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.

Sam Sprik, Jennifer Kurtz, Chris 

Ainscough, Genevieve Saur, Mike 

Peters, and Matthew Jeffers

November 2015

Next Generation Hydrogen Station 

Composite Data Products

Data through Quarter 2 of 2015

NREL/PR-5400-65485
2

CDP-INFR-01

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

0

1

2

3

4

5

6

7

8

2009Q1

2009Q22009Q32009Q42010Q12010Q2

2010Q32010Q42011Q12011Q2

2011Q3

2011Q4

2012Q1

2012Q2

2012Q3

2012Q4

2013Q1

2013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

Hydrogen Dispensed By Quarter

 Cumulative Hydrogen Dispensed = 80,907 kg 

All Sites By Quarter

Cumulative By Site

Cumulative Amount [1,000 kg]

0

5

10

15

20

25

30

35

40

H2 Dispensed [1,000 kg]

0 50 100

2009

2010

2011

2012

2013

2014

2015Q2

 1.91

 4.17

 12.225

 29.658

 45.994

 65.732

 80.907

Cumulative

NREL 

Created: Oct-19-15 4:00 PM 
3

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

2.5 minute fill of

5 kg

26,409 Events

Average = 0.61 kg/min

5% >1.51 kg/min

3% >2 kg/min

Histogram of Fueling Rates

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Oct-21-15 1:19 PM 
4

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

Average = 5.65 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: Oct-21-15 1:12 PM 
5

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

 Average = 2.68 kg 

Histogram of Fueling Amounts

NREL 

Created: Oct-21-15 11:56 A 
6

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]

Daily Average [kg/day]

0

10

20

30

40

max station avg: 35 kg/day

NREL 

Created: Nov-11-15 5:38 PM 

 
7

CDP-INFR-06

Station Capacity Utilization

Station (Sorted By Increasing Station Capacity)

1 2 3 4 5 6 7 8 9

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: Nov-11-15 5:48 PM 

 

 

 

 

 
8

CDP-INFR-07

Station Usage

Station (Sorted By Increasing Station Capacity)

1 2 3 4 5 6 7 8 9

Fills Per Day 1

0

5

10

15

20

25

30

35

40

Station Usage

Maximum Daily Fills

Average Daily Fills 2

NREL 

Created: Nov-11-15 5:49 PM 

 

 

 

 
9

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

73 % of fills have more than 20 minutes between them

26532 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: Oct-20-15 11:59 A 
10

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 = 5872

Avg Final Pressure = 722 bar

% of Fills > 700 bar = 64%

Number of Fills = 20284

Fueling Final Pressures

Average

Nominal

NREL 

Created: Nov-12-15 8:54 AM 

 
11

Number of Stations

0

10

20

30

40

50

60

2011Q4 2012Q1 2012Q2 2012Q3 2012Q4 2013Q1 2013Q2 2013Q3 2013Q4 2014Q1 2014Q2 2014Q3 2014Q4 2015Q1 2015Q2 

Cumulative Stations

Future

Current

Retired

NREL 

Created: Oct-12-15 4:01 PM 

CDP-INFR-10

Cumulative Number of Stations
12

Number of Stations

0

5

10

15

20

25

30

Trailers 

Mobile Fueler 

On-Site Electrolysis 

On-Site SMR 

On-Site Tri-Gen 

Delivered Compressed SMR 

Delivered Liquid SMR 

Delivered Liquid By-Product 

Delivered Pipeline 

Delivered On-Site Production Other Projects

Hydrogen Station Type

Retired

Future

Current

NREL 

Created: Sep-25-15 2:59 PM 

CDP-INFR-11

Hydrogen Stations by Type
13

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

2.5 minute fill of

5 kg

Fill Type Avg %>1.51 %>2 Count

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

350 bar 0.50 2 1% 5965

700 bar 0.64 6 3% 20443

Histogram of Fueling Rates

350 vs 700 bar Fills

350 bar

700 bar

2020 MYRDD Target

Ultimate MYRDD Target

NREL 

Created: Oct-19-15 4:32 PM 
14

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: Oct-19-15 4:35 PM 

 

 

 
15

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

14 Hydrogen Dispensed Per Hour

NREL 

Created: Oct-19-15 4:37 PM 

 

 

 
16

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

33,154 fills

Number of Fueling Events per Time of Day

H2 Fueling

Gasoline Profile 1

NREL 

Created: Nov-13-15 10:28 A 

 
17

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

Total Dispensed [% of Total]

0

1

2

3

4

5

6

7

8

9

Amount Included

85,404 kg

Fueling Amounts per Time of Day

Total

Max

Average

Max and Avg Dispensed [kg]

