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Controlled Hydrogen Fleet and InfrastructureDemonstration and Validation ProjectSpring 2010Composite Data ProductsFinal Version March 29, 2010Keith Wipke, Sam Sprik, Jennifer Kurtz, and Todd Ramsden
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Spring 2010Composite ProductsMarch 29, 2Keith WipkeJennifer KuRamsden

Controlled Hydrogen Fleet and InfrastrucDemonstration and Validation Project
National Renewable Energy Laboratory 4 Inno

CDP#1: Hours Accumulated and Projected Hours to 10% Stack Voltage Deg

Gen1 Gen2 Gen1 Gen2 Gen1 

0

200400

600800

1000120014001600180020002200240026002800

2006 Target2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Vol

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durability:

Based on Data Through 2009 Q2

Max Hrs Accumulated1,2 Avg Hrs Accumulated1,3 Projection to 10% Voltage D

NREL CDP01

Created: Mar-23-10 10:39 AM

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% voltage degrad(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world(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 progress ag may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal pr The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and m Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demonstrated op 
National Renewable Energy Laboratory 5 Inno

Dyno Range (2) Window-Sticker Range (3) On-Road Rang

0

50

100150200250300

Vehicle Range (miles)

Vehicle Range1

201200 Ge Ge

NREL CDP02

Created: Mar-10-10 1:18 PM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(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 Range
National Renewable Energy Laboratory 6 Inno

CDP#3: Fuel Cell System Power DensIncluding Hydrogen Storage

0

50

100150200250300350

400

Power Density (W/L)

FC System (Including Hydrogen Storage) Power Density (W/L)

2010 and 2015 FreedomCAR Research Goal1

NREL CDP03

Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electri
National Renewable Energy Laboratory 7 Inno

0

50

100150200250300350400

Specific Power (W/kg)

FC System (Including Hydrogen Storage) Specific Power (W/kg

2010 and 2015 FreedomCAR Research Goal1

NREL CDP04

Created: Aug-28-09 8:42 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and elect

CDP#4: Fuel Cell System Specific PowIncluding Hydrogen Storage
National Renewable Energy Laboratory 8 Inno

12 hr Equilibrium 12 hr Equilib

0

100200300400500600

Time to Drive Away Time to Max FC Powe

Time [s]

Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition

NREL CDP05

Created: Sep-08-09 10:54 AM

(1) Learning Demo soak temperature for freeze tests were between -9 and -20 oC

(2) 2010 & 2015 DOE MYPP Cold Start Up Time Target: 30 seconds to 50% of rated power from -20 oC (soak duration not s

CDP#5: Fuel Cell Start Times from Sub-Freezing Soak Conditions
National Renewable Energy Laboratory 9 Inno

Dyno (1) Window-Sticker (2) On-Road (3

0

1020304050607080

Fuel Economy (miles/kg H

2

)

Fuel Economy

NREL CDP06

Created: Mar-10-10 1:18 PM

(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).(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(4) Calculated from on-road fuel cell stack current or mass flow readings.

CDP#6: Fuel Economy
National Renewable Energy Laboratory 10 Inno

05

10152025

Operating Time [%]

Operating Time at Fuel Cell Stack Voltage Levels: DOE Fleet

<50%50-55%55-60%60-65%65-70%70-75%75-80%80-85%85-90%90-95%95-100%>

% Max Fuel Cell Stack Voltage

All timeTime at low current

NREL CDP07

Created: Mar-09-10 4:13 PM

CDP#7: Fuel Cell Voltage
National Renewable Energy Laboratory 11 Inno

0 10 20 30 40 50 60 70 80 9

0

102030405060

Net System Power [%]

Efficiency [%]

Fuel Cell System1 Efficiency2

 Eff. at 25% Pwr Eff. at 100% Pwr

 

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

 

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

Gen1 51 - 58% 30 - 54%

Gen2 53 - 59% 42 - 53%

DOE Target at 25DOE Target at 10Gen 1 Efficiency Gen 2 Efficiency 

NREL CDP08

Created: Sep-02-09 11:27 AM

1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electr2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen). 3 Individual test data linearly interpolated at 5,10,15,25,50,75,and 100% of max net power. Values at high power linearly 

 due to steady state dynamometer cooling limitations.

