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.
Performance & Reliability of Fuel Cell Systems in the Field
Fuel Cell End Users’ Forum
Chris Ainscough, Jennifer Kurtz, Keith Wipke, Sam Sprik, Leslie Eudy, Genevieve Saur, Todd Ramsden
February 4th, 2013
This presentation does not contain any proprietary, confidential, or otherwise restricted information
V2, 4/5/12
2
Outline
• Combined Results • Light Duty Vehicle results from the U.S.
DOE Learning Demonstration Project: 2004 – 2012
• American Recovery & Reinvestment Act (ARRA) fuel cell backup power & material handling and systems.
https://powerpedia.energy.gov/w/images/7/77/DOE_Seal_Color_Hi-Res.jpg
3
CDPs
DDPs
Public
Composite Data Products (CDPs) • Aggregated data across multiple systems,
sites, and teams • Publish analysis results every six months
without revealing proprietary data2
Detailed Data Products (DDPs) • Individual data analyses
• Identify individual contribution to CDPs • Shared every six months only with the
partner who supplied the data1
1) Data exchange may happen more frequently based on data, analysis, & collaboration 2) Results published via NREL Tech Val website, conferences, and reports (http://www.nrel.gov/hydrogen/proj_learning_demo.html)
Project Approach Supporting Both DOE/Public as Well as Technology Developers
Results
Bundled data (operation & maintenance/safety) delivered
to NREL quarterly
Internal analysis completed quarterly
4
Combined Results
5
Fuel Cell Deployment mAp
0
25
50
75
100
125
Material Handling Equipment (14 Sites and 684 FC Units)Backup Power (316 Sites and 335 FC Units)Stationary (2 Sites and 4 FC Units)APU (1 Sites and 1 FC Units)Bus (9 Sites and 16 FC Units)Car (22 Sites and 22 FC Units)
NREL cdp_XApp_02Created: Oct-31-12 2:48 PM
Number of FCUnits in
State/Site
Deployments we track
6
Fueling Rates
Rate typically scales with the on-board fuel capacity. Larger capacity requires faster fueling.
7
Fueling Times
Fast fueling (< 3 minutes) is a key parameter to the value proposition in MHE. It is a key differentiator between fuel cell and battery electric vehicles. The latter can take up to 20 hours on a level 1 charger or 8 hours on level 2.
8
Light Duty Vehicles
9
2nd Generation Vehicles Demonstrated Technology Improvements Over Gen 1
Generation 1 Vehicles • FC not freeze-capable • ~2003 stack technology • Storage: liquid H2 & 350
and 700 bar • Range: 100-200 miles • Efficiency: 51-58% at ¼
power
Generation 2 Vehicles • FC freeze-capable • ~2007-2009 stack tech. • Storage: All 700 bar
• Range: 200-250 miles • Efficiency: 53-59% at ¼
power • Longer FC durability
10
7
12
6
0
5
10
15
20
25
Num
ber o
f Sta
tions
Reporting Period
Cumulative Stations
Continuing Outside of ProjectRetired StationsCurrent Project Stations
NREL cdp_fcev_31Created Dec-9-11 9:15 AM
Infrastructure Status: Out of 25 Project Stations, 13 Are Still Operational* (6 outside of DOE project)
Jan-31-2012
2 Online 3 Future
54 Online 15 Future
6 Online
SF Bay Area
DC to New York
3 Online
Detroit Area
Los Angeles Area
16 Online 11 Future
3 mile radius
6 mile radius
12
7
6
**
** Funded by state of CA or others, outside of this project
* CDP station status is as of 9/30/11
11
Total of 99 CDPs Published, Including 40 Winter 2011 CDPs
