Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation ProjectSpring 2007 Composite Data ProductsMarch 8, 2007K. Wipke, S. Sprik, H. Thomas, and C. Welch
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Controlled Hydrogen Fle

Infrastructure Demonstra

Validation Project

Spring 2007 

Composite Data Produ

3/8/07

Keith Wipke, Sam Sprik, Holly Thomas
Max Hrs Accumulated (1)(2) Avg Hrs Accu

0

200400600800

Time (Hours)

DOE Learning Demonstration:

Fuel Cell Stack Hours Accumulated Through 2006 Q

Created: Feb-28-07 8:27 PM

(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 individ(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each O

CDP#1A: Learning Demo Fuel 

Hours Accumulated Through 
Projected Hours to 10% Voltage Degradation (1)(2)

0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabi

Based on Data Through 2006 Q4

Created: Feb-28-07 8:27 PM

(1) 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 membra(2) 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 limita as additional data are accumulated.(3) Projections based on limited accumulated stack hours to date. Average stack hours accumulated to-date range  stack hours accumulated to-date range between 300 and 642.

CDP#1B: Projected Ho

to 10% Stack Voltage Degr
0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hour

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

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabi

Based on Data Through 2006 Q4

Created: Feb-28-07 8:27 PM

(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 membra(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 limita as additional data are accumulated.

CDP#1C: Hours Accumulate

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

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Feb-27-07 4:49 PM

(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-27-07 4:49 PM

(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 Pow

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 Effici
CDP#9: Safety Incidents – V

Safety Incidents - Vehicle Operation

05

101520253035404550

2005 Q2

2005 Q3

2005 Q4

2006 Q1

2006 Q2

2006 

Number of Incidents

H2 Leak - During FuelingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment

Created: 2/28/07 8:45AM
CDP#10: Storage Weight % H

0123456789

All OEMs

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

2015 2010 2007 

Created: 23-Feb-2006

1Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced 
CDP#11: Volumetric Capaci

Storage

0

0.010.020.030.040.050.060.070.080.09

0.1

All OEMs

Mass H2 per Liter (kg/L)

Mass of Hydrogen Per Liter

2015 2010 2007 

Created: 23-Feb-2006

1Emphasis is on advanced materials-based technologies.
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

102030405060708090

100110120130140150160170180190200210220230240250260270

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty Through 2006Q4

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 

2006 Tech 2010 MYPP 

Created: Feb-28-07 1:42 PM

CDP#18: Refueling Ra
CDP#20: Safety Incidents – Inf

Total Infrastructure Safety Events by 

and Event Type Through 2006 Q

05

101520253035404550556065

Non-Event Near Miss 

Severity

Number of Events

H2 Release - SignElectrical IssueNon-H2 ReleaseAutomatic System Equipment MalfunAlarms OnlyH2 Release - Mino

Created 07-Mar-2007
-30-20-10

0

102030405060

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: Mar-07-07 3:35 PM

CDP#21: Range of Ambient Tem

During Vehicle Operatio
CDP#22: Vehicle Operating 

Vehicle Hours: All OEMs Combined

02468

1012141618

0-100

100-200

200-300

300-400

400-500

500-600

600-700

700-800

Total Vehicle Hours

Number of Vehicles

Throu

gh 

Q4 2006

Created: 28-Feb-07

Total Vehicle Hours = 28

Through Q4 2006

Vehicle Hours: All OEMs Combined

02468

1012141618

0-100

100-200

200-300

300-400

400-500

500-600

600-700

700-800

Total Vehicle Hours

Number of Vehicles

Throu

gh 

Q4 2006

Created: 28-Feb-07

Total Vehicle Hours = 28

Through Q4 2006
CDP#23: Vehicles vs. Miles 

Vehicle Miles: All OEMs Combined

02468

101214

0-2000

2000-4000

4000-6000

6000-8000

8000-10000

10000-12000

12000-14000

14000-16000

160

Total Vehicle Miles

Number of Vehicles

Total Miles Traveled = 

Through Q4 2006

Created: 28-Feb-07
CDP#24: Cumulative Vehic

Traveled

Cumulative Vehicle Miles Traveled: All 

-

100,000200,000300,000400,000500,000600,000700,000

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2

Vehicle Miles Traveled

Created: 28-Feb-07
CDP#25: Vehicle H2 Storage Te

On-Board Hydrogen Storage Methods

-

1020304050607080

2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2

# of Vehicles (All Teams)

Liquid H210,000 psi tanks5,000 psi tanks

Created Feb-28-2007 
Cumulative Hydrogen Produced or D

0123456789

10111213141516171819202122Q2 2005 Q3 2005 Q4 2005 Q1 2006 Q2 2006 

Calendar Quarter

Mass of Hydrogen (kg) (thousands)