CDP#8: FC System Efficiency
National Renewable Energy Laboratory 12 Inno

0123

Number of Reports

Safety Reports - Vehicle Operation

Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartme

Created: Mar-10-10 2:35 PM

NREL CDP09 NR

CDP#9: Safety Reports – Vehicles
National Renewable Energy Laboratory 13 Inno

CDP#10: Storage Weight % Hydrogen

350bar 700bar 0

123456789

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

2015 DOE MYP2010 DOE MYP2007 DOE MYP

NREL CDP10

Created: Aug-19-08 11:39 AM

1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 14 Inno

CDP#11: Volumetric Capacity of H2 S

350bar 700bar 0

0.010.020.030.040.050.060.070.080.09

0.1

Mass H2 per Liter (kg/L)

Mass of Hydrogen Per Liter

2015 DOE MYP2010 DOE MYP2007 DOE MYP

NREL CDP11

Created: Aug-19-08 11:39 AM

1Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 15 Inno

CDP#12: Vehicle Hydrogen Tank Cyc

0 

2000 4000 6000 8000 

1000012000140001600018000

Number of cycles

Hydrogen Tank Cycle Life1

All OEMs

2015 DOE MYPP Target22010 DOE MYPP Target22007 DOE MYPP Target2 Gen 1 Gen 2

NREL CDP12

Created: Sep-17-08 10:29 AM

1Data reported reference NGV2, HGV2, or EIHP standards.2Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based te
National Renewable Energy Laboratory 16 Inno

CDP#13: On-Site Hydrogen ProductioEfficiency

On-Site Natural Gas Reforming On-Site Electrolysis 0

1020304050607080

2010 MYPP Target2015 MYPP Target

2012 MYPP Target2017 MYPP Target

Production Efficiency (LHV %)

Hydrogen Production Conversion Efficiency1

Average Station EfficiencyQuarterly Efficiency DataHighest Quarterly EfficiencyEfficiency Probability Distribution2

NREL CDP13

Created: Mar-09-10 3:16 PM

1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by th

the energy into the production process from the feedstock and all other energy as needed. Conversion efficiency does not incenergy used for compression, storage, and dispensing.

2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency base

monthly conversion efficiency data from the Learning Demonstration.
National Renewable Energy Laboratory 17 Inno

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 

0

500

1000150020002500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

350 vs 700 bar Fills - All Light Duty Through 2009Q4

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

Fill Type Avg (kg/min) %>1 Count------------- ------------------ ------- --------350 bar 0.82 29% 19659700 bar 0.63 4% 5590

350 bar700 bar2006 MYPP Tech V2012 MYPP Tech V

NREL CDP14

Created: Mar-09-10 3:10 PM

CDP#14: Fueling Rates – 350 and 700 
National Renewable Energy Laboratory 18 Inno