Only selected highlights (mostly from the last year) will be covered
12
Project Achieved Both Technical Goals; Outside Analysis Used for Cost Evaluation
Vehicle Performance Metrics Gen 1 Vehicle Gen 2 Vehicle 2009 Target After 2009Q4
Fuel Cell Stack Durability 2,000 hours Max Team Projected Hours to
10% Voltage Degradation 1,807 hours 2,521 hours --
Average Fuel Cell Durability Projection 821 hours 1,062 hours 1,748 hours
Max Hours of Operation by a Single FC Stack to Date 2,375 hours 1,261 hours 1,582 hours
Driving Range 250 miles
Adjusted Dyno (Window Sticker) Range 103-190 miles 196-254 miles --
Median On-Road Distance Between Fuelings 56 miles 81 miles 98 miles
Fuel Economy (Window Sticker) 42 – 57 mi/kg 43 – 58 mi/kg no target --
Fuel Cell Efficiency at ¼ Power 51 – 58% 53 – 59% 60% --
Fuel Cell Efficiency at Full Power 30 – 54% 42 – 53% 50% --
Infrastructure Performance Metrics 2009 Target After 2009Q4
H2 Cost at Station (early market)
On-site natural gas reformation
$7.70 – $10.30/kg
On-site Electrolysis
$10.00 – $12.90/kg
$3/gge --
Average H2 Fueling Rate 0.77 kg/min 1.0 kg/min 0.65 kg/min
Outside of this project, DOE independent panels concluded at 500 replicate stations/year: Distributed natural gas reformation at 1500 kg/day: $2.75-$3.50/kg (2006) Distributed electrolysis at 1500kg/day: $4.90-$5.70 (2009)
Outside review panel
1)
2)
3)
13
0 50 100 150 200 250 3000
5
10
Perc
enta
ge o
f Ref
uelin
gs
Distance between refuelings [Miles]2
Distance Driven Between Refuelings: All OEMs
Gen1Gen2After 2009Q4
NREL cdp_fcev_80
1. Some refueling events are not detected/reported due to data noise or incompleteness.2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the vehicle.
Gen1 Refuelings1 = 18941 Median distance between refuelings = 56 Miles Gen2 Refuelings1 = 6870 Median distance between refuelings = 81 Miles
Created: Dec-13-11 3:57 PM
Refuelings after 2009Q41 = 9937 Median distance between refuelings = 98 Miles
RANGE: Results Show Significant Improvement in Real-World Driving Range Between 3 Sets of Vehicles
+45% improvement Gen 1 to Gen 2
+75% improvement in real-world driving
range with latest adv. tech. vehicles
Note: Actual range possible >200 miles
2
2
2
14
0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000
5
10
15
20
25Fuel Cell Stack4 Operation Hours
FC S
tack
s [%
]
Operation Hours
25% of FC Stacks > 937 hoursM
edia
n (6
20 h
ours
)
In Service1
Retired2
Not in Service3
NREL cdp_fcev_86Created: Dec-15-11 12:32 PM
1) Stacks that are in service and accumulating operation hours.2) Stacks retired due to low-performance or catastrophic failure.3) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performancerelated issues or c)removed from DOE program.4) Only includes systems operating after 2009Q4.
Evaluated FC Durability Data from FCEVs After 2009Q4 – Fuel Cell Stack Operation Hours and Max Power Degradation
Some stacks operated over 1,400 hours, but half were still below 600 hours
0
20
40
60
80
100
120
0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments2
% P
ower
1
Max Fuel Cell Stack3 Power Degradation Over Operation
1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.3) Only includes systems operated after 2009Q4.
