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Contract No. DE-AC36-08GO28308

National FCEV Learning Demonstration

Winter 2011

Composite Data Products

Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden, 

Chris Ainscough, and Genevieve Saur 

Technical Report 

NREL/TP-5600-54020

January 2012
NOTICE

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Winter 2011 Composite Data Products: 

National FCEV Learning Demonstration

January 18, 2012

Keith Wipke, Sam Sprik, 

Jennifer Kurtz, Todd 

Ramsden, Chris 

Ainscough, Genevieve 

Saur
National Renewable Energy Laboratory 2 Innovation for Our Energy Future

0

1

2

3

Number of Reports

Safety Reports - Vehicle Operation

Tank Scratch

Traffic Accident

H2 Leak - During Fueling

H2 Alarm - Fuel System

H2 Alarm - Passenger Compartment

Created: Dec-06-11 3:12 PM

NREL cdp_fcev_09

Created: Dec-06-11 3:12 PM

NREL cdp_fcev_09

CDP#9: Safety Reports – Vehicles
National Renewable Energy Laboratory 3 Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Histogram of Fueling Rates

350 vs 700 bar Fills

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 Count

------------- ------------------ ------- --------

Through 2009Q4

350 bar 0.82 29% 19659

700 bar 0.63 4% 5590

------------- ------------------ ------- --------

After 2009Q4

350 bar 0.70 8% 2594

700 bar 0.64 7% 5208

Number of Fueling Events (Through 2009Q4)

350 bar (Through 2009Q4)

700 bar (Through 2009Q4)

700 bar (After 2009Q4)

350 bar (After 2009Q4)

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

0

100

200

300

400

500

600

700

800

Number of Fueling Events (After 2009Q4)

NREL cdp_fcev_14

Created: Jan-10-12 10:23 AM

CDP#14: Fueling Rates by Fill Pressure
National Renewable Energy Laboratory 4 Innovation for Our Energy Future

CDP#18: Refueling Rates

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

200

400

600

800

1000

1200

1400

1600

1800

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

Vehicle and Infrastructure

5 kg in 

5 minutes 

5 kg in

3 minutes

25464 Events

Average = 0.77 kg/min

23% >1 kg/min

8,050 Events

Average = 0.65 kg/min

7% >1 kg/min

 2006 MYPP Tech Val Milestone

 2012 MYPP Tech Val Milestone

 Through 2009Q4

 After 2009Q4

NREL cdp_fcev_18

Created: Dec-07-11 11:08 AM
National Renewable Energy Laboratory 5 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

40

45

50

Number of Vehicles

Total Vehicle Hours

Vehicle Hours: All OEMs, Gen 1 and Gen 2

In Service

Retired (1)

Total Vehicle Hours = 154,407

Through 2011 Q3

Created: Dec-13-11 04:15 PM

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL

Some project teams concluded in Fall/Winter 2009

NREL cdp_fcev_22

CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 6 Innovation for Our Energy Future

0

10

20

30

40

50

60

Number of Vehicles

Total Vehicle Miles

Vehicle Miles: All OEMs, Gen 1 and 2

In Service

Retired (1)

Total Vehicle Miles Traveled = 3,590,828

Through 2011 Q3

Created: Dec-13-11 03:23 PM

NREL cdp_fcev_23 (1) Retired vehicles have left DOE fleet and are no longer providing data to NREL

Some project teams concluded in Fall/Winter 2009

CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 7 Innovation for Our Energy Future

CDP#24: Cumulative Vehicle Miles Traveled

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 

Vehicle Miles Traveled

Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2

Created: Dec-13-11 03:23 PM

Through 2011 Q3

NREL cdp_fcev_24
National Renewable Energy Laboratory 8 Innovation for Our Energy Future

CDP#25: Vehicle H2 Storage Technologies

4

83

45

51

-

20 

40 

60 

80 

100 

120 

140 

160 

180 

200 

Cumulative Vehicles Deployed/Retired1

Vehicle Deployment by On-Board Hydrogen Storage Type

700 bar on-road

350 bar on-road

Liquid H2 on-road

700 bar retired

350 bar retired

Liquid H2 retired

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL Created Dec-13-11 3:12 PM (2) Two project teams concluded in Fall/Winter 2009

