NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Next Generation Hydrogen Station 

Composite Data Products 

Data through Quarter 4 of 2015

Sam Sprik, Jennifer Kurtz, 

Chris Ainscough, Genevieve Saur, 

Michael Peters, and Matthew Jeffers

May 2016

NREL/PR-5400-66580
2

H2 Station Project Partners

Current

o California Air Resources Board

o California Energy Commission

o California State University Los Angeles

o Gas Technologies Institute

o Linde

o H2 Frontier

o Proton OnSite

o Shell

o IPHE and HySUT
3

Analysis Categories

Cost

Deploy

Energy

Safety

Reliability

Utilization

Quality

Performance Specs

(Coming)
All Composite Data Products 

(CDPs)
Deployment
6

Number of Stations

0

5

10

15

20

25

30

35

2011Q42012Q12012Q22012Q32012Q42013Q12013Q22013Q32013Q42014Q12014Q22014Q32014Q42015Q12015Q22015Q32015Q42016Q1

Future

Cumulative Stations

Retired

Future

Current

NREL 

Created: Apr-11-16 5:07 PM 

CDP-INFR-10

Cumulative Number of Stations
7

Number of Stations

0

5

10

15

20

25

30

35

Trailers 

Mobile Fueler 

On-Site Electrolysis 

On-Site SMR 

On-Site Tri-Gen 

Delivered Compressed SMR 

Delivered Compressed By-Product 

Delivered Liquid SMR 

Delivered Liquid By-Product 

Delivered Pipeline 

Delivered On-Site Production Other Projects

Hydrogen Station Type

Retired

Future

Current

NREL 

Created: Mar-30-16 11:06 A 

CDP-INFR-11

Hydrogen Stations by Type
8

Duration [days]

0 100 200 300 400 500 600 700 800

Station

1

2

3

4

5

6

7

Hydrogen Station Timeline

Design

Permit

Construction

Commission

NREL 

Created: Apr-20-16 1:48 PM 

CDP-INFR-27

Hydrogen Station Timeline
Safety
10

Safety (and Maintenance) Learnings

From Safety Reports Template

• Alarms not communicated

• Breakaway leak

• Check compressor oil filter

• Check integrity of delivered equipment

• Compressor leaking at startup normal?

• Does isolated leak need to shut down station?

• Electrical glitch

• Estop activated after hearing escaping gas-nitrogen

• Estop activated when nozzle stuck on car

• Estop activated without cause

• Estop flooded prevented restart

• False Alarm - No Fire

• Fill and leak check together caused shutdown - false leak alarm

• Filter to catch scrap from material processing

• Forgot to turn back on after maintenance

• Freezing and thawing caused moisture in 

communication connector

• Frozen cooling block - defrost

• HTO sensor fault

• Heat trace short caused false fire alarm

• Heavy rain triggered fire alarm

• Hose vent failure - nozzle stuck on car

• Loose wire intermittent problems

• Loud popping could be relief valve

• Mass balance alarm bug

• Mass balance alarm caused by high ambient 

temperature

• Power Issue - 3 Phase

• Predict service life better

• Proper installation prevents leaks

• Rain on sensor causing alarm

• Regular inspection of compressor valves

• Regular leak checks

• Regular station inspection

• Reset

• Spider web obscuring sensor

• Thermocouple failure shutdown station

• Vibration from normal activity shutdown 

dispenser

• Vibration isolation
11

Number of Reports

0 5 10 15 20 25 30 35 40 45

Severity

Minor H2 Leak

Near Miss

Incident

Safety Reports Primary Factors

Component Failure

Design Flaw

Inadequate Training, Protocol, SOP

Inadequate/ Non-working Equipment

Maintenance Required

Mischief/Vandalism

New Equipment Materials

Vibration

NREL 

Created: May-01-16 11:40 A 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-31