Data Range25th & 75th PercentilesGroup MedianOutlier
NREL cdp_fcev_90Created: Jan-10-12 10:29 AM
Median power differencefrom 0 hour segment to1300 hour segment = -18.2%
Recent data from stacks shows knee
in FC power degradation curve
at ~200 hours
15
0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000102030405060
Fuel Cell Stacks4 Projected Hours to 10% Voltage Degradation
1,74
8
FC S
tack
s [%
]
Time 0 Fit (In Service)Time 0 Fit (Retired or Not in Service)2
Weighted Average (Fleet)
0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000102030405060
2,26
1
Projected Hours to 10% Voltage Degradation 1,3
FC S
tack
s [%
]
Steady Operation Fit (In Service)5
Steady Operation Fit (Retired or Not in Service)2, 5Weighted Average (Fleet)
NREL cdp_fcev_87Created: Jan-10-12 10:28 AM
1) Projection using field data, calculated at high stack current, from operation hour 0 or a steady operation period. 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.4) Only includes systems operating after 2009Q4.5) Not all stacks have a steady operation fit which is calculated from data after 200 hr break-in period. The steady operation starting hour is an approximation of the period after initial break-in where degradation levels to a more steady rate.
Projected Fuel Stack Durability to 10% Voltage Degradation; Two Fits
Using all data from t0
Fitting after first 200 hours
Average projections
Gen 1: 821 Gen 2: 1,062 Recent: 1,748
Many stacks have projections that we
limit to 2X to minimize extrapolation
16
Infrastructure Safety
0
10
20
30
40
50
Num
ber o
f Rep
orts
Type of Infrastructure Safety Reports by Quarter Through 2011 Q3
05Q2
05Q3
05Q4
06Q1
06Q2
06Q3
06Q4
07Q1
07Q2
07Q3
07Q4
08Q1
08Q2
08Q3
08Q4
09Q1
09Q2
09Q3
09Q4
10Q1
10Q2
10Q3
10Q4
11Q1
11Q2
11Q3
IncidentNear MissNon-EventAvg # Reports/Station
NREL cdp_fcev_36Created: Dec-15-11 3:36 PM
Reporting PeriodAn 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
Positive Trend. No incidents since 09Q1
17
5%
5%
6%
8%
9%
9%12%
21%
21%
Classified Events = 1,095160% unscheduled
multiplesystems 0
misc 190
entiresystem 203
classifiedevents1
1095
Event Count
9%
11%
6%
14%
16%
29%
Total Hours = 6,57050% unscheduled
electricalsoftwarehydrogen compressorsensorsvalvesair systemdispenserfittings&pipingcontrol electronicsH2 storage
NREL cdp_fcev_94
MISC includes the following failure modes: purifier, nitrogen system, feedwater system,seal, safety, reformer, electrolyzer, thermal management, other
2. Includes data from stations operating after 2009 Q4. Forlegacy results refer to CDP #63.
Created: Jan-17-12 1:53 PM
Infrastructure Maintenance By Equipment Type2
Infrastructure Maintenance: Equipment
Among hydrogen-specific equipment, compressors are a leading cause of maintenance.
18
Backup Power
19
Reliability: 99.5% successful starts
0
20
40
60
80
100
120
140
160
180
200
220
Star
ts
Starts by Month
07/09
08/09
09/09
10/09
11/09
12/09
01/10
02/10
03/10
04/10
05/10
06/10
07/10
08/10
09/10
10/10
11/10
12/10
01/11
02/11
03/11
04/11
05/11
06/11
07/11
08/11
09/11
10/11
11/11
12/11
01/12
02/12
03/12
04/12
05/12
06/12
Calendar Month
1526 of 1533 Starts Successful (99.5%)52% Conditioning Starts
StartsConditioning1 StartSuccessful Start
0
15
30
45
60
75
90
105
120
135
150
Rep
ortin
g FC
Sys
tem
s
NREL cdp_bu_04
Created: Sep-13-12 6:37 PM 1) FC system conditioning is an automated operation for regularsystem checks; activitated after long periods of no operation.
