Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation ProjectSpring 2008 Composite Data ProductsFinal Version: February 29, 2008Keith Wipke, Sam Sprik, Jennifer Kurtz
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Controlled Hydrogen Fle

Infrastructure Demonstra

Validation Project

Spring 2008 

Composite Data Produ

Final Version: February 29

Keith Wipke, Sam Sprik, Jennife
0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hou

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durab

Based on Data Through 2007 Q4

Created: Feb-26-08 11:46 AM

(1) Range bars created using one data point for each OEM.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack (3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's flee(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing  may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membr(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = averag The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limi as additional data are accumulated.

CDP#1: Hours Accumulated 

Projected Hours to 10% Stack Voltag
Dyno Range (2) Window-Sticker Range (3) On-

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Feb-15-08 7:37 AM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each (2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAE J2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.

CDP#2: Vehicle Rang
Dyno (1) Window-Sticker (2) 

0

1020304050607080

Fuel Economy (miles/kg H

2

)

Fuel Economy

Created: Feb-15-08 7:17 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAE J2572.(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).(4) Calculated from on-road fuel cell stack current or mass flow readings.

CDP#6: Fuel Econom
0

10203040506070

All OEMs

Efficiency (%) 

Fuel Cell System1 Efficiency2 at ~25% Net Po

Created: Aug-29-06 4:09 PM

1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAEJ2615.2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).

Excludes power electronics and electric drive.

CDP#8: FC System Effic
Safety Reports - Vehicle Operation

0123

2005 Q2

2005 Q3

2005 Q4

2006 Q1

2006 Q2

2006 Q3

2006 Q4

2007 Q1

2007 

Number of Reports

Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger C

Created: 2/15/07 9AM

CDP#9: Safety Reports – V
350bar 700

0123456789

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

Created: Feb-15-08 7:32 AM

1Targets are set for advanced materials-based hydrogen storage technologies.

CDP#10: Storage Weight % H
350bar 700

0

0.010.020.030.040.050.060.070.080.09

0.1

Mass H2 per Liter (kg/L)

Mass of Hydrogen Per Liter

Created: Feb-15-08 7:32 AM

1Targets are set for advanced materials-based hydrogen storage technologies.

CDP#11: Volumetric Capacity o
CDP#12: Vehicle Hydrogen Tan

0

2000400060008000

1000012000

All OEMs

Number of cycles

Hydrogen Tank Cycle Life

2015 2010 2007 

Created: 23-Feb-2006

1Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced 
0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

100200300400500600

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty Through 2007Q4

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 b

Average = 0.79

 % >1 = 24

2006 Tech V2010 MYPP 

Created: Feb-15-08 1:44 PM

CDP#18: Refueling Ra
0 20 40 60 80 

Non-Event

Near Miss

Incident

Number of Reports

Severity

Total Infrastructure Safety Reports by Severity

and Report Type Through 2007 Q4

Alarms OnlyAutomatic SysteElectrical IssueEquipment MalfFalse Alarm/MisH2 Release - MinH2 Release - SigNon-H2 ReleaseStructural IssueSystem Trouble

Created: Feb-15-08 1:24 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 fuelsA NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#20: Safety Reports – Infr
-30-20-10

0

102030405060

1.4oF122.9oF

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: Feb-14-08 5:40 PM

CDP#21: Range of Ambient Tem

During Vehicle Operatio
Vehicle Hours: All OEMs Combined

02468

1012141618

0-150

150-300

300-450

450-600

600-750

750-900

900-1050

1050-1200

120

Total Vehicle Hours

Number of Vehicles

Throu

gh 2007 Q4

Created: Feb-15-08

Total Vehicle Hours = 5

CDP#22: Vehicle Operating 
Vehicle Miles: All OEMs Combined

02468

10121416

0-3500

3500-7000

7000-10500

10500-14000

14000-17500

17500-21000

21000-24500

24500-28000

28000

Total Vehicle Miles

Number of Vehicles

Total Miles Traveled = 1,

Through 2007 Q4

Created: Feb-15-08

CDP#23: Vehicles vs. Miles 
Cumulative Vehicle Miles Traveled: A

-

200,000400,000600,000800,000

1,000,0001,200,000

2005Q2

2005Q3

2005Q4

2006Q1

2006Q2

2006Q3

2006Q4

2007Q1

2007

Vehicle Miles Traveled

Created: Feb-15-08

CDP#24: Cumulative Vehicle Mi
On-Board Hydrogen Storage Methods

-

102030405060708090

100

2005Q2

2005Q3

2005Q4

2006Q1

2006Q2

2006Q3

2006Q4

2007Q1

2007Q

Cumulative Vehicles Deployed

Liquid H2700 bar tanks350 bar tanks

Created Feb-08-2008 8:57AM

CDP#25: Vehicle H2 Storage Te
Cumulative Hydrogen Produced or D

Through 2007 Q4

05

101520253035404550

2005 Q2

2005 Q3

2005 Q4

2006 Q1

2006 Q2

2006 Q3

2006 Q4

2007 Q1

2007 Q2

Calendar Quarter

Mass of Hydrogen (kg) 