183

NREL cdp_fcev_25

(2)
National Renewable Energy Laboratory 9 Innovation for Our Energy Future

CDP#26: Cumulative H2 Produced or Dispensed

0

20

40

60

80

100

120

140

160

Mass of Hydrogen 

(1000 kg)

Calendar Quarter

Cumulative Hydrogen Produced or Dispensed 

Through 2011 Q3

NREL cdp_fcev_26

Created Dec-9-11 9:15 AM

*

*Some project teams 

concluded in Fall/Winter 2009

151,900 kg of hydrogen 

produced or dispensed 

since project inception
National Renewable Energy Laboratory 10 Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Histogram of Fueling Rates

Comm vs Non-Comm Fills

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 

------------- ------------------ -------

Through 2009Q4

Comm 0.86 30%

Non-Comm 0.66 12%

------------- ------------------ -------

After 2009Q4

Comm 0.58 3%

Non-Comm 0.81 16%

Number of Fueling Events (Through 2009Q4)

Comm (Through 2009Q4)

Non-Comm (Through 2009Q4)

Non-Comm (After 2009Q4)

Comm (After 2009Q4)

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

0

100

200

300

400

500

600

700

800

Number of Fueling Events (After 2009Q4)

NREL cdp_fcev_29

Created: Jan-10-12 10:28 AM

CDP#29: Fueling Rates by Communication 

Type 
National Renewable Energy Laboratory 11 Innovation for Our Energy Future

7

12

6

0

5

10

15

20

25

Number of Stations

Reporting Period

Cumulative Stations

Continuing Outside of Project

Retired Stations

Current Project Stations

NREL cdp_fcev_31

Created Dec-9-11 9:15 AM

CDP#31: Number of Online Stations
National Renewable Energy Laboratory 12 Innovation for Our Energy Future

0

1

2

3

4

5

6

7

8

9

Compressed Liquid Pipeline Reforming Electrolysis

Number of Stations

Learning Demonstration Hydrogen Stations by Type

Operating Outside of Project

Operating Within Project

Historical 2005-2009*

NREL cdp_fcev_32

Created Dec-9-11 9:15 AM

Delivered On-Site Production

*Some project teams concluded Fall/Winter 2009. Markers show the cumulative stations operated during the 2005-2009 period

CDP#32: Infrastructure Hydrogen Production 

Methods 
National Renewable Energy Laboratory 13 Innovation for Our Energy Future

CDP#36: Type of Infrastructure Safety Report 

By Quarter

0

10

20

30

40

50

Number of Reports

Type of Infrastructure Safety Reports by Quarter Through 2011 Q3

05Q205Q305Q406Q106Q206Q306Q407Q107Q207Q307Q408Q108Q208Q308Q409Q109Q209Q309Q410Q110Q210Q310Q411Q111Q211Q3

Incident

Near Miss

Non-Event

Avg # Reports/Station

NREL cdp_fcev_36

Created: Dec-15-11 3:36 PM

Reporting Period 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
National Renewable Energy Laboratory 14 Innovation for Our Energy Future

CDP#38: Refueling Times

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

500

1000

1500

2000

2500

3000

3500

Time (min)

Number of Fueling Events

Histogram of Fueling Times

Vehicle and Infrastructure

Average = 3.26 min

86% <5 min

Average = 4.49 min

69% <5 min

 2006 MYPP Tech Val Milestone (5 kg in 5 min)

 2012 MYPP Tech Val Milestone (5 kg in 3 min)

 Through 2009Q4

 After 2009Q4

NREL cdp_fcev_38

Created: Dec-07-11 11:10 AM
National Renewable Energy Laboratory 15 Innovation for Our Energy Future

CDP#39: Refueling Amounts

0 1 2 3 4 5 6 7 0

100

200

300

400

500

600

700

800

900

1000

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling Amounts

Vehicle and Infrastructure

Average = 2.13 kg

 Average = 2.64 kg 

 Through 2009Q4

 After 2009Q4

NREL cdp_fcev_39

Created: Dec-07-11 11:13 AM
National Renewable Energy Laboratory 16 Innovation for Our Energy Future

CDP#40: H2 Tank Level at Refueling

Through 2009Q4

After 2009Q4

Tank Levels: DOE Fleet

14%

E F

14%

NREL cdp_fcev_40

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

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.