CDP#15: H2 Production Cost vs. Proc

02

468

10121416

Projected Early Market 1500 kg/day Hydrogen Cost1

$/kg

Natural Gas Reforming2 Electrolysis2

2015 DOE Hydrogen Program Goal Range3

Median

25th & 75th Percentile10th & 90th Percentile

Created: Jan-19-10 11:08 AM

(1) Reported hydrogen costs are based on estimates of key cost elements from Learning Demonstration energy company partnecost of producing hydrogen on-site at the fueling station, using either natural gas reformation or water electrolysis, dispensed to reflect an assessment of hydrogen production technologies, not an assessment of hydrogen market demand.(2) Hydrogen production costs for 1500 kg/day stations developed using DOE’s H2A Production model, version 2.1. Cost modelinlifetime cost of producing hydrogen at fueling stations installed during an early market rollout of hydrogen infrastructure and are costs that might be seen in a fully mature market for hydrogen installations. Modeling uses default H2A Production model inputs feedback from Learning Demonstration energy company partners, based on their experience operating on-site hydrogen producH2A-based Monte Carlo simulations (2,000 trials) were completed for both natural gas reforming and electrolysis stations using d10th percentile to 90th percentile estimated ranges for key cost parameters as shown in the table. Capacity utilization range is baof the production technologies and could be significantly lower if there is inadequate demand for hydrogen.(3) DOE has a hydrogen cost goal of $2-$3/kg for future (2015) 1500 kg/day hydrogen production stations installed at a rate of 500 

Key H2 Cost Elements a

Input Parameter Min

(P

Facility Direct Capital Cost $Facility Capacity Utilization 8Annual Maintenance & Repairs $1Annual Other O&M $1Annual Facility Land Rent $Natural Gas Prod. Efficiency (LHV) 6Electrolysis Prod. Efficiency (LHV) 3

NREL CDP15
National Renewable Energy Laboratory 19 Inno

0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 

05

1015202530

Segmented Trips/Hour Histogram: DOE Fleet

Trips/Hour*

Frequency [%]

*Trips/Hour based on 50 hspanning stack operating 

NREL CDP16

Created: Mar-09-10 4:13 PM

CDP#16: Fuel Cell Stack Trips Per HoHistogram
National Renewable Energy Laboratory 20 Inno

01234567

89

10

0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 

Stack Op Hour Groups

Trips/Hour*

Statistics of Trips/Hour vs Operating Hour: DOE Fleet

*Trips/Hour based on 50 hspanning stack operating 

Data Range

25th & 75th PGroup MediaOutlier

NREL CDP17

Created: Mar-09-10 4:13 PM

CDP#17: Statistics of Trips/Hour vs. Operating Hour
National Renewable Energy Laboratory 21 Inno

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 

0

200400600800

10001200140016001800

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty Through 2009Q4

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

25464 Events

Average = 0.77 kg/min

23% >1 kg/min

2006 MYPP Tech V2012 MYPP Tech V

NREL CDP18

Created: Mar-09-10 3:18 PM

CDP#18: Refueling Rates
National Renewable Energy Laboratory 22 Inno

0-10 10-30 30-60 60-360 >

05

101520253035

Time [min]

Trip Frequency [%]

Time Between Trips with Ambient Temperature: DOE Fleet

<0oC0-10oC10-24oC24-40oC>40oC

NREL CDP19

Created: Mar-09-10 4:13 PM

CDP#19: Time Between Trips & AmbiTemperature
National Renewable Energy Laboratory 23 Inno

0 50 100 150 200 250 

Non-Event

Near Miss

Incident

Number of Reports

Severity

Total Infrastructure Safety Reports by Severity

and Report Type Through 2009 Q4

Alarms OnlyAutomatic System ShutElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO H2 Release - SignificantManual System ShutdowNon-H2 ReleaseSite Power OutageStructural IssueSystem Trouble, not Ala

NREL CDP20

Created: Mar-11-10 2:45 PM

An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#20: Safety Reports – Infrastructu
National Renewable Energy Laboratory 24 Inno

0 2 4 6 8 10 

-30-20-10

0

102030405060

1.4 % trips below 0 oC

Max Op = 

Min Op = 

28.2 % trips above 28 oC

Trip Frequency [%]

Temperature [

oC]

Average Ambient Trip Temperature: DOE Fleet

NREL CDP21

Created: Mar-09-10 4:12 PM

CDP#21: Range of Ambient TemperatDuring Vehicle Operation
National Renewable Energy Laboratory 25 Inno

05

10152025303540

Number of Vehicles

Total Vehicle Hours

Vehicle Hours: All OEMs, Gen 1 and Gen 2

In ServiceRetired (1)