(thousands)

Cumulative Number of 

Created Feb-28-08

CDP#26: Cumulative H2 Produced 
99.7399.7499.7599.7699.7799.7899.79

99.8

99.8199.8299.8399.8499.8599.8699.8799.8899.89

99.9

99.9199.9299.9399.9499.9599.9699.9799.9899.99

100

Hydrogen Fuel Quality Index (%)

Hydrogen Fuel Quality Index Sampled from Stations

Created: Feb-15-08 2:10 PM

(1) Includes sampling from both electrolysis and reforming

CDP#27: Hydrogen Purity Sc
0 1 2 3 4 5 6 

Particulates 

μg/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Eq

0 500 1000 1500 2000 

(N2 + He + Ar) 

0 5 10 15 20 25 

H20 

Total HC 

O2 

CO2 

CO 

NH3 

μmol/mol (ppm)

0 10 20 30 40 50 60 7

Total S* 

nmol/mol (ppb)

Created: Feb-15-08 2:10 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP #28: Hydrogen Impurities 
0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

50

100150200250300350400

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

Comm vs Non-Comm Fills - All Light Duty Through 20

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 b

Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.94 36%Non-Comm 0.66 20%

CommNon-Comm2006 Tech V2010 MYPP 

Created: Feb-27-08 11:26 AM

CDP#29: Fueling Rates – Commun

Non-Communication Fil
0 20 40 60 80 100 12

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since Inc

Through 2007 Q4

0 5 10 15 20 25 

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Number of Events Per Station Since 

0% 10% 20% 30% 40% 50% 60% 70% 

# of Events

Hours

Comparison of Scheduled/Un-Scheduled Maintenan

Created: Feb-13-08 4:54 PM

CDP#30: Infrastructure Main
Online Stations

02468

10121416

2005

Q2

2005

Q3

2005

Q4

2006

Q1

2006

Q2

2006

Q3

2006

Q4

2007

Q1

2

Reporting Period

Number of Stations

Created Feb-15-08

CDP#31: Number of Reportin
Infrastructure Hydrogen Product

012345

Delivered

Compressed H2

Natural Gas On-site

Reforming

Electrolysis 

Production Technology

# of Stations

Created Feb-15-08

CDP#32: Infrastructure Hydrogen 

Methods
0 10 20 30 40 50 60 70 

0123456789

101112

Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refuelings

Percentage of Refuelings

0 10 20 30 40 50 60 70 

Created: Feb-15-08 9:20 AM

Total refueli

1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPAadjusted) and usable fuel on board.2. Some refueling events are not detected/reported due to data noise or incompleteness.

CDP#33: Percentage of Theoreti

Traveled Between Refueli
0 10 20 30 40 50 60 70 

Vehicle Range Factors

Percentage of chassis dyno range1.

All OEMs

On-Road 

3

Created: Feb-15-08 9:20 AM

1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City.3. Using fuel economy from on-road data (excluding trips > 1 mile, consistent with other data products).

CDP#34: Effective Vehicle 
2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 200

05

1015

Reporting Period

Number of Stations

Infrastructure Safety Trend and Online Stations Through 2

Number of Online StationsAvg Refuelings Between Safety Reports

Created: Feb-15-08 1:24 PM

7 13

34

41

114

125 129

43

6

CDP#35: Average Refuelings B

Infrastructure Safety Rep
2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 200

05

10152025

Reporting Period

Number of Reports

Type of Infrastructure Safety Reports by Quarter Through 

IncidentNear MissNon-EventStations OnlineAvg # Reports/Station

Created: Feb-15-08 1:24 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 fuelsA NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#36: Type of Infrastructure Sa

By Quarter
0 20 40 60 80 

Non-Event

Near Miss

Incident

Number of Reports

Severity

Primary Factors of Infrastructure Safety Reports

Through 2007 Q4

Calibration/Settings/ Software ControlsDesign FlawEnvironment (Weather, Power Disruption, OtheInadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel Error

Created: Feb-15-08 1:24 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 fuelsA NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#37: Primary Factors of Infr