Safety Reports Primary Factors
12

Number of Reports

0 5 10 15 20 25 30 35 40 45

Severity

Minor H2 Leak

Near Miss

Incident

Safety Reports By Equipment Involved

Dispenser

H2 Compressor

H2 Storage

Pipes, Fittings, Valves

Reformer

Safety

Security Device

NREL 

Created: May-01-16 11:40 A 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-32

Safety Reports by Equipment Involved
13

Number of Safety Reports

0

1

2

3

4

5

6

7

8

2011Q12011Q22011Q32011Q42012Q12012Q22012Q32012Q42013Q12013Q22013Q32013Q42014Q12014Q22014Q32014Q42015Q12015Q22015Q32015Q4

Safety Reports By Quarter

Incident

Near Miss

Minor H2 Leak

NREL 

Created: May-01-16 11:41 A 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-33

Safety Reports by Quarter
14

Number of Reports

0 5 10 15 20 25 30 35 40 45

Severity

Minor H2 Leak

Near Miss

Incident

Safety Reports By Event Description

Equipment Malfunction

H2 Release - Accumulation

H2 Release - No Accumulation

H2 Release-Minor

Vandalism

NREL 

Created: May-01-16 11:41 A 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-34

Safety Reports by Event Description
15

CDP-INFR-48

Mean Fills per Hydrogen Leak

Station

1 2 3 4 5

Mean Fills per H 2 Leak

0

50

100

150

200

250

300

350

Mean Fills per H 2

 Leak

NREL 

Created: Apr-27-16 4:34 PM 

 

 

 

 
16

CDP-INFR-54

Mean Hydrogen Dispensed per Hydrogen Leak

Station

1 2 3 4 5

Mean kg H 2 Dispensed per H 2 Leak

0

100

200

300

400

500

600

700

800

900

Mean H

2 Dispensed (kg) per Leak

NREL 

Created: Apr-25-16 2:17 PM 

 

 

 

 
Maintenance and Reliability
18

CDP-INFR-21

Maintenance by Equipment Type

Total Events 1 = 3,140

40% unscheduled

6%

7%

8%

13%

16%

19%

24%

multiple

systems 368

classified

events 2772

Event Count

Total Hours 1 = 9,260

45% unscheduled

5%

5%

6%

11%

16%

17%

34%

compressor

dispenser

entire

safety

storage

reformer

thermal management

chiller

feedwater

NREL 

Created: Apr-25-16 2:18 PM 

 

 

 

 
19

CDP-INFR-22

Maintenance Labor Hours per Event

Labor Hours Per Event

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Frequency (% of total)

 0

 5

10

15

20

25

30

35

40

Infrastructure Maintenance Labor Hours per Event

NREL 

 

 

 

NREL 

Created: Apr-25-16 2:22 PM 

 

 
20

CDP-INFR-23

Equipment Category Repair Time Repair Labor Time (Hours)

0

5

10

AIR

CHILLER

COMPRESSOR

DISPENSER

ELECTRICAL

ELECTROLYZER

ENTIRE

FEEDWATER

FUEL

PURIFIER

REFORMER

SAFETY

STATION OTHER

STORAGE

THERMAL MANAGEMENT

Equipment Category Repair Time

NREL 

Created: Apr-25-16 2:18 PM 
21

CDP-INFR-24

Failure Modes for Top Equipment Categories

Total Event Count

0 200 400 600 800

COMPRESSOR

DISPENSER

ENTIRE

SAFETY

24%*

19%*

16%*

13%*

COLLISION

COMMUNICATION ERROR

DEBRIS

FAILED PART

LOOSE MECHANICAL

MANUFACTURING DEFECT

NA

OUT OF CALIBRATION

POWER OUTAGE/QUALITY

SOFTWARE BUG

UNDETERMINED

MISC

SCHEDULED (PREV MAINT, UPGRADES)

Total Labor Hours

0 500 1000 1500 2000 2500 3000 3500

COMPRESSOR

DISPENSER

ENTIRE

SAFETY

34%*

17%*

16%*

11%*

NREL 

Created: Apr-25-16 2:20 PM 

 

 

 

 

 

 

 

 
22

2009 2010 2011 2012 2013 2014 2015 2016

Labor Hours

0

50

100

150

200

250

Overall Averages

16 hours per station per month.

