 400 600 8000
102030405060708090
100
Site MTBSI2 (Calendar Days in Operation)
Pe
rcen
t o
f S
ite
s
Mean Calendar Days Between Incidents
0 100 200 300 400 5000
10
20
30
Site MTBSNM3 (Calendar Days in Operation)
Pe
rcen
t o
f S
ite
s
Mean Calendar Days Between Near Miss
NREL cdp_mhe_55
Created: Mar-14-12 2:40 PM
1. Cumulative Mean Time Between Safety Report (days)
2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)
56
CDPARRA-MHE-56MHE Mean Time Between Safety Events
0 100 200 300 400 500 600 7000
10
20
30
40
50
Unit MTBSR1
Per
cen
t o
f U
nit
s
Mean Calendar Days Between Safety Reports (MTBSR): ARRA MHE
0 100 200 300 400 500 6000
10
20
30
40
50
Unit MTBSI2
Pe
rcen
t o
f U
nit
s
Mean Calendar Days Between Incidents
0 200 400 600 8000
10
20
30
Unit MTBSNM3
Pe
rcen
t o
f U
nit
s
Mean Calendar Days Between Near Miss
NREL cdparra_mhe_56_mhe
Created: Mar-27-12 9:12 AM
1. Cumulative Mean Time Between Safety Report (days)
2Mean Time Between Safety Incident (days) 3Mean Time Between Safety Near Miss (days)74% of unitshave no safety issues.
57
CDPARRA-MHE-57MHE Equipment Category of Safety Events
5%
5%
7%
10%
21%
50%
By Number of ReportsTotal Near Miss Reports = 210
14%
14%
14%
14%
14%
29%
By Number of IncidentsTotal Incidents = 7
control electronics
operator protocol
electrical
fuel system
fc stack
valves
air system
fittings & piping
thermal management
Misc
NREL cdparra_mhe_57
Created: Mar-26-12 4:23 PM
Safety Reports By Equipment Category: ARRA MHE
MISC includes the following categories:SOFTWAREELECTRICALREFORMERSENSORS
SEALOTHER
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
58
CDP-MHE-58MHE Total Cost of Ownership
59
CDP-MHE-59MHE Total Cost of Ownership - Sensitivity
60
CDP-MHE-60MHE Intensive Deployment Total Cost of Ownership
61
CDPARRA-MHE-61MHE Maintenance Event by Mode
5%
5%
8%
8%
9%
11%
16%
19%
Classified Events = 2,2411
74% unscheduled
preventativemaintenance
465
misc 487
upgrade 499
classified
events1 2241
Event Count
5%
6%
8%
7%
6%
12%
15%
13%
18%
Total Hours = 4,84779% unscheduled
flow low
replace failed parts
voltage low
hydrogen leak
out of calibration
inspect trouble alarm or report
failed open
fluid leak_non_hydrogen
software bug
data error
pressure low
broken wire
unspecified electronics failure
NREL cdparra_mhe_61
Created: Mar-28-12 3:38 PM
MHE Maintenance By Mode - ARRA
MISC includes the following failure modes: cavitation, drive off, improper handling,excessive noise, flow high, load above design limit, loose fastener, metal fatigue,
ambient temperature too low, moisture infiltration, false alarm, fire, temperature low,debris infiltration, voltage high, current high, failed closed, pressure high, manufacturingdefect, low cell voltage, low coolant, electrical short, improper installation, maintenance
error, operator protocol, temperature high, other
62
CDPARRA-MHE-62Final Pressure of Hydrogen Fills
200 250 300 350 400 450 5000
0.5
1
1.5
2
2.5
3x 10
4 Fueling Final Pressures
Nu
mb
er o
f F
uel
ing
s
Final Pressure [bar]NREL cdparra_mhe_62
Created: Mar-15-12 10:14 AM
63
CDPARRA-MHE-63Key Performance Areas by Classification
Class 1 Class 2 Class 30
0.2
0.4
0.6
0.8
1
Avg
Fill
Am
ou
nt
[kg
]
Class 1 Class 2 Class 30
5
10
15
20
Avg
Op
erat
ion
per
Fill
[h
ou
r]
Class 1 Class 2 Class 30
2000
4000
6000
8000
10000
12000
14000
Avg
Tim
e to
10%
Vo
lt D
rop
[h
ou
r]Class 1 Class 2 Class 3
0
2
4
6
8
10
12
14
Avg
Op
erat
ion
per
Day
[h
ou
r]
Class 1 Class 2 Class 30
1000
2000
3000
4000
Avg
Op
erat
ion
per
Yea
r [h
ou
r]
Class 1 Class 2 Class 30
200
400
600
800
1000
1200
1400
Avg
MT
BF
[h
ou
r]NREL cdp_mhe_63
Created: Mar-28-12 3:37 PM
Material Handling Equipment Performance By Class
64
CDPARRA-MHE-64aGeneral & Capital Cost Inputs for Class I/II MHE
65
CDPARRA-MHE-64bGeneral & Capital Cost Inputs for Class I/II MHE
66
CDPARRA-MHE-64cGeneral & Capital Cost Inputs for Class III MHE
67
CDPARRA-MHE-64dGeneral & Capital Cost Inputs for Class III MHE