0

10

20

30

40

50

60

70

NREL 

Created: Oct-19-15 4:42 PM 
18

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: Oct-19-15 4:43 PM 
19

CDP-INFR-18

Fueling Amount vs. Time to Fill
20

CDP-INFR-19

Hydrogen Dispensed by Month Monthly Amount [kg]

0

500

1000

1500

2009201020112012201320142015

Hydrogen Dispensed By Month

NREL 

Created: Oct-19-15 4:47 PM 
21

CDP-INFR-20

Number of Fills by Month Monthly Number of Fills

0

50

100

150

200

250

300

350

400

450

500

2009201020112012201320142015

Number of Fills By Month

NREL 

Created: Oct-19-15 4:47 PM 
22

CDP-INFR-21

Maintenance by Equipment Type

Total Events 1 = 3,531

37% unscheduled

5%

5%

6%

7%

9%

15%

17%

23%

entire

system 80

multiple

systems 252

misc 692

classified

events 2507

Event Count

Total Hours 1 = 24,304

17% unscheduled

7%

11%

18%

8%

13%

32%

hydrogen compressor

dispenser

safety

thermal management

reformer

sensors

electrolyzer

storage

control electronics

electrical

feedwater system

fittings&piping

NREL 

Created: Nov-11-15 12:47 P 

 

 

 

 
23

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: Oct-07-15 5:25 PM 

 

 
24

CDP-INFR-23

Equipment Category Repair Time Repair Labor Time (Hours)

0

5

10

15

20

25

ACTUATORS

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ELECTRICAL

ELECTROLYZER

ENTIRE SYSTEM

FEEDWATER SYSTEM

FITTINGS&PIPING

FUEL SYSTEM

HYDROGEN CHILLER

HYDROGEN COMPRESSOR

MULTIPLE SYSTEMS

NITROGEN SYSTEM

OTHER

PURIFIER

REFORMER

SAFETY

SEAL

SENSORS

SOFTWARE

STORAGE

THERMAL MANAGEMENT

VALVES

Equipment Category Repair Time

NREL 

Created: Oct-07-15 5:22 PM 
25

CDP-INFR-24

Failure Modes for Top Equipment Categories

Total Event Count

0 100 200 300 400 500 600 700

HYDROGEN COMPRESSOR

DISPENSER

SAFETY

THERMAL MANAGEMENT

23%*

17%*

15%*

9%*

FLUID LEAK_NON_HYDROGEN

HYDROGEN LEAK

IMPROPER INSTALLATION

INSPECT TROUBLE ALARM OR REPORT

REPLACE FAILED PARTS

SOFTWARE BUG

MISC

SCHEDULED (PREV MAINT, UPGRADES)

Total Labor Hours

0 1000 2000 3000 4000 5000 6000

HYDROGEN COMPRESSOR

DISPENSER

SAFETY

THERMAL MANAGEMENT

32%*

13%*

8%*

18%*

NREL 

Created: Oct-07-15 5:25 PM 

 

 

 

 

 
26

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*

2009Q12009Q22009Q32009Q42010Q12010Q22010Q32010Q42011Q12011Q22011Q32011Q42012Q12012Q22012Q32012Q42013Q12013Q22013Q32013Q42014Q12014Q22014Q32014Q42015Q12015Q2

H2 Quality

NREL 

Created: Oct-06-15 3:30 PM 

 

 

 

 

 

CDP-INFR-25

Hydrogen Quality
27

2009 2010 2011 2012 2013 2014 2015 2016

Labor Hours

0

50

100

150

200

250

Overall Averages

12 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

 3 events per station per month.

180 kg dispensed per maintenance event.

NREL 

Created: Nov-02-15 5:07 PM 

 

CDP-INFR-26

Compressor Monthly Maintenance
28

Duration [days]

0 100 200 300 400 500 600 700 800

Station

1

2

3

4

5

Hydrogen Station Timeline

Design

Permit

Construction

Commission

NREL 

Created: Nov-12-15 10:52 A 

CDP-INFR-27

Hydrogen Station Timeline
29

Avg. Maintenance Labor Hours per Station per Month

0

50

100

150

200

250

Mar-11Jun-11

Sep-11

Dec-11

Mar-12Jun-12

Sep-12

Dec-12

Mar-13Jun-13

Sep-13

Dec-13

Mar-14Jun-14

Sep-14

Dec-14

Mar-15Jun-15

Maintenance Labor Hours By Month

NREL 

Created: Oct-07-15 5:26 PM 

 

 

 

CDP-INFR-28

Maintenance Labor Hours by Month
30

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15

Rate [kg/min]

0.4

0.6

0.8

1

- Avg: 0.64

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

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15

Time [min]

5

6

7

8

- Avg: 6.1

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15

Amount [kg]

2.5

3

3.5

4

- Avg: 3

NREL 

Created: Oct-19-15 4:48 PM 

CDP-INFR-29

Monthly Averages for 700 bar Fills >1 kg with Pre-Cool of −20°C
31

2012 2013 2014 2015

Total Cost [$1,000]

0

20

40

60

80

100

120

Overall Average: $20,532 per station per quarter.