54 kg dispensed per maintenance hour.

Compressor Monthly Maintenance

2009 2010 2011 2012 2013 2014 2015 2016

Number of Events

0

5

10

15

Overall Averages

 4 events per station per month.

138 kg dispensed per maintenance event.

NREL 

Created: Apr-25-16 2:18 PM 

 

 

CDP-INFR-26

Compressor Monthly Maintenance
23

Avg. Maintenance Labor Hours per Station per Month

0

50

100

150

200

250

Apr-11

Jul-11

Oct-11

Jan-12

Apr-12

Jul-12

Oct-12

Jan-13

Apr-13

Jul-13

Oct-13

Jan-14

Apr-14

Jul-14

Oct-14

Jan-15

Apr-15

Jul-15

Oct-15

Jan-16

Maintenance Labor Hours By Month

NREL 

Created: Apr-25-16 2:15 PM 

 

 

 

CDP-INFR-28

Maintenance Labor Hours by Month
24

2012 2013 2014 2015 2016

Total Cost [$1,000]

0

20

40

60

80

100

120

Overall Average: $12,478 per station per quarter.

Maintenance Costs Over Time

Average

Individual Stations

NREL 

Created: Apr-25-16 2:15 PM 

 

CDP-INFR-30

Maintenance Costs Over Time
25

Shape Parameter ( )

1

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

1 2 3 4 5 6 7 8 9

Overall Site Reliability Growth

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous mean Calendar Days between failures

3. Some sites are no longer active. Final results are shown for those sites.

Entire history

Last 20% of events

Early History

Calendar Days

Instantaneous MTBF

(Calendar Days)

0

100

200 Instantaneous MTBF (Calendar Days)

sites

NREL 

Created: Apr-28-16 11:31 A 

 

 

CDP-INFR-37

Reliability Growth
26

CDP-INFR-38

Mean Time Between Failures (MTBF) MTBF (Days)

0

50

100

150

AIR

CHILLER

COMPRESSOR

DISPENSER

ELECTRICAL

ELECTROLYZER

ENTIRE

FEEDWATER

REFORMER

SAFETY

STATION OTHER

STORAGE

THERMAL MANAGEMENT

MTBF

Median Site

Lowest Site

 f 38

 
27

CDP-INFR-49

Mean Fills Between Failures Mean Fills Between Failures

0

50

100

150

200

250

300

350

AIR

CHILLER

COMPRESSOR

DISPENSER

ELECTRICAL

ELECTROLYZER

ENTIRE

FEEDWATER

REFORMER

SAFETY

STATION OTHER

STORAGE

THERMAL MANAGEMENT

Mean Fills Between Failures

Median Site

Lowest Site

 f 49

 
28

CDP-INFR-50

Reliability Growth by Fills Shape Parameter ( )

1

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

1 2 3 4 5 6 7 8 9

Overall Site Reliability Growth By Fills

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous mean Fills between failures

3. Some sites are no longer active. Final results are shown for those sites.

Entire history

Last 20% of events

Early History

Fills

Instantaneous MTBF

(Fills)

0

100

200 Instantaneous MTBF (Fills)

sites

NREL 

Created: Apr-28-16 11:34 A 

 

 
29

CDP-INFR-51

Mean Amount Dispensed Between Failures Mean H 2 Dispensed Between Failures (kg)

0

100

200

300

400

500

600

700

800

AIR

CHILLER

COMPRESSOR

DISPENSER

ELECTRICAL

ELECTROLYZER

ENTIRE

FEEDWATER

REFORMER

SAFETY

STATION OTHER

STORAGE

THERMAL MANAGEMENT

Mean H

2 Dispensed Between Failures (kg)

Median Site

Lowest Site

 f1

 
30

CDP-INFR-52

Reliability Growth by Amount Dispensed Shape Parameter ( )