Total Vehicle Hours = 106,413

Through 2009 Q4

Created: Mar-09-10 02:36 PM

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL

Some project teams concluded in Fall/Winter 2009

NREL CDP22

C t d M 09 10

NRE

CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 26 Inno

05

1015202530354045

Number of Vehicles

Total Vehicle Miles

Vehicle Miles: All OEMs, Gen 1 and 2

In ServiceRetired (1)

Total Vehicle Miles Traveled = 2,580,382

Through 2009 Q4

Created: Mar-09-10 03:16 PM C tdM 09 10

NREL CDP23 (1) Retired vehicles have left DOE fleet and are no longer providing data 

Some project teams concluded in Fall/Winter 2009

CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 27 Inno

2,580,

-

250,000 500,000 750,000 

1,000,000 1,250,000 1,500,000 1,750,000 2,000,000 2,250,000 2,500,000 2,750,000 

Vehicle Miles Traveled

Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2

Created: Mar-09-10 03:16 PM

Through 2009 Q4

C t d M 09 1

NREL CDP24

CDP#24: Cumulative Vehicle Miles Tr
National Renewable Energy Laboratory 28 Inno

-

20 40 60 80 

100 120 140 160 

Cumulative Vehicles Deployed/Retired

1

Vehicle Deployment by On-Board Hydrogen Storage T

700 bar on-road350 bar on-roadLiquid H2 on-road700 bar retired350 bar retiredLiquid H2 retired

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL

Some project teams concluded in Fall/Winter 2009 Created Mar-09-2010 8:34 AM

Created Mar 09 20

NREL CDP25

CDP#25: Vehicle H2 Storage Technolo
National Renewable Energy Laboratory 29 Inno

CDP#26: Cumulative H2 Produced or Dispe

0

20406080

100120140160

Mass of Hydrogen* 

(1000 kg)

Calendar Quarter

Cumulative Hydrogen Produced or Dispens

Through 2009 Q4

Cumulative HydroNumber of Station

NREL CDP26

Created 2010-Mar-22 2:50pm

NRE

Created 2010 Mar 2

*Some pconclud
National Renewable Energy Laboratory 30 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

99.7

99.75

99.8

99.85

99.9

99.95

100

Calculated H

2

 Index (%)

H2 Calculated Quality Index by Year and Production Method

On-Site NG Reformer (DOn-Site Electrolysis (DaDelivered (Data Range)SAE J2719 APR2008 GuCalculated Data

NREL CDP27

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#27: Hydrogen Quality Index
National Renewable Energy Laboratory 31 Inno

0 2 4 6 8 10 12 14 16 

Particulates 

g/L

H2 Fuel Constituents

Data Range SAE J2719 APR2008 Guideline Measured Less Than or Equal To 

0 500 1000 1500 2000 2

(N2+He+Ar) 

He 

(Ar+N2) 

0 5 10 15 20 25 30 

H2O 

Total HC 

O2 

CO2 

CO 

NH3 

mol/mol (ppm)

0 10 20 30 40 50 60 

Total S* 

NREL CDP28 nmol/mol (ppb)

Created: Mar-10-10 11:05 AM Data is from Learning Demonstration and California Fuel Cell Partnership testing

*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

CDP#28: Hydrogen Fuel Constituents
National Renewable Energy Laboratory 32 Inno

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

1020

3040506070

Total S* (nmol/mol)(ppb)

Total S* (nmol/mol)(ppb)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).