Maintenance Costs Over Time

Average

Individual Stations

NREL 

Created: Nov-12-15 11:19 A 

 

CDP-INFR-30

Maintenance Costs Over Time
32

Number of Reports

0 5 10 15 20 25 30 35 40

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

Not Defined

Vibration

NREL 

Created: Nov-04-15 1:45 PM 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-31

Safety Reports Primary Factors
33

Number of Reports

0 5 10 15 20 25 30 35 40

Severity

Minor H2 Leak

Near Miss

Incident

Safety Reports By Equipment Involved

Dispenser

H2 Compressor

H2 Storage

Not Defined

Pipes, Fittings, Valves

Reformer

Safety

NREL 

Created: Nov-04-15 1:45 PM 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-32

Safety Reports by Equipment Involved
34

Number of Safety Reports

0

1

2

3

4

5

6

7

2011Q12011Q22011Q32011Q42012Q12012Q22012Q32012Q42013Q12013Q22013Q32013Q42014Q12014Q22014Q32014Q42015Q12015Q2

Safety Reports By Quarter

Incident

Near Miss

Minor H2 Leak

NREL 

Created: Nov-04-15 1:49 PM 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-33

Safety Reports by Quarter
35

Number of Reports

0 5 10 15 20 25 30 35 40

Severity

Minor H2 Leak

Near Miss

Incident

Safety Reports By Event Description

Equipment Malfunction

H2 Release - Accumulation

H2 Release - No Accumulation

H2 Release-Minor

Not Defined

Other

Vandalism

NREL 

Created: Nov-04-15 1:46 PM 

 

 

 

 

 

 

 

 

 

 

 

CDP-INFR-34

Safety Reports by Event Description
36

Compression Energy per kg [MJ/kg]

0 10 20 30 40 50 60 70

Data Points Reported

0

5

10

15

20

25

30

Average = 14.9 [MJ/kg]

Compressor Energy

NREL 

Created: Oct-01-15 4:08 PM 

CDP-INFR-35

Compressor Energy
37

Production Energy per kg [MJ/kg]

0 20 40 60 80 100 120 140 160 180 200 220 240 260

Data Points Reported

0

2

4

6

8

10

12

14

Average = 230 [MJ/kg]

Electrolyzer Energy

NREL 

Created: Oct-01-15 4:08 PM 

CDP-INFR-36

Electrolyzer Energy
38

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

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

First 120 Calendar Days

Calendar Days

Instantaneous MTBF (Calendar Days)

0

10

20

30 Instantaneous MTBF (Calendar Days)

sites

NREL 

Created: Oct-07-15 4:29 PM 

 

 

CDP-INFR-37

Reliability Growth
39

MTBF (Days)

0

10

20

30

40

50

60

70

80

90

100

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ELECTRICAL

ELECTROLYZER

FEEDWATER SYSTEM

FITTINGS&PIPING

HYDROGEN CHILLER

HYDROGEN COMPRESSOR

OTHER

REFORMER

SENSORS

SOFTWARE

STORAGE

THERMAL MANAGEMENT

VALVES

MTBF

Median Site

Lowest Site

 f 38

 

CDP-INFR-38

Maintenance Mean Time Between Failures (MTBF)
40

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

Average = 0.67 [$/kg]

Compressor Operation Cost

NREL 

Created: Nov-03-15 3:22 PM 

CDP-INFR-39

Compressor Operation Cost
41

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: Oct-12-15 3:52 PM 
42

CDP-INFR-41

Average Station Cost by Category

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

4%

84%

8%

4%

General & Administration

Station**

Commissioning

Data Reporting***

NREL 

Created: Nov-11-15 2:15 PM 

 

 

 

 
43

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: Nov-05-15 2:18 PM 
44

CDP-INFR-43

Station Cost by Type Cost [$M]

0

2

4

6

8

10

12

14

16

18

1

9

28

1

1 1

5

1

1

Delivered Liquid By-Product 

Delivered Liquid SMR 

Delivered Compressed SMR 

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: Oct-05-15 8:40 AM 
45

CDP-INFR-44

Station Capacity Utilization Trends by Quarter

Quarters

Average Utilization 2 (%)