1

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

1 2 3 4 5 6 7 8 9

Overall Site Reliability Growth By H 2 Dispensed (kg)

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous mean H_2 Dispensed (kg) between failures

3. Some sites are no longer active. Final results are shown for those sites.

Entire history

Last 20% of events

Early History

H 2

 Dispensed (kg)

Instantaneous MTBF

(H 2 Dispensed (kg))

0

200

400

600

Instantaneous MTBF (H 2

 Dispensed (kg))

sites

NREL 

Created: Apr-28-16 11:35 A 

 

 

 
31

CDP-INFR-59

Historical Failure Rate by Fills

Fills

0 2000 4000 6000 8000 10000 12000 14000

Failure Rate (Failures/Fills)

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

Historical Failure Rate (bathtub curve) by Fills

Station Data

Least Squares Fit

NREL 

Created: Apr-27-16 4:32 PM 
32

CDP-INFR-60

Historical Failure Rate by Amount Dispensed

kg H 2 Dispensed 10 4

0 0.5 1 1.5 2 2.5 3 3.5 4

Failure Rate (Failures/kg H 2 Dispensed)

0

0.05

0.1

0.15

0.2

0.25

0.3

Historical Failure Rate (bathtub curve) by kg H 2 Dispensed

Station Data

Least Squares Fit

NREL 

Created: Apr-27-16 4:32 PM 

 
33

CDP-INFR-61

Historical Failure Rate by Calendar Days

Calendar Days

0 200 400 600 800 1000 1200 1400 1600

Failure Rate (Failures/Calendar Days)

0

1

2

3

4

5

6

7

8

9

10 Historical Failure Rate (bathtub curve) by Calendar Days

Station Data

Least Squares Fit

NREL 

Created: Apr-27-16 4:33 PM 

 
Performance
35

CDP-INFR-01

Hydrogen Dispensed by Quarter Hydrogen Dispensed [1,000 kg]

0

1

2

3

4

5

6

7

8

2009Q1

Q2Q3Q4

2010Q1

Q2Q3Q4

2011Q1

Q2Q3Q4

2012Q1

Q2Q3Q4

2013Q1

Q2Q3Q4

2014Q1

Q2Q3Q4

2015Q1

Q2Q3Q4

Hydrogen Dispensed By Quarter

 Cumulative Hydrogen Dispensed = 92,287 kg 

All Sites By Quarter

Cumulative By Site

Cumulative Amount [1,000 kg]

0

5

10

15

20

25

30

35

40

45

H2 Dispensed [1,000 kg]

0 50 100

2009

2010

2011

2012

2013

2014

2015

 1.91

 4.17

 12.225

 29.658

 45.994

 65.732

 92.287

Cumulative

NREL 

Created: Apr-15-16 12:04 P 
36

CDP-INFR-58

Hydrogen Fills by Quarter Number of Fills [1,000]

0

0.5

1

1.5

2

2.5

3

2009Q1

Q2Q3Q4

2010Q1

Q2Q3

Q4

2011Q1

Q2Q3Q4

2012Q1

Q2Q3Q4

2013Q1

Q2Q3Q4

2014Q1

Q2Q3Q4

2015Q1

Q2Q3Q4

Hydrogen Fills By Quarter

 Cumulative Fuelings = 35,579

All Sites By Quarter

Cumulative By Site

Cumulative Fuelings [1,000]

0

2

4

6

8

10

12

14

16

18

H2 Fills [1,000]

0 20 40

2009

2010

2011

2012

2013

2014

2015

 1.119

 2.352

 5.891

 13.055

 19.438

 26.283

 35.579

Cumulative

NREL 

Created: Apr-15-16 11:46 A 
37

CDP-INFR-02

Histogram of Fueling Rates

Avg Fuel Rate (kg/min)