20
21
Material Handling Equipment
22
MHE Operation Status
*Through June 2012
Key Operation Metric CDPARRA-MHE-# Units in Operation
(100 Class 1, 62 Class 2, 172 Class 3) 490* 01
Hours Accumulated 1,248,384 hrs* 11
25% of FC Systems > 5,260 hrs* 02
FC Systems Average > 6 hours Daily 66%* 24
Hydrogen Dispensed 141,500 kg* 04
Hydrogen Fills 197,991* 03
Average Fill Amount 0.6 kg/fill* 10
Average Fill Time 2.3 min/fill* 06
Average Op Time between Fill 4.7 hrs* 08
The majority of sites have delivered liquid hydrogen. 2 of the 8 sites are greenfield sites. 4 sites have more than one class of MHE in operation.
23
Annualized Total Cost of Ownership per Unit Identifies Key Cost Advantages are Dependent on Deployment Size
CDP Ref #: 58
Fuel
Infra.
Hardware
Warehouse Space
Fueling Labor
Maint.
Results assume replacements as needed and do not reflect technology generation improvements or other productivity improvements such as constant power, emissions, and cold environment. FC costs include current tax credit of $3,000/kW or 30% of purchase price. Data source: ARRA & DLA project partner questionnaire & fuel cell performance data.
Class III Annualized Cost • $11,700 FC • $12,400 Battery
Analysis inputs are averages per category, some key inputs are: • 58 FC lifts • 333 days per year, 2.5
shifts per day (2,100 pedal hours per year)
• 3 min per hydrogen fill & 10 min per battery change out
24
MHE Availability
90
91
92
93
94
95
96
97
98
99
100
% A
vaila
bilit
y
MHE Availability - ARRA & DLA1
Jan-1
0
Feb-1
0
Mar-1
0
Apr-1
0
May-1
0
Jun-1
0Ju
l-10
Aug-1
0
Sep-1
0
Oct-1
0
Nov-1
0
Dec-1
0
Jan-1
1
Feb-1
1
Mar-1
1
Apr-1
1
May-1
1
Jun-1
1Ju
l-11
Aug-1
1
Sep-1
1
Oct-1
1
Nov-1
1
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 %
25
Reliability - Fuel Cell System
0 500 1000 1500 2000 2500 3000 3500 4000 4500 50000
10
20
30
40
Unit MTBF1 (Hours)
Perc
ent o
f Uni
ts
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
26
Reliability - Infrastructure
Compressor
Feedwater
Dispenser
Infrastructure consistently delivering 250 and 350 bar fills even though the majority of the sites have a MTBF of 25 days or less.
27
Deep Dive: Hydrogen Leaks
6%6%
6%
16%
18%
47%
Classified Events = 491100% 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
28
Deep Dive: Hydrogen Compressors
5%9%
9%
14%
17%
21%
26%
Classified Events = 137198% 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
29
Hydrogen Compressors: Improving Reliability
• DOE & NREL have begun an accelerated test program to evaluate H2 compressor failures & solutions in more detail.
• NREL provides the test facilities and labor. Compressor partners provide test articles.
30
Technical Summary – What We’ve Learned
Light Duty Vehciles • 183 Vehicles:
• 154,000 hours • 3.6M miles • 500K trips
• 25 Stations: • 152,000 kg produced/dispensed • 33K fuelings
• Met DOE target of 2000 hours stack durability • Met DOE target of 250 mile driving range.
31
Technical Summary – What We’ve Learned Fuel Cell Backup Power • Operating reliability in 15 states with
99.5% successful starts. • Maximum continuous run time of 29
hours due to an unplanned grid outage.
Fuel Cell Material Handling Equipment • Operating with an average availability
of ~98% at 8 end-user facilities. • Most systems operate at least 6 hours
a day. • Cost of ownership comparison
between fuel cell and battery MHE indicate significant cost savings cost for refueling labor and infrastructure space but much greater cost for hydrogen infrastructure and fuel.
Aggregated data showcases performance over the last two
years in MHE and backup power.
Performance results address a need for published results on
the technology status.
Data analyses develop as systems operate and based on the key performance areas in
the markets.