Safety Reports
0 2 4 6 8 10 12 14 

0

200400600800

100012001400

Time (min)

Number of Fueling Events

Histogram of Fueling Times

All Light Duty Through 2007Q4

Average = 3.43

 % <5 = 87

Created: Feb-15-08 1:44 PM

CDP#38: Refueling Tim
0 0.5 1 1.5 2 2.5 3 3.5 

0

50

100150200250300350

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling AmountsAll Light Duty Through 2007Q4

Average = 2.25

Created: Feb-15-08 1:44 PM

CDP#39: Refueling Amo
Tank Levels: DOE Fleet

15%

E 

Created: Feb-27-08 10:51 AM

1. Some refueling events not recorded/detected due to data noise or inco

Median Tank Level = 39% at Fill

2. The outer arc is set at 20% total refuelings.3. If tank level at fill was not available, a complete fill up was assumed.

CDP#40: H2 Tank Level at R
E 

Tank Level Medians: DOE Fleet, All Vehicles

Created: Feb-27-08 10:51 AM

1. Some refueling events not recorded/detected due to data noise or inco2. If tank level at fill was not available, a complete fill up was assumed.

CDP#41: Refueling Tank Level
Refueling by Time of Day: DOE Fleet

9%

3

12

9

6

Created: Feb-27-08 10:51 AM

% of fills b/t 6 AM & 6 PM: 86.5% 

1. Fills between 6 AM & 6 PM2. The outer arc is set at 12 % total Fill.3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

CDP#42: Refueling by Time 
Sunday Monday Tuesday Wednesday Thursday Fri

05

101520

Fills by Day of Week: DOE Fleet

% of Fills in a Day

Day

Created: Feb-27-08 10:51 AM

CDP#43: Refueling by Day 
Driving Start Time - Day: DOE Fleet

9%

3

12

9

6

Created: Feb-27-08 10:51 AM

% of driving trips b/t 6 AM & 6 PM: 88.7% 

1. Driving trips between 6 AM & 6 PM2. The outer arc is set at 12 % total Driving.3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

% of NHTS trips b/t 6 AM & 6 PM: 81.5%

2A

CDP#44: Driving Start Tim
Sunday Monday Tuesday Wednesday Thursday Fri

05

101520

Driving Trips by Day of Week: DOE Fleet

% of Driving Trips in a Day

Day

Created: Feb-27-08 10:51 AM

2A

CDP#45: Driving by Day o
05

101520253035404550

%Time at Power Levels v2: DOE Fleet

% Time at Power Level

0-5% 5-10%10-15%15-20%20-25%25-30%30-35%35-40%40-45%45-50%50-55%55-60%60-65%65-70%70-75%75-80%

Created: Feb-27-08 12:04 PM % Fuel Cell Power (Gross) of Max

17.6%-47.9% of operating time at idle(Vehicle Speed = 0 & F.C. Power > 0)

CDP#46: Fuel Cell System Oper
0 5 10 15 

05

1015202530354045

Frequency (%)

Trip Length (miles)

Trip Length: DOE Fleet

Created: Feb-27-08 11:56 AM

2001 NHTS DASCII.csv So

CDP#47: Trip Length
CDP#48: Primary Factors Affectin

Demo Fleet Fuel Cell Degrad

DOE Fleet

High Current Time

Hot Starts

Starts/hour

Low Volta

High Volta

Cold S

Short 

0 Spee

Hot Ambie

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance. 

Created: Feb-21-08 9:32 AM

H*: Factor group aL**: Factor group a

Due to differences 

DOE Fleet Analysis 

out and concrete co

to d

Individual team an

focused on patte

DOE Fleet

High Current Time

Hot Starts

Starts/hour

Low Volta

High Volta

Cold S

Short 

0 Spee

Hot Ambie

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance. 

Created: Feb-21-08 9:32 AM

H*: Factor group aL**: Factor group a

Due to differences 

DOE Fleet Analysis 

out and concrete co

to d

Individual team an

focused on patte
CDP#49: Primary Factors Affectin

Demo Team Fuel Cell Degra

High Volt

High Cur

Hot Amb

Short TripsStarts/hour

Team 3

Team 4

Hot Start

Starts/hou

High Voltage Ti

Low Current Tim

Idle Time

Cold Starts

Warm Ambient T

Long Trips

High Voltage Time

Low Current Time

Hot Starts

Idle Time

Short TripsStarts/hour

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for each team.

2) Teams’ PLS models have a high percentage of explained decay rate variance, 

but the models are not robust and results are scattered. 