0 0.5 1 1.5 2 2.5 3

Number of Fueling Events [1,000]

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

2.5 minute fill of

5 kg

29,831 Events

Average = 0.58 kg/min

4% >1.51 kg/min

2% >2 kg/min

Histogram of Fueling Rates

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Apr-21-16 11:37 A 
38

CDP-INFR-03

Histogram of Fueling Times

Time (min)

0 2 4 6 8 10 12 14 16 18 20

Number of Fueling Events [1,000]

0

0.5

1

1.5

2

2.5

3

Average = 5.71 min

24% <3.3 min

13% <2.5 min

Histogram of Fueling Times

 2020 MYRDD Target for 5kg

 Ultimate MYRDD Target (5 kg in 2.5 min)

NREL 

Created: Apr-21-16 12:22 P 
39

CDP-INFR-04

Histogram of Fueling Amounts

Amount Fueled (kg)

0 1 2 3 4 5 6 7

Number of Fueling Events [1,000]

0

0.2

0.4

0.6

0.8

1

1.2

1.4

 Average = 2.62 kg 

Histogram of Fueling Amounts

NREL 

Created: Apr-21-16 11:32 A 
40

CDP-INFR-08

Time Between Fueling

Time Between Fuelings* [min]

<0 0 2 4 6 8 10 12 14 16 18 20

# of Fuelings [% of total]

0

2

4

6

8

10

9 % of fills are within 0-5 minutes of each other

72 % of fills have more than 20 minutes between them

30193 Total Fills

Histogram of Time Between Fuelings

Back-to-Back Fills

Simultaneous Fills

All Sites Combined

Individual Sites

Final Pressure [bar]

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900

# of Fuelings

0

100

200

300

400

500

Final Pressures for Fills with <5 Minutes in Between

Previous Fill

Next Fill

NREL 

Created: Apr-15-16 12:18 P 
41

CDP-INFR-09

Fueling Final Pressures

Final Pressure [bar]

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900

% of Fueling Events

0

1

2

3

4

5

6

450 bar*

350 bar Fills (200 to 450 bar) 700 bar Fills ( > 450 bar)

Avg Final Pressure = 346 bar

% of Fills > 350 bar = 48%

Number of Fills = 6373

Avg Final Pressure = 723 bar

% of Fills > 700 bar = 66%

Number of Fills = 23609

Fueling Final Pressures

Average

Nominal

NREL 

Created: Apr-15-16 12:20 P 

 
42

CDP-INFR-12

Fueling Rates 350 vs. 700 bar

Avg Fuel Rate (kg/min)

0 0.5 1 1.5 2 2.5 3

Number of Fueling Events

0

1000

2000

3000

4000

5000

6000

7000

2.5 minute fill of

5 kg

Fill Type Avg %>1.51 %>2 Count

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

350 bar 0.50 2 1% 6435

700 bar 0.63 6 3% 23827

Histogram of Fueling Rates

350 vs 700 bar Fills

350 bar

700 bar

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Apr-15-16 12:23 P 
43

CDP-INFR-13

Number of Fueling Events per Hour

Number of Fuelings in an Hour

0 5 10 15 20 25

Frequency [% of total]

0

10

20

30

40

50

60

Number of Fuelings Per Hour

NREL 

Created: Apr-15-16 12:26 P 

 

 

 
44

CDP-INFR-14

Hydrogen Dispensed per Hour

Amount Fueled in an Hour [kg]

0 10 20 30 40 50 60

Frequency [% of total]

0

2

4

6

8

10

12

Hydrogen Dispensed Per Hour

NREL 

Created: Apr-15-16 12:29 P 

 

 

 
45

CDP-INFR-15

Number of Fills by Time of Day

Time of Day [hours]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Number of Fills [% of Total]

0

1

2

3

4

5

6

7

8

Number Included

34,944 fills

Number of Fueling Events per Time of Day

H2 Fueling

Gasoline Profile 1

NREL 

Created: Apr-26-16 8:59 AM 

 
46

CDP-INFR-16

Fueling Amounts per Time of Day

Time of Day [hours]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Amount Dispensed [% of Total]