Year 1 Year 2 Year 3 Year 4 Y
National Renewable Energy Laboratory 33 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

0.5

1

1.5

2

Total HC (

mol/mol)(ppm)

Total HC (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 34 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

05

10152025

Total Halogenates (

mol/mol)(ppm)

Total Halogenates (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 35 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

02468

10121416

182022

Particulate Concentration (

g/L)

Particulate Concentration (g/L)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 36 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

05

10

152025303540

O

2

(

mol/mol)(ppm)

O2(mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)

On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 37 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

500

1000150020002500

N

2

 (

mol/mol)(ppm)

N2 (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)

On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 38 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

500

10001500

200025003000

N

2

+He+Ar (

mol/mol)(ppm)

N2+He+Ar (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 39 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

5000

1000015000200002500030000

Particulate Size (

m)

Particulate Size (m)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 40 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

50

100150200250300

He (

mol/mol)(ppm)

He (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 41 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

05

1015

H2O (

mol/mol)(ppm)

H2O (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 42 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

0.05

0.1

0.15

0.2

Formic acid (

mol/mol)(ppm)

Formic acid (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 43 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

0.020.040.060.08

0.1

Formaldehyde (

mol/mol)(ppm)

Formaldehyde (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limited)

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 44 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

0.2

0.40.60.8

1

CO (

mol/mol)(ppm)

CO (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 45 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

01234

56789

CO

2

 (

mol/mol)(ppm)

CO2 (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 46 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

500

10001500

200025003000

Calcultated Total Constituents (

mol/mol)(ppm)

Calcultated Total Constituents (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (DOn-Site Electrolysis (DaDelivered (Data Range)SAE J2719 APR2008 GCalculated Data

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 47 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

500

1000150020002500

Ar+N

2

 (

mol/mol)(ppm)

Ar+N2 (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 48 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

0

50

100150200

Ar (

mol/mol)(ppm)

Ar (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 49 Inno

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. E

01234

56

NH3 (

mol/mol)(ppm)

NH3 (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method

On-Site NG Reformer (Data Range)On-Site Electrolysis (Data Range)Delivered (Data Range)SAE J2719 APR2008 GuidelineMeasuredLess Than or Equal To (Detection Limite

NREL CDP28

Created: Mar-10-10 11:07 AM

Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3

Year 1 Year 2 Year 3 Year 4 Y

CDP#28 Supplemental: Hydrogen Constituents by Year and Production 
National Renewable Energy Laboratory 50 Inno

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 

0

500

1000150020002500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

Comm vs Non-Comm Fills - All Light Duty Through 2009Q4

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.86 30%Non-Comm 0.66 12%

Comm

Non-Comm2006 MYPP Tech V2012 MYPP Tech V

NREL CDP29

Created: Mar-09-10 3:08 PM

CDP#29: Fueling Rates CommunicatioNon-Communication Fills
National Renewable Energy Laboratory 51 Inno

0 20 40 60 80 100 120 140 160 1

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since Inception

Through 2009 Q4

SchedUn-Sch

0 5 10 15 20 25 30 35 

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Number of Events Per Station Since Inception

0% 10% 20% 30% 40% 50% 60% 70% 80% 9

# of Events

Hours

Comparison of Scheduled/Un-Scheduled Maintenance

NREL CDP30

Created: Mar-10-10 9:30 AM

CDP#30: Infrastructure Maintenance
National Renewable Energy Laboratory 52 Inno

CDP#31: Number of Online Stations

05

10152025

Number of Stations

Reporting Period

Cumulative Stations

Existing StationsContinuing Outside of ProjectRetired Stations

NREL CDP31

Created Mar-19-10 9:05am

NRE
National Renewable Energy Laboratory 53 Inno

CDP#32: Infrastructure Hydrogen ProMethods

0123456789

Delivered Compressed 

H2

Natural Gas On-site 

Reforming

Electrolysis Deliv

# of Stations

Production Technology

Infrastructure Hydrogen Production Method

Existing StatioContinuing OuRetired Station

NREL CDP32 NRE

Created Mar-19-10 9:05am
National Renewable Energy Laboratory 54 Inno

CDP#33: Percentage of Theoretical RTraveled Between Refuelings

0 10 20 30 40 50 60 70 80 

0123456789

10111213

Range Histogram: All OEMs

Percentage of chassis dyno range1 between refuelings

Percentage of Refuelings

0 10 20 30 40 50 60 70 80 

NREL CDP33

Created: Mar-23-10 10:53 AM

Total refuelings2 = 25811

1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPAadjusted) and usable fuel on board.2. Some refueling events are not detected/reported due to data noise or incompleteness.
National Renewable Energy Laboratory 55 Inno

0 10 20 30 40 50 60 70 80 

Gen1Gen2

Vehicle Range Factors

Percentage of chassis dyno range1.