Median Tank Level (At Fill) = 42% Total refuelings1

 = 27113

Created: Dec-13-11 3:56 PM

Total refuelings1 Median Tank Level (At Fill) = 50% = 9,965
National Renewable Energy Laboratory 17 Innovation for Our Energy Future

CDP#42: Refueling by Time of Day

Through 2009Q4

After 2009Q4

Refueling by Time of Day

9%

3

12

9

6

Total Fill3 % of fills b/t 6 AM & 6 PM: 89.7% Events = 22657

1. Fills between 6 AM & 6 PM

2. The outer arc is set at 12 % total Fill.

3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

10%

NREL cdp_fcev_42

Created: Dec-13-11 3:56 PM

Total Fill3 % of fills b/t 6 AM & 6 PM: 88.3% Events = 9983
National Renewable Energy Laboratory 18 Innovation for Our Energy Future

CDP#43: Refueling by Day of Week

Sun Mon Tues Wed Thur Fri Sat 0

5

10

15

20

25

Refueling by Day of Week

% of Fills in a Day

Day

Through 2009Q4

After 2009Q4

NREL cdp_fcev_43

Created: Dec-13-11 3:56 PM
National Renewable Energy Laboratory 19 Innovation for Our Energy Future

Driving by Time of Day

9%

3

12

9

6

Total Driving3 % of driving trips b/t 6 AM & 6 PM: 85.3% Events = 295222

1. Driving trips between 6 AM & 6 PM

2. The outer arc is set at 12 % total Driving.

3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

7%

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

Through 2009Q4

After 2009Q4

NHTS

NREL cdp_fcev_44

Created: Dec-06-11 5:10 PM

Total Drive3 % of driving trips b/t 6 AM & 6 PM: 75.0% Events = 60623

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#44: Driving Start Time – Day
National Renewable Energy Laboratory 20 Innovation for Our Energy Future

Sun Mon Tues Wed Thur Fri Sat 0

5

10

15

20

25

Driving by Day of Week

% of Trips in a Day

Day

Through 2009Q4

After 2009Q4

NHTS

NREL cdp_fcev_45

Created: Dec-06-11 5:10 PM

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#45: Driving by Day of Week
National Renewable Energy Laboratory 21 Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

100

200

300

400

500

600

700

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Year Avg (kg/min) %>1 

------- ----------------- -------

2005 0.66 16%

2006 0.74 21%

2007 0.81 26%

2008 0.77 23%

2009 0.77 22%

2010 0.63 2%

2011 0.68 12%

2005

2006

2007

2008

2009

2010

2011

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

NREL cdp_fcev_52

Created: Jan-10-12 11:49 AM

CDP#52: Fueling Rates by Year
National Renewable Energy Laboratory 22 Innovation for Our Energy Future

CDP#80: Miles Between Refuelings

0 50 100 150 200 250 300 0

5

10

Percentage of Refuelings

Distance between refuelings [Miles]2

Distance Driven Between Refuelings: All OEMs

Gen1

Gen2

After 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
National Renewable Energy Laboratory 23 Innovation for Our Energy Future

CDP#81: Average Trip Speed

0 5 10 15 20 25 30 35 40 45 0

2

4

6

8

10

12

14

16

18

20

Trip Frequency1 [%]

Average Trip Speed [mph]

Histogram of Average Trip Speed

179,424 trips

1) Excludes trips <= 1 mile (40.9%)