H*

L**

High Voltage Time

Low Current Time

Idle Time

Low Voltage Time

Cold Starts

Hot Ambient Temp

Short TripsStarts/hour

H*

L**

H*: Factor group asL**: Factor group a

Created: Feb-27-08 12:17 PM

High Volt

High Cur

Hot Amb

Short TripsStarts/hour

Team 3

Team 4

Hot Start

Starts/hou

High Voltage Ti

Low Current Tim

Idle Time

Cold Starts

Warm Ambient T

Long Trips

High Voltage Time

Low Current Time

Hot Starts

Idle Time

Short TripsStarts/hour

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for each team.

2) Teams’ PLS models have a high percentage of explained decay rate variance, 

but the models are not robust and results are scattered. 

H*

L**

High Voltage Time

Low Current Time

Idle Time

Low Voltage Time

Cold Starts

Hot Ambient Temp

Short TripsStarts/hour

H*

L**

H*: Factor group asL**: Factor group a

Created: Feb-27-08 12:17 PM
Refueling by Time of Night: DOE Fleet

5%

3

12

9

6

Created: Feb-27-08 10:51 AM

% of fills b/t 6 PM & 6 AM: 13.5% 

1. Fills between 6 PM & 6 AM2. The outer arc is set at 12 % total Fill.3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

CDP#50: Refueling by Time 
Driving Start Time - Night: DOE Fleet

3%

3

12

9

6

Created: Feb-27-08 10:51 AM

% of driving trips b/t 6 PM & 6 AM: 11.3% 

1. Driving trips between 6 PM & 6 AM2. The outer arc is set at 12 % total Driving.3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

% of NHTS trips b/t 6 PM & 6 AM: 18.4%

2A

CDP#51: Driving Start Time 
0 0.2 0.4 0.6 0.8 1 1.2 1.4 

0

50

100150200250300350

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year Through 2007Q4

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 b

Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 17%2006 0.72 20%2007 0.86 28%

2005200620072006 Tech V2010 MYPP 

Created: Feb-27-08 11:39 AM

CDP#52: Refueling Data b
02468

10

% Energy by Power levels: DOE Fleet

% Energy

0-5% 5-10%10-15%15-20%20-25%25-30%30-35%35-40%40-45%45-50%50-55%55-60%60-65%65-70%70-75%75-80%

% Fuel Cell Power (Gross) of Max

Created: Feb-27-08 12:04 PM

CDP#53: Fuel Cell System E

within Power Levels
0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7

0

102030405060

% Trips

Time

Time between Trips: DOE Fleet

0-10 min 10-20 min 20-30 min 

0

102030405060

% Trips

Tim

0-60 min Breakd

Created: Feb-27-08 11:56 AM

CDP#54: Time Between 
0-0.5 0.5-1 1-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-

05

10152025303540

Trip Energy: DOE Fleet

% Trips

Energy Consumed [kWh]

Created: Feb-27-08 12:04 PM

CDP#55: Fuel Cell System 
0 5 10 15 20 25 30 

05

10152025

Frequency (%)

Daily Distance (miles)

Daily Distance: DOE Fleet

Created: Feb-27-08 11:56 AM

Cumulative Frequency

@ 20 miles

DOE Fleet: 50.9%

NHTS: 27.2%

2001 NHTS DASCII.csv So

CDP#56: Daily Driving Dis
Average Breakout of H2 Sto

73

24%

3%

Average Breakout of H2 Storage System Mass

73%

23%

3.26%

 350 bar

35% 

10%

H2 Volume (%)Pressure Vessel VBalance of Plant V

26%

3.45%

71%

H2 Mass (%) Pressure Vessel Mass (%) Balance of Plant Mass (%)

 700 bar

Created: Feb-15-08 6:53 AM

CDP#57: H2 Storage System Mass 

Breakdown
F1147-E(09/2007) 

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5a. CONTRACT NUMBER

DE-AC36-99-GO10337 

5b. GRANT NUMBER

4. TITLE AND SUBTITLE

Controlled Hydrogen Fleet and Infrastructure Demonstration and 

Validation Project, Spring 2008 Composite Data Products 

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

NREL/TP-560-43049 

5e. TASK NUMBER

H2708100 

6. AUTHOR(S)

K. Wipke 

5f. WORK UNIT NUMBER

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National Renewable Energy Laboratory 

1617 Cole Blvd. 

Golden, CO 80401-3393 

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13. SUPPLEMENTARY NOTES

14. ABSTRACT (Maximum 200 Words)

Graphs of composite data products produced by DOE's Controlled Hydrogen Fleet and Infrastructure Demonstration 

and Validation project through February 2008. 

15. SUBJECT TERMS

composite data product; CDP; learning demonstration 

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