Completed Learning Demonstration Composite Data Products as of December 1, 2006Keith Wipke
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Completed Learning Demon

Composite Data Produ

as of 12/01/06

Prepared under Task No. H270.8100
Max Hrs Accumulated (1)(2) Avg Hrs Accum

0

200400600800

Time (Hours)

DOE Learning Demonstration:

Fuel Cell Stack Hours Accumulated Through August 2

Created: Oct-05-06 4:32 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 individu(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OE

CDP#1A: Learning Demo Fuel 

Hours Accumulated Through A
Projected Hours to 10% Voltage Degradation (1)(2)(3

0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabili

Based on Data Through August 2006

Created: Oct-05-06 4:32 PM

(1) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing p may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membran(2) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average  The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitat as additional data are accumulated.(3) Projections based on limited accumulated stack hours to date. Average stack hours accumulated to-date range b stack hours accumulated to-date range between 256 and 485.

CDP#1B: Projected Ho

to 10% Stack Voltage Degr
CDP#1C: Hours Accumulate

Projected Hours to 10% Stack Voltag

0

200400600800

10001200140016001800200022002400

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours 

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

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durabili

Based on Data Through August 2006

Created: Oct-05-06 4:32 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 in (3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing p may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membran(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average  The shaded green bar represents an engineering judgment of the uncertainty due to data and methodology limitat as additional data are accumulated.
Dyno Range (2) Window-Sticker Range (3) On-R

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

Created: Oct-03-06 8:07 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 SAEJ2572.(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) On

0

1020304050607080

Fuel Economy (miles/kg H

2

)

Fuel Economy

Created: Aug-25-06 10:45 AM

(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/mode(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT (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 Effic
Safety Incidents - Vehicle Operation

0123456789

10

'05 Q2

'05 Q3

'05 Q4

'06 Q1

Number of Incidents

H2 Leak - StackH2 Leak - Fuel SystemH2 Leak While FuelingPassenger Compartment H2 alarm

Created: 8/28/2006

CDP#9: Safety Incidents – V
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 Capac

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

50

100150

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Vehicle Fueling Rates (Thru 2006Q2)

5 minute fill of5 kg at 350 bar

3 minute fill 5 kg at 350 b

2006 Tech V2010 MYPP 

Created: Aug-29-06 4:47 PM

CDP#18: Histogram: Refuel
Safety Incidents - Infrastructure

2005 Q2 - 2006 Q2

ElectricalNon-H2 Leak

Failed/Broken 

Equipment

Mischief, Vandalism

Calibration/ Settings/ 

Maintenance

Environment 

Power Disrup

H2 Leak

U

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

Electrical

Failed/Broken

Equipment

Calibration/

Settings/

Maintenance

H2

Leak/Unplanned

Vent

General Category

Created 30-Aug-06 Number of Incidents

CDP#20: Safety Incidents – Inf
CDP#21: Range of Ambient Tem

During Vehicle Operatio

-30-20-10

0

1020304050

Degrees Celsius

Ambient Temperature During Operation

All OEMs

Created: 16-Feb-2006
Vehicle Hours: All OEM's Combined

05

10152025

0-100

100-200

200-300

300-400

400-500

500-600

600-700

700-800

800-90

Total Vehicle Hours

Number of Vehicles

Throu

gh Q2 2006

Created: 25-Aug-06

Total Vehicle Hours = 19,3

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

02468

1012141618

0-1500

1500-3000

3000-4500

4500-6000

6000-7500

7500-9000

9000-10500

10500-12000

12000

Total Vehicle Miles

Number of Vehicles

Total M iles Traveled = 360

Through Q2 2006

Created: 25-Aug-06

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

-

50,000

100,000150,000200,000250,000300,000350,000400,000

Q205 Q305 Q405 Q1

Vehicle Miles Traveled

Created: 28-Aug-06

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

-

10203040506070

Q205 Q305 Q405 Q106 

# of Vehicles (All Teams)

5,000 psi tanks 10,000 psi tanks Liqu

Created 25-Aug-2006

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

All Teams 

0

1,0002,0003,0004,0005,0006,0007,0008,0009,000

10,00011,00012,00013,00014,000

Q2 2005 Q3 2005 Q4 2005 Q1 200

Reporting Calendar Quarter

Mass of Hydrogen (kg)

Created 24-Aug-2006

CDP#26: Cumulative H2 Pro

Dispensed
99.95299.95499.95699.95899.96099.96299.96499.96699.96899.97099.97299.97499.97699.97899.98099.98299.98499.98699.98899.99099.99299.99499.99699.998

100.000

Hydrogen Purity (%)

Hydrogen Purity Sampled from Stations(1)

Created: Sep-07-06 3:32 PM (1) Includes sampling from both electrolysis and reforming

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

Particulates 

μg/L

H2 Impurities

Data Range SAE J2719 Measured Less Than or Eq

0 50 100 150 200 250 300 3

(N2 + He + Ar) 

0 1 2 3 4 5 6 

H20 

Total HC 

O2 

CO2 

CO 

NH3 

μmol/mol (ppm)

0 10 20 30 40 50 60 7

Total S* 

nmol/mol (ppb)

Created: Sep-26-06 3:47 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP #28: Hydrogen Impurities 
0 50 100 

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since Inc

0 2 4 6 8 10 12 14 

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 Maintenanc

Created: Aug-30-06 3:04 PM

CDP#30: Infrastructure Ma
Number of Stations

0123456789

10

2005 Q2 2005 Q3 2005 Q4 200

Reporting Period

# of Stations

Created 28-Aug-06

CDP#31: Number of Reporting 
H2 Production Methods

Through Q2 2006

012345

Delivered Compressed H2 NG On-site Reforming Electrolysis 

Production Technolgy

# of Stations

Created 28-Aug-06

CDP#32: Hydrogen Productio
0 10 20 30 40 50 60 70 

0

102030405060708090

100

Range Histogram: All OEMs

Percentage of chassis dyno range1 b/w refueli

Percentage of refuelings

PercentageCumulative Percentage

Created: Aug-30-06 3:09 PM

Total refuelings2 = 2048

1. Range calculated using the combined city/hwy fuel economy from dyno testing (not 2. Some refueling events are not detected/reported due to data noise or incompletene

CDP#33: Percentage of Theore

Between Refuelings
0 10 20 30 40 50 60 70 

Vehicle Range Factors

Percentage of chassis dyno range1.

All OEMs

On-Road 

3

Created: Aug-30-06 3:09 PM

1. Calculated using the combined city/hwy fuel economy from dyno testing (non-adjuste2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x C3. Using fuel-economy from on-road data (excluding trips > 1 mile, consistent with othe

CDP#34: Effective Vehicle 
F1147-E(12/2004) 

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4. TITLE AND SUBTITLE

Completed Learning Demonstration Composite Data Products as of 

12/01/06 

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

NREL/TP-560-41090 

5e. TASK NUMBER

H270-8100 

6. AUTHOR(S)

Keith Wipke 

5f. WORK UNIT NUMBER

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1617 Cole Blvd. 

Golden, CO 80401-3393 

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REPORT NUMBER

NREL/TP-560-41090 

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14. ABSTRACT (Maximum 200 Words)

These public technical analysis results from DOE's Controlled Hydrogen Fleet and Infrastructure Demonstration and 

Validation Project are generated in the form of composite data products. 

15. SUBJECT TERMS

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

Validation Project; learning demonstration 

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