48,568 trips

Average trip speed of 25.3 mph

2) 2001 NHTS data includes Car, Truck, Van & SUV day trips 1) Excludes trips <= 1 mile (19.9%)

Through 2009Q4

After 2009Q4

NHTS Data2

NHTS Avg Speed

NREL cdp_fcev_81

Average trip speed of 23.2 mph

Created: Dec-06-11 5:10 PM
National Renewable Energy Laboratory 24 Innovation for Our Energy Future

CDP#82: Daily FC Operation Hours in 

Automotive Application

0 1 2 3 4 0

20

40

60

80

Hours of Operation Per Day

Days of Operation [%]

Fuel Cell System Operation Hours Per Day

Through 2009Q4

After 2009Q4

0 1 2 3 4 0

20

40

60

80

Average Hours of Operation Per Day

Fuel Cell Systems [%]

Average Daily Fuel Cell System Operation Hours

9.9% Fuel Cell Systems Average > 30 mins Daily

18.3% Fuel Cell Systems Average > 30 mins Daily

Through 2009Q4

After 2009Q4

NREL cdp_fcev_82

Created: Dec-15-11 12:40 PM
National Renewable Energy Laboratory 25 Innovation for Our Energy Future

CDP#83: Hydrogen Dispensed by Day of 

Week

Sun Mon Tues Wed Thur Fri Sat 0

2

4

6

8

10

12

14

16

18

20

Dispensed Hydrogen [% of total]

Day of Week

Dispensed Hydrogen per Day of Week

0

3

6

9

12

15

18

21

24

27

30

Daily Average [kg]

27 kg/day avg All Stations

Individual Stations

NREL cdp_fcev_83

Created: Dec-15-11 1:20 PM
National Renewable Energy Laboratory 26 Innovation for Our Energy Future

CDP#84: Effect of Average Trip Speed on 

Fuel Economy

0 5 10 15 20 25 30 35 40 45 50 55 0

0.2

0.4

0.6

0.8

1

1.2

Effect of Average Trip Speed on Fuel Economy

1Fuel Economy [normalized]

Avg Trip Speed [miles/hour]

Average of Fleet Medians

25th to 75th Percentile

NREL cdp_fcev_84

Created: Dec-06-11 5:11 PM

(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet.

 Data binned every 5 mph for calculating median and percentiles.
National Renewable Energy Laboratory 27 Innovation for Our Energy Future

CDP#85: Effect of Trip Length on Fuel 

Economy 

0 10 20 30 40 50 60 70 0

0.2

0.4

0.6

0.8

1

1.2

Effect of Average Trip Length on Fuel Economy

1Fuel Economy [normalized]

Trip Length [miles]

Average of Fleet Medians

25th to 75th Percentile

NREL cdp_fcev_85

Created: Dec-06-11 5:11 PM

(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet.

 Data binned every 5 miles for calculating median and percentiles.
National Renewable Energy Laboratory 28 Innovation for Our Energy Future

CDP#86: Fuel Cell Stack Operation Hours

0 200 400 600 800 1000 1200 1400 1600 1800 2000 >2000 0

5

10

15

20

25

Fuel Cell Stack4

 Operation Hours

FC Stacks [%]

Operation Hours

25% of FC Stacks > 937 hours

Median (620 hours)

In Service1

Retired2

Not in Service3

NREL cdp_fcev_86

Created: 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 performance

related issues or c)removed from DOE program.

4) Only includes systems operating after 2009Q4.
National Renewable Energy Laboratory 29 Innovation for Our Energy Future

CDP#87: Fuel Cell Stacks Projected Hours to 

10% Voltage Degradation with Two Fits

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >3000 0

10

20

30

40

50

60

Fuel Cell Stacks4

 Projected Hours to 10% Voltage Degradation 1,748

FC Stacks [%]

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 >3000 0

10

20

30

40

50

60

2,261

Projected Hours to 10% Voltage Degradation 1,3

FC Stacks [%]

Steady Operation Fit (In Service)5

Steady Operation Fit (Retired or Not in Service)2, 5

Weighted Average (Fleet)