0

1

2

3

4

5

6

7

8

9 Fueling Amounts per Time of Day

Total [%]

Max [kg]

Average [kg]

Max and Avg Dispensed [kg]

0

2

4

6

8

10

12

14

Amount Included

91,003 kg

NREL 

Created: Apr-25-16 2:45 PM 
47

CDP-INFR-17

Fueling Rates by Amount Filled

Average Fuel Rate [kg/min]

0 0.5 1 1.5 2 2.5 3

Number of Fueling Events

0

500

1000

1500

2000

2500 Histrogram of Fueling Rates by Amounts

0 to 0.5 kg

0.5 to 1 kg

1 to 2 kg

2 to 4 kg

4 to 6 kg

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Apr-15-16 12:34 P 
48

CDP-INFR-18

Fueling Amount vs. Time to Fill
49

CDP-INFR-56

Fueling Rates by Year

Avg Fuel Rate (kg/min)

0 0.5 1 1.5 2 2.5 3 3.5 4

Number of Fueling Events

0

200

400

600

800

1000

1200

1400

1600

1800

3.3 minute fill of

5 kg

2.5 minute fill of

5 kg

Year Avg (kg/min) %>1.51 

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

2010 0.54 0%

2011 0.66 17%

2012 0.56 14%

2013 0.54 12%

2014 0.70 20%

2015 0.61 12%

Histogram of Fueling Rates

By Year

2010

2011

2012

2013

2014

2015

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Apr-15-16 12:50 P 
50

2012 2013 2014 2015 2016

Rate [kg/min]

0

1

2

3

- Avg: 0.63

Monthly Averages for 700bar Fills >1kg with Pre-Cool of -20 C

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Time [min]

0

5

10

15

- Avg: 6.2

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Amount [kg]

0

2

4

6

- Avg: 3

Overall Avg

Individual Station Avg

NREL 

Created: Apr-22-16 5:36 PM 

CDP-INFR-29

Monthly Averages for 700 bar Fills >1 kg with Pre-Cool of –20°C
51

CDP-INFR-55

Monthly Averages for All Fills

2012 2013 2014 2015 2016

Rate [kg/min]

0

1

2

3

- Avg: 0.62

Monthly Averages for All Fills

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Time [min]

0

5

10

15

- Avg: 5.8

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Amount [kg]

0

2

4

6

- Avg: 2.7

Overall Avg

Individual Station Avg

NREL 

Created: Apr-15-16 12:48 P 
52

2012 2013 2014 2015 2016

Rate [kg/min]

0

0.5

1

1.5

- Avg: 0.87

Monthly Averages for 700bar Fills >1kg with Pre-Cool of -40 C (SAEJ2601)

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Time [min]

2

4

6

8

- Avg: 3.7

Overall Avg

Individual Station Avg

2012 2013 2014 2015 2016

Amount [kg]

1

2

3

4

- Avg: 2.8

Overall Avg

Individual Station Avg

NREL 

Created: Apr-26-16 4:00 PM 

CDP-INFR-57

Monthly Averages for 700 bar Fills >1 kg with Pre-Cool of –40°C
Cost
54

Electrical Energy Cost per kg [$/kg]

0 0.5 1 1.5 2 2.5 3 3.5

Data Points Reported

0

5

10

15

20

25

30

35

40

45

Average = 0.665 [$/kg]

Compressor Operation Cost

NREL 

Created: Apr-01-16 1:36 PM 

CDP-INFR-39

Compressor Operation Cost
55

CDP-INFR-40

Station Costs by Daily Capacity

State Funding + Cost Share [$M]

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Daily Capacity [kg]

