Introduction to the U.S. Dep

Energy’s Controlled Hydro

and Infrastructure Demonst

Validation Project

Keith Wipke, Senior Enginee

National Renewable Energy Labo

Co-authors: 

Cory Welch, Holly Thomas (NREL

Sigmund Gronich, John Garbak, Doug Hoo

NREL/PR-560-39980Posted with Permission 
Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36Department of Energy (the “DOE”). The United States Government (the “Government”) retains athe work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrepublish or reproduce the published form of this work, or allow others to do so, for Government puNeither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employeeor implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulnesproduct, or process disclosed, or represents that its use would not infringe any privately owned ri

specific commercial product, process, or service by trade name, trademark, manufacturer, or othimply its endorsement, recommendation, or favoring by the Government or any agency thereof. authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the agency thereof. 
Outline

• Project Overview

– Objectives & key targets– Teams & plans

• Data Analysis

– Data collection– Sample data analyses

• Conclusions

No confidential or proprietary data is 

contained in this presentation
Project Objectives and 

• Objectives

– Validate “System” Solutions for H

2 Tran

– Identify Status of Technology– Re-Focus Research and Development– Support Industry Commercialization De

Performance Measure Fuel Cell Stack Durability Vehicle Range Hydrogen Cost at Station * To verify progress toward ** Subsequent projects to v

Key Targets

Hydrogen and gasoline station, WA DC

Photo: Shell Hydrogen
(1) Fuel cells supplied by Ballard 

(1)

Successful Teams Ann
Team Overview – Chevro

• 32 Fuel 

-SUVs-2 Fue

• Up to 6 F• 2 regions
Team Overview – Daimler

• 36 Fuel 

-F-CeSprint-2 Fue

• Up to 8 • 3 region
Team Overview – Fo

• 26 Fuel 

-Ford (Gen -2 Fue

• Up to 7 • 3 region
Team Overview – G

• 40 Fuel C

-Opel Z(Gen 1

-2 Fuel 

• Up to 7 F• 4 regions
Refueling Stations from All Fou

Begin to Create Regional Ne

Additional Planned Stations DaimlerChrysler & BP (up to 2)General Motors & Shell (1)ChevronTexaco (up to 2)

SE Michigan

Online Stations

Ford & BPChevronTexacoDaimlerChrysler & BPGeneral Motors & ShellOther Companies

Northern California

Additional Planned Stations Ford & BP (up to 4)DaimlerChrysler & BP (up to 3)General Motors & Shell (1)ChevronTexaco & Hyundai (up to 2)

Southern California

Additional Planned Stations

DaimlerChrysler & BP (2)General Motors & Shell (1)ChevronTexaco (2)
Data Collection: Diverse Geo

Addresses Four Key U.S. C

Cold, Moderate, Hot/Humid, Hot/A
Teams Will Field 

Four Main* Types of Veh

*DaimlerChrysler will also have FCV Sprinter vans
Sample Hydrogen Refueling In

Chino, CA

Hydrogen and gasoline station, WA DC

LAX refueling station

Photo:Shell Hydrogen

Photos: DTE

DTE/BP Power Park, Southfield, MI
Data Collection: Ove

Key Infra

Conve

Produc

Maintenan

Hydrogen 

Refuelin

H

2 Pro

Conversio

Storage 

E

Key Vehicle Data

Stack Durability

Fuel Economy (Dyno & On-Road) 

and Vehicle Range

Fuel Cell System Efficiency

Maintenance, Safety Events

Top Speed, Accel., Grade

Max Pwr & Time at 40C

Freeze Start Ability (Time, Energy)

Continuous Voltage and Current 

(or Power) from Fuel Cell Stack, 

Motor/Generator, Battery & Key 

Auxiliaries: (Dyno & On-Road)
Data Collection & Analysi

Hydrogen Secure Data 

Center (HSDC)

Raw Data, 

Reports

• @ NREL: Strictly Controlled Access• Detailed Analyses, Data Products, Internal Reports• HSDC ADVISOR

Com

P

• PUpDa• NInf

.6000

0

10002000300040005000

2000 

Durability (Operating Hours) Me

.6000

0

10002000300040005000

2000 

Durability (Operating Hours) Me
Sample Composite Data Exam

Presented to Public Within Ne

Fuel Economy

All OEM's

0

10203040506070

Dyno On-Road

mi/gge

(1) (2)

(1) One data point for each make/model(2) One data point for the on-road fleet  average of each make/model

MaxMinMedian

Pro

2468

1012

# of Vehicles (all Teams)

Fuel Cell Durability

Actual vs. DOE Targets

All OEM's, All Fuel Cell Stacks

0

100020003000400050006000

2000 2005 2010 2015

Durability (Operating Hours) .

Median

Actual Target 90% Prediction Interval

100150200250300350

20

Range (miles) 

MaxMinMedian
Handling Data Security a

• Protects all raw data 

and our analysis results

• Only things that leave 

room:

– composite data results– trend feedback into R&D

PIN reader 

badge scanner 

1350 lb. safe for backups

Server, workstation, 

tape backup and UPS

Motion sensors

Audible alarm
Analysis Example: FC Stack 

Various Fuel Cell Polarization Cur

200250300350400450

0 100 200 

Current (A)

Voltage (V)

Overall Drop

Slope Change

MasApp

Baseline
Analysis Example: Stack De
Analysis Example: Stack De

0 50 100 150 200 25

200220240260280300320340360380400

Operating T ime (hrs)

Predicted (Curve Fit) Voltage (V)

Predicted (Curve Fit) Voltage vs. time for Sim

V @ 50.0A = 349.6394+ -0.0059* (hrs) 95% C.I. for slope (V/hr) V @ 100.0A = 326.6046+ -0.0207* (hrs) 95% C.I. for slope (V/hr) V @ 150.0A = 308.1169+ -0.0354* (hrs) 95% C.I. for slope (V/hr) V @ 200.0A = 291.4908+ -0.0502* (hrs) 95% C.I. for slope (V/hr) V @ 250.0A = 275.8848+ -0.0650* (hrs) 95% C.I. for slope (V/hr) 

11.7 hours of data per curve fit

6000 data points per curve fit
HSDC ADVISOR Will Assist in 

Studies and Refocusing 

% Net Power

Efficiency

Vehicle, Power Plant Parameter Summary

Include parameters for each vehicle and power plant

Report Date insert report dateAutomaker insert automaker

Parameter Units

veh_CD (1) dimensionless

veh_FA (1) m2

Vehicle Mass (1) kg

veh_front_wt_frac (1) dimensionless

veh_cg_height (1)

m

veh_wheelbase (1)

m

Fuel Cell System

c. Power Rating (net) kW

Propulsion Battery or Capacitor

c. Maximum Rated AmpereHour Capacity Ampere*hrs

Electric Propulsion Motor 

b. Peak Power Rating kW

AD

0

20406080

Miles/kg H2 
Recent Activities – Open

ChevronTexaco Station in 
Conclusions

• A data collection and management system 

implemented to provide critical information 

– Fuel cell lifetime, voltage degradation, and syst– Vehicle range, fuel economy, and progress of H– Hydrogen production efficiencies and H2 purity– Refueling infrastructure performance– Other data to mark progress toward DOE techn

• Data will:

– Help to identify status of technology– Re-Focus Research and Development– Support Commercialization Decision by 2015

• 25 key composite data products will be av

– Show progress toward DOE/industry targets

• Data collection/reporting by partners has b• DOE coordination internationally through i

programs and with state initiatives
Questions?

keith_wipke@nrel.gov

1.303.275.4451