NREL cdp_fcev_87

Created: 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.
National Renewable Energy Laboratory 30 Innovation for Our Energy Future

CDP#88: Comparison of Fuel Cell Operation Hours 

and Projected Hours to 10% Voltage Degradation

0 500 1000 1500 2000

0

500

1000

1500

2000

2500

3000

3500

Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation5

Projected Hours1,2,4

Operation Hours

projected hrs = operation hrs

FC System

FC System (Limited)2

FC System (Retired)3

Unity Line

NREL cdp_fcev_88

Created: Jan-10-12 10:29 AM

25% of stacks are

below the unity line

and have operated

past 10% voltage

degradation.

On average, these

stacks have

operated for 990

hours.

Stacks above the

unity line have not

operated 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.

5) Only includes systems operated after 2009Q4.
National Renewable Energy Laboratory 31 Innovation for Our Energy Future

CDP#89: Fuel Cell Stack Durability as a 

Function of Voltage Drop

10 15 20 25 30 0

500

1000

1500

2000

2500

3000

3500

4000

Fuel Cell Stack6 Durability as a Function of Voltage Drop4

% Voltage Drop

Projected Hours2,3

10th/90th Percentile Projections3

Average of Fleet Projections1,5

NREL cdp_fcev_89

Created: Dec-15-11 12:14 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) 10th and 90th 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 fleet has one voltage projection value that is the weighted average of the fleet's fuel cell stack projections.

6) Only includes systems operated after 2009Q4.
National Renewable Energy Laboratory 32 Innovation for Our Energy Future

CDP#90: Max Fuel Cell Stack Power 

Degradation Over Operation

0

20

40

60

80

100

120

 0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000

Stack Op Hour Segments2

% Power1

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 Range

25th & 75th Percentiles

Group Median

Outlier

NREL cdp_fcev_90

Created: Jan-10-12 10:29 AM

Median power difference

from 0 hour segment to

1300 hour segment = -18.2%
National Renewable Energy Laboratory 33 Innovation for Our Energy Future

1 2 3 4 5 6 7 0

50

100

150

200

250

Station (Sorted By Increasing Station Capacity)

Capacity Utilization 1 [%]

Demonstration Station Capacity Utilization

58.9%

Maximum Daily Utilization

Maximum Quarterly Utilization2

Average Daily Utilization2

NREL cdp_fcev_91

Created: Jan-10-12 11:38 AM

Note: Learning Demonstration

priority was for good station

coverage not high station utilization

1

Station nameplate capacity reflects a variety of system design consderations including system capacity, throughput,

 system reliability and durability, and maintenance. Actual daily usage may exceed nameplate capacity.

2

Maximum quarterly utilization considers all days; average daily utilization considers only days when at least one filling occurred

CDP#91: Station Capacity Utilization
National Renewable Energy Laboratory 34 Innovation for Our Energy Future

CDP#92: Station Usage (fills per day)

1 2 3 4 5 6 7 0

5

10

15

20

25

30

Station (Sorted By Increasing Station Capacity)

Fills Per Day 1

Demonstration Station Usage

Maximum Daily Fills

Average Daily Fills2

NREL cdp_fcev_92

Created: Jan-10-12 11:38 AM

Note: Learning Demonstration

priority was for good station

coverage not high station utilization

1

Excludes hydrogen fills of < 0.5 kg

2

Average daily fills considers only days when at least one fill occurred
National Renewable Energy Laboratory 35 Innovation for Our Energy Future

0

500

1000

1500

2000

2500

3000

3500

4000

Station 1 Station 2 Station 3 Station 4 Station 5 Station 6

H2 Equipment Footprint (sq.ft.)

1Station capacities range from 25 to 100 kg/day, arranged from smallest to largest. 

Footprint size does not include dispenser footprint (about 10 sq.ft. per dispenser). 