0

50

100

150

200

250

300

350

400 Station Cost by Daily Capacity*

Delivered Compressed

Delivered Liquid

On-Site Production

NREL 

Created: Apr-07-16 1:19 PM 
56

CDP-INFR-41

Station Cost by Category

Budget Amounts* (Avg Total = $2.2M), 46 Stations

5%

84%

7%

4%

General & Administration

Station**

Commissioning

Data Reporting***

NREL 

Created: Apr-07-16 1:14 PM 

 

 

 

 
57

CDP-INFR-42

Station Costs

Stations

0 5 10 15 20 25 30 35 40 45 50

Cost [$M]

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Station Cost*

State Funding

Cost Share

NREL 

Created: Mar-29-16 10:54 A 
58

CDP-INFR-43

Station Cost by Type Cost [$M]

0

2

4

6

8

10

12

14

16

18 29

8

1

1

1

1

5

1

1

Delivered Compressed SMR 

Delivered Liquid SMR 

Delivered Compressed By-Product 

On-Site Electrolysis;Delivered Liquid SMR 

On-Site Electrolysis;Delivered Liquid By-Product 

On-Site Electrolysis;Delivered Compressed SMR 

On-Site Electrolysis 

Mobile Fueler 

Trailers 

Station Cost by Type*

Total Budgeted Cost Share**

Documented Cost Share**

CEC Award Range per Project

Cost Share** Range per Project

# Number of Projects

NREL 

Created: Apr-26-16 11:01 A 

 
59

CDP-INFR-44

Station Capacity Utilization Trends by Quarter

Quarters

Average Utilization 2 (%)

0

10

20

30

40

50

60

70

80

90

100

2011Q1

2011Q22011Q32011Q42012Q1

2012Q22012Q32012Q42013Q1

2013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

2015Q3

2015Q4

Station Capacity Utilization Trends by Quarter

Number of Stations = 11 Total

Total H2 Dispensed = 88,352 kg

Individual Site 1

Average of All Sites 2

Maximum Daily Fueling Capacity (kg)

50 100 150 200 250 300 350

Range of Station Capacities 3

NREL 

Created: Apr-15-16 12:42 P 

 

 

 

 

 
60

CDP-INFR-45

Station Amount Dispensed by Quarter

Quarters

Amount of Fuel Dispensed (kg)

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

2011Q12011Q22011Q32011Q42012Q1

2012Q22012Q32012Q4

2013Q12013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

2015Q3

2015Q4

Station Amount Dispensed by Quarter

Number of Stations = 11 Total

Total H2 Dispensed = 88,352 kg

Individual Site 1

Average of All Sites 2

NREL 

Created: Apr-15-16 12:43 P 

 

 

 
61

CDP-INFR-53

Maintenance Cost per kg of Hydrogen Dispensed

2012 2013 2014 2015 2016

Cost per Amount Dispensed [$/kg]

0

50

100

150

200

250

300

350

Overall Average: $28 per kg.

Maintenance Costs Per kg Dispensed Over Time

Average

Individual Stations

NREL 

Created: Apr-27-16 4:32 PM 

 
Utilization
63

CDP-INFR-05

Dispensed Hydrogen per Day of Week

Day of Week

Sun Mon Tues Wed Thur Fri Sat

Dispensed Fuel [% of total]

0

5

10

15

20 Dispensed Hydrogen per Day of Week

H2 Stations [%]

Gasoline Station [%] 1

Individual Stations [kg/day]

Average of Stations [kg/day]

Daily Average [kg/day]

0

10

20

30

40

max station avg: 35 kg/day

NREL 

Created: Apr-25-16 1:59 PM 

 
64

CDP-INFR-06

Station Capacity Utilization

Station (Sorted By Increasing Station Capacity)

1 2 3 4 5 6 7 8 9 10 11

Capacity Utilization 1 [%]

0

20

40

60

80

100

120

140

160

180

200

62.3%

Station Capacity Utilization

Maximum Daily Utilization

Maximum Quarterly Utilization 2

Average Daily Utilization 2

NREL 

Created: Apr-27-16 5:12 PM 

 