Created 20-Feb-2007

CDP#26: Cumulative H2 Pro

Dispensed
CDP#27: Hydrogen Purity S

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-28-07 12:06 PM

(1) Includes sampling from both electrolysis and reforming
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 

Total S* 

nmol/mol (ppb)

Created: Feb-28-07 12:06 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP #28: Hydrogen Impurities 
CDP#30: Infrastructure Mai

0 20 40 60 80 100 120 140 

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since Inc

0

5 10 15 20 

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-28-07 7:16 PM
CDP#31: Number of Reporting 

Online Stations

02468

1012

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 

Reporting Period

Number of Stations

Created 20-Feb-2007
CDP#32: Infrastructure Hy

Production Methods

Infrastructure H

ydro

gen Production 

012345

Delivered

Compressed H2

Natural Gas Onsite Reforming Electrolysis 

Production Technology

# of Stations

Created 07-Mar-2007
0 10 20 30 40 50 60 70 

0

102030405060708090

100

Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refuelings

Percentage of refuelings

PercentageCumulative Percentage

Created: Feb-26-07 12:53 PM

Total refuelings2 = 5480

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

CDP#33: Percentage of Theore

Traveled Between Refue
0 10 20 30 40 50 60 70 

Vehicle Range Factors

Percentage of chassis dyno range1.

All OEMs

On-Road 

3

Created: Feb-26-07 12:53 PM

1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted) and usable fuel 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 
Infrastructure Safety Trend and Online Stations

11 10

20

31

104

110

02468

1012

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 Q3 

Reporting Period

Number of Stations

Number of Online StationsAverage Refuelings Between SafetyEvents

Created 28-Feb-2007

CDP#35: Average Refuelings 

Infrastructure Safety Ev
CDP#36: Type of Infrastructu

Event By Quarter

Type of Infrastructure Safety Event by Quarter Through 

02468

1012141618

2005 Q2 2005 Q3 2005 Q4 2006 Q1 2006 Q2 2006 

Reporting Period

Number of Events

IncidentNear MissNon-EventStations OnAverage # E

Created 07-Mar-2007
CDP#37: Primary Factors of Inf

Safety Events

Primary Factors of Infrastructure 

Through 2006 Q4

0 10 20 30 40 5

Total Non-Events

Total Near Miss

Total Incidents

Severity

Number Of Events

Calibration/Settings/ Software Environment (Weather, PoweInadequate/ Non-working EquNot Yet DeterminedMischief, Vandalism, SabotagMaintenance RequiredDesign Flaw Operator/Personnel Error

Created 07-Mar-2007
CDP#38: Refueling Tim

0 2 4 6 8 10 12 14 

0

102030405060708090

100110120130140150160170180190200210220230240250

Time (min)

Number of Fueling Events

Histogram of Fueling Times

All Light Duty Through 2006Q4

Created: Feb-28-07 1:43 PM
0 0.5 1 1.5 2 2.5 3 3.5 

0

102030405060708090

100110120130140150

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling AmountsAll Light Duty Through 2006Q4

Created: Feb-28-07 1:43 PM

CDP#39: Refueling Amo
F1147-E(12/2004) 

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Spring 2007 

5a. CONTRACT NUMBER

DE-AC36-99-GO10337 

5b. GRANT NUMBER

4. TITLE AND SUBTITLE

Controlled Hydrogen Fleet and Infrastructure Demonstration and 

Validation Project: Spring 2007 Composite Data Products 

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

NREL/TP-560-41413 

5e. TASK NUMBER

H270-8100 

6. AUTHOR(S)

Keith Wipke, Sam Sprik, Holly Thomas, and Cory Welch 

5f. WORK UNIT NUMBER

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National Renewable Energy Laboratory 

1617 Cole Blvd. 

Golden, CO 80401-3393 

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NREL/TP-560-41413 

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14. ABSTRACT (Maximum 200 Words)

This presentation provides the composite data products as of Spring 2007 from NREL's Controlled Hydrogen Fleet 

and Infrastructure Demonstration and Validation Project. 

15. SUBJECT TERMS

composite data products; technology validation; Controlled Hydrogen Fleet and Infrastructure Demonstration and 

Validation Project; learning demonstration 

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