32
More information available
• www.nrel.gov/hydrogen/proj_tech_validation.html • or search for “NREL CDP”
Link to sunburst
http://www.nrel.gov/hydrogen/media/demo/source/sunburst.html
33
Backup Slides
34
Cumulative Mileage
3,590,828
-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
Vehi
cle
Mile
s Tr
avel
ed
Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2
Created: Dec-13-11 03:23 PM
Through 2011 Q3
NREL cdp_fcev_24
35
0 5 10 15 20 25 300
1
2
3
4
Site MTBF1 (Days)
Cou
nt o
f Site
s
Site MTBF (Calendar Days In Operation): Infrastructure2
NREL cdp_fcev_98Created: Jan-09-12 4:26 PM 1. Cumulative Mean Time Between Failure 2. Includes data from stations operating after 2009 Q4.
Infrastructure Maintenance: MTBF
Lifetime cumulative MTBF < 25 days, but improving at 5 of 7 stations.
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Shap
e Pa
ram
eter
( β)1
Overall Site Reliability Growth: Infrastructure3
Site: 1 Site: 2 Site: 3 Site: 4 Site: 5 Site: 6 Site: 7
1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.
2.% change in instantaneous MTBF
3. Includes data from stations operating after 2009 Q4.
Entire historyLast 20% of eventsFirst 120 Days
NREL cdp_fcev_97Created: Jan-09-12 4:23 PM
Sites Sorted by Increasing Age (Calendar Days)
Failu
re R
ate
Incr
easi
ngFa
ilure
Rat
e D
ecre
asin
g
Instantaneous MTBF improved for 5 of 7 sites for the last 20% of events.
12%2 522%2
43%2
127%2
-64%2 -20%2
379%2
36
Cost of Ownership: Backup power Fuel Cell* Diesel Battery Reliability + o + Capital Cost ($/kW) - + ++ Extended Run Time ++ ++ -- Emissions ++ - ++ Noise + + ++ Environmental ~ - ~ Weight + - - Efficiency + - ++ Annual Fuel Cost + - ++ Annual Maintenance Cost + - ++ Maintenance Frequency ++ - ? Refurbishment + + -- Conditioning Tests + - ~ Operation Lifetime + ++ --
Gathering data on: • Site Description • System Description • System Requirements • Capital Cost • Operating & Maintenance
Cost • Operating Lifetime for fuel cells, batteries, and generators
*Tax credit $3,000/kW or 30% total
Performance and Reliability of Fuel Cell Systems in the FieldOutlineProject Approach Combined ResultsDeployments we trackFueling RatesFueling TimesLight Duty Vehicles2nd Generation Vehicles Demonstrated Technology Improvements Over Gen 1Infrastructure StatusTotal of 99 CDPs Published, �Including 40 Winter 2011 CDPsProject Achieved Both Technical Goals; �Outside Analysis Used for Cost EvaluationRANGE: Results Show Significant Improvement in �Real-World Driving Range Between 3 Sets of VehiclesEvaluated FC Durability Data from FCEVs After 2009Q4 – �Fuel Cell Stack Operation Hours and Max Power DegradationProjected Fuel Stack Durability to 10% Voltage Degradation; Two FitsInfrastructure SafetyInfrastructure Maintenance: EquipmentBackup PowerReliability: 99.5% successful startsMaterial Handling EquipmentMHE Operation StatusAnnualized Total Cost of Ownership per Unit Identifies Key Cost �Advantages are Dependent on Deployment SizeMHE AvailabilityReliability - Fuel Cell SystemReliability - InfrastructureDeep Dive: Hydrogen LeaksDeep Dive: Hydrogen CompressorsHydrogen Compressors: Improving ReliabilityTechnical Summary – What We’ve LearnedTechnical Summary – What We’ve LearnedMore information availableBackup SlidesCumulative MileageInfrastructure Maintenance: MTBFCost of Ownership: Backup power
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