Demonstration Station Area Dedicated to H2 Equipment1

NREL cdp_fcv_93

Created Jan-9-12 4:15 PM

CDP#93: Hydrogen Equipment Footprint
National Renewable Energy Laboratory 36 Innovation for Our Energy Future

CDP#94 Infrastructure Maintenance by 

Category 

5%

5%

6%

8%

9%

9%

12%

21%

21%

Classified Events = 1,0951

60% unscheduled

multiple

systems 0

misc 190

entire

system 203

classified

events1 1095

Event Count

9%

11%

6%

14%

16%

29%

Total Hours = 6,570

50% unscheduled

electrical

software

hydrogen compressor

sensors

valves

air system

dispenser

fittings&piping

control electronics

H2 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. For

legacy results refer to CDP #63.

Created: Jan-17-12 1:53 PM

Infrastructure Maintenance By Equipment Type2
National Renewable Energy Laboratory 37 Innovation for Our Energy Future

CDP#95 Infrastructure Maintenance By 

Quarter 

 0

10

20

30

40

50

60

70

80

Maintenance Events

Average # of Events Per Thousand Fills

09Q4

10Q1

10Q2

10Q3

10Q4

11Q1

11Q2

11Q3

 0

 50

100

150

200

250

300

Maintenance Hours

Average Hours Per Thousand Fills

09Q4

10Q1

10Q2

10Q3

10Q4

11Q1

11Q2

11Q3

Scheduled

Unscheduled

Operator

NREL cdp_fcev_95

Created: Dec-15-11 12:10 PM

Infrastructure Maintenance by Quarter1

1. Includes data from stations operating after 2009 Q4.
National Renewable Energy Laboratory 38 Innovation for Our Energy Future

CDP#96 Infrastructure Maintenance Labor 

Hours 

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

 5

10

15

20

25

30

Labor Hours Per Event

Frequency (% of total)

Maintenance Labor Hours Breakdown Infrastructure1

NREL cdp_fcev_96

1 2 3 4 5 6 7

 0

10

20

30

40

50

Site

Event Labor (hrs)

Maximum and Mean Event Labor Hours

for each site.

*excluded outlier

Mean

Max

NREL cdp_fcev_96

Created: Dec-15-11 11:57 AM

>12

78% of repairs require less than the mean of 4.6 hours of labor.

Median labor hours: 2.0

1. Includes data from stations operating after 2009 Q4.
National Renewable Energy Laboratory 39 Innovation for Our Energy Future

CDP#97 Infrastructure Reliability Growth

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Shape Parameter (

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 history

Last 20% of events

First 120 Days

NREL cdp_fcev_97

Created: Jan-09-12 4:23 PM

Sites Sorted by Increasing Age (Calendar Days)

Failure Rate Increasing

Failure Rate Decreasing

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
National Renewable Energy Laboratory 40 Innovation for Our Energy Future

CDP#98 Infrastructure MTBF (based on 

Calendar Days of Operation)

0 5 10 15 20 25 30 0

1

2

3

4

Site MTBF1 (Days)

Count of Sites

Site MTBF (Calendar Days In Operation): Infrastructure2

NREL cdp_fcev_98

Created: Jan-09-12 4:26 PM 1. Cumulative Mean Time Between Failure 2. Includes data from stations operating after 2009 Q4.
National Renewable Energy Laboratory 41 Innovation for Our Energy Future

CDP#99 Infrastructure Mean Time between 

Scheduled Maintenance

0 10 20 30 40 50 60 0

1

2

3

4

Site MTBSM1 (Days)

Count of Sites

Site MTBSM (Calendar Days In Operation): Infrastructure4

0 20 40 60 80

0

1

2

3

4

Site MTBPM2

 (Days)

Count of Sites

0 500 1000 1500 2000

0

1

2

3

4

Site MTBU3

 (Days)

Count of Sites

NREL cdp_fcev_99

Created: Jan-09-12 4:20 PM 1. Mean Time Between Scheduled Maintenance. 

Includes Preventative and Upgrades

4. Includes data from stations operating after 2009 Q4.

2

Mean Time Between Preventative Maintenance 3Mean Time Between Upgrade