 

 

 

 
65

CDP-INFR-07

Station Usage

Station (Sorted By Increasing Station Capacity)

1 2 3 4 5 6 7 8 9 10 11

Fills Per Day 1

0

5

10

15

20

25

30

35

40

Station Usage

Maximum Daily Fills

Average Daily Fills 2

NREL 

Created: Apr-15-16 12:16 P 

 

 

 

 
66

CDP-INFR-19

Hydrogen Dispensed by Month Monthly Amount [kg]

0

200

400

600

800

1000

1200

1400

1600

20092010201120122013201420152016

Hydrogen Dispensed By Month

Individual station

Average of all stations

NREL 

Created: Apr-15-16 12:38 P 
67

CDP-INFR-20

Number of Fills by Month Monthly Number of Fills

0

100

200

300

400

500

600

20092010201120122013201420152016

Number of Fills By Month

Individual station

Average of all stations

NREL 

Created: Apr-15-16 12:38 P 
68

CDP-INFR-46

Days with Fills by Quarter

Quarters

% Of Days With At Least One Fill

0

10

20

30

40

50

60

70

80

90

100

2011Q1

2011Q22011Q32011Q42012Q12012Q2

2012Q32012Q42013Q12013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

2015Q3

2015Q4

Days with Fills by Quarter

Number of Stations = 11 Total

Individual Site 1

Average of All Sites 2

NREL 

Created: Apr-15-16 12:44 P 

 

 

 

 

 
69

CDP-INFR-47

Summary of Station Usage Statistics Quarterly Amount Dispensed (kg)

0

1000

2000

3000

4000

Summary of Station Usage Statistics

4

Days With

Fills By

Quarter (%)

0

25

50

75

100

Station Number

1 2 3 4 5 6 7 8 9 10 11

Utilization By

Quarter 1,2,3 (%)

0

25

50

75

100

NREL 

Created: Apr-15-16 12:45 P 

 

 

 

 

 
Hydrogen Quality
71

Number of Samples Reported

0

1

2

3

4

5

6

7

8

9

10

H

2

O = 22*

H

2

O = 400*

H

2

O = 97*

H

2

O = 20*

H

2

O = 52*

H

2

O = 6.2*

H

2

O = 55*

HC = 2.2*

HC = 7.5*

CO = 2.7*

HC = 8*

CO = 4.5*

Psize = 750, 210...*

HC = 7.3*

HC = 5.8*

HC = 2.3*

HC = 2.5*

HC = 3.3*

2009Q12009Q22009Q32009Q42010Q12010Q22010Q32010Q42011Q12011Q22011Q32011Q42012Q12012Q22012Q32012Q42013Q12013Q22013Q32013Q42014Q12014Q22014Q32014Q42015Q12015Q22015Q32015Q4

H2 Quality

NREL 

Created: Apr-18-16 5:00 PM 

 

 

 

 

 

CDP-INFR-25

Hydrogen Quality
Component Energy
73

Compression Energy per kg [kWh/kg]

0 2 4 6 8 10 12 14 16 18

Monthly Data Points

0

10

20

30

40

50

60

70 Average = 4.2 [kWh/kg]

Compressor Energy

Amount Compressed [kg]

20 30 40 50 60 70 80 90 100

Compression Energy [kWh/kg]

0.5

1

1.5

2

2.5

3

3.5 Energy Consumed Only in Start Up and Shut Down

2013 2014 2015 2016

Compression Energy [kWh/kg]

0

5

10

15

20

NREL 

Created: Apr-26-16 4:12 PM 

CDP-INFR-35

Compressor Energy
74

Production Energy per kg [kWh/kg]

0 10 20 30 40 50 60 70 80

Data Points Reported

0

5

10

15

20

25

30

Average = 62.6 [kWh/kg]

Electrolyzer Energy

NREL 

Created: Apr-15-16 12:41 P 

CDP-INFR-36

Electrolyzer Energy