0

10

20

30

40

50

60

70

80

90

100

2011Q12011Q22011Q32011Q42012Q12012Q22012Q3

2012Q42013Q12013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

Station Capacity Utilization Trends by Quarter

Number of Stations = 9 Total

Total H2 Dispensed = 76,973 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: Nov-13-15 11:00 A 

 

 

 

 

 
46

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

2011Q12011Q22011Q3

2011Q4

2012Q1

2012Q2

2012Q3

2012Q4

2013Q1

2013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

Station Amount Dispensed by Quarter

Number of Stations = 9 Total

Total H2 Dispensed = 76,973 kg

Individual Site 1

Average of All Sites 2

NREL 

Created: Nov-13-15 11:01 A 

 

 

 
47

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

2011Q12011Q22011Q32011Q42012Q1

2012Q2

2012Q3

2012Q4

2013Q1

2013Q2

2013Q3

2013Q4

2014Q1

2014Q2

2014Q3

2014Q4

2015Q1

2015Q2

Days with Fills by Quarter

Number of Stations = 9 Total

Individual Site 1

Average of All Sites 2

NREL 

Created: Nov-13-15 11:10 A 

 

 

 

 

 
48

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

1 2 3 4 5 6 7 8 9

Utilization By

Quarter 1,2,3 (%)

0

25

50

75

100

Station Number

NREL 

Created: Nov-03-15 3:54 PM 

 

 

 

 

 
49

CDP-INFR-48

Mean Fills per Hydrogen Leak

Station

1 2 3 4 5 6

Mean Fills per H 2 Leak

0

200

400

600

800

1000

1200

Mean Fills per H 2

 Leak

NREL 

Created: Nov-03-15 3:07 PM 

 
50

CDP-INFR-49

Mean Fills Between Failures Mean Fills Between Failures

0

50

100

150

200

250

300

350

400

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ELECTRICAL

ELECTROLYZER

FEEDWATER SYSTEM

FITTINGS&PIPING

HYDROGEN CHILLER

HYDROGEN COMPRESSOR

OTHER

REFORMER

SENSORS

SOFTWARE

STORAGE

THERMAL MANAGEMENT

VALVES

Mean Fills Between Failures

Median Site

Lowest Site

 f 49

 
51

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

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

First 120 Fills

Fills

Instantaneous MTBF (Fills)

0

50

100 Instantaneous MTBF (Fills)

sites

NREL 

Created: Oct-07-15 4:24 PM 

 

 
52

CDP-INFR-51

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

0

100

200

300

400

500

600

700

800

900

1000

AIR SYSTEM

CONTROL ELECTRONICS

DISPENSER

ELECTRICAL

ELECTROLYZER

FEEDWATER SYSTEM

FITTINGS&PIPING

HYDROGEN CHILLER

HYDROGEN COMPRESSOR

OTHER

REFORMER

SENSORS

SOFTWARE

STORAGE

THERMAL MANAGEMENT

VALVES

Mean H

2 Dispensed Between Failures (kg)

Median Site

Lowest Site

 f1

 
53

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

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

First 120 H 2

 Dispensed (kg)

H 2

 Dispensed (kg)

Instantaneous MTBF (H 2 Dispensed (kg))

0

100

200

300

Instantaneous MTBF (H 2

 Dispensed (kg))

sites

NREL 

Created: Oct-07-15 4:24 PM 

 

 

 
54

CDP-INFR-53

Maintenance Cost per Kilogram of Hydrogen Dispensed

2012 2013 2014 2015

Cost per Amount Dispensed [$/kg]

0

50

100

150

200

250

300

Overall Average: $45 per kg.

Maintenance Costs Per kg Dispensed Over Time

Average

Individual Stations

NREL 

Created: Nov-02-15 4:48 PM 

 
55

CDP-INFR-54

Mean Hydrogen Dispensed per Hydrogen Leak

Station

1 2 3 4 5 6

Mean kg H 2 Dispensed per H 2 Leak

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Mean H

2 Dispensed (kg) per Leak

NREL 

Created: Nov-03-15 3:08 PM 

 
56

CDP-INFR-55

Monthly Averages for All Fills

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15 Rate [kg/min]

0

1

2

3

- Avg: 0.62

Monthly Averages for All Fills

Overall Avg

Individual Station Avg

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15

Time [min]

0

5

10

15

- Avg: 5.7

Overall Avg

Individual Station Avg

Oct11 Jan12 Apr12 Jul12 Oct12 Jan13 Apr13 Jul13 Oct13 Jan14 Apr14 Jul14 Oct14 Jan15 Apr15 Jul15

Amount [kg]

0

2

4

6

- Avg: 2.7

Overall Avg

Individual Station Avg

NREL 

Created: Nov-04-15 2:59 PM 
57

CDP-INFR-56

Histogram of 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

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: Nov-13-15 10:05 A