All OEMs

Window-Sticker 

2 Window-Sticker 2

On-Road 

3 On-Road 3

NREL CDP34

Created: Mar-10-10 1:25 PM

1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.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 Range
National Renewable Energy Laboratory 56 Inno

02468

1012141618202224

Number of Stations

Infrastructure Safety Trend and Number of Stations Through 2009 Q4

05Q205Q305Q406Q106Q206Q306Q407Q107Q207Q307Q408Q108Q208Q308Q409Q109Q209Q

Number of StationsAvg Refuelings Between Safety Reports

7 11

32 34

88 102 115

47

68

124

101

57 54

73

51

138

447

1

NREL CDP35

Created: Mar-23-10 2:43 PM Reporting Period

CDP#35: Average Refuelings Between Infrastructure Safety Reports
National Renewable Energy Laboratory 57 Inno

0

1020304050

Number of Reports

Type of Infrastructure Safety Reports by Quarter Through 2009 Q4

05Q205Q305Q406Q106Q206Q306Q407Q107Q207Q307Q408Q108Q208Q308Q409Q109Q209Q

IncidentNear MissNon-EventNumber of StationsAvg # Reports/Station

NREL CDP36

Created: Mar-23-10 2:15 PM

Reporting Period An INCIDENT is an event that results in:

 - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#36: Type of Infrastructure Safety By Quarter
National Renewable Energy Laboratory 58 Inno

0 50 100 150 200 250 

Non-Event

Near Miss

Incident

Number of Reports

Severity

Primary Factors of Infrastructure Safety Reports

Through 2009 Q4

Calibration/Settings/ Software ContrDesign FlawElectrical Power to SiteEnvironment (Weather, Power DisruFalse AlarmInadequate Training, Protocol, SOPInadequate/ Non-working EquipmenMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel ErrorSystem Manually Shutdown

NREL CDP37

Created: Mar-11-10 2:45 PM

An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame

CDP#37: Primary Factors of InfrastrucSafety Reports
National Renewable Energy Laboratory 59 Inno

0 2 4 6 8 10 12 14 16 1

0

500

10001500200025003000

3500

Time (min)

Number of Fueling Events

Histogram of Fueling Times

All Light Duty Through 2009Q4

Average = 3.26 min

86% <5 min

 2006 MYPP Tech Val Milestone (5 kg in 5 m 2012 MYPP Tech Val Milestone (5 kg in 3 m

NREL CDP38

Created: Mar-09-10 3:18 PM

CDP#38: Refueling Times
National Renewable Energy Laboratory 60 Inno

0 0.5 1 1.5 2 2.5 3 3.5 4 4.

0

100200300400500600700800

900

1000

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling AmountsAll Light Duty Through 2009Q4

Average = 2.13 kg

NREL CDP39

Created: Mar-09-10 3:18 PM

CDP#39: Refueling Amounts
National Renewable Energy Laboratory 61 Inno

CDP#40: H2 Tank Level at Refueling

Tank Levels: DOE Fleet

14%

E F

NREL CDP40

Created: Mar-09-10 4:14 PM

Total r

1. Some refueling events not recorded/detected due to data noise or incompleteness.

Median Tank Level (At Fill) = 42%

2. The outer arc is set at 20% total refuelings.3. If tank level at fill was not available, a complete fill up was assumed.
National Renewable Energy Laboratory 62 Inno

CDP#41: Refueling Tank Levels - Med

E F

Tank Level Medians (At Fill): DOE Fleet, All Vehicles

NREL CDP41

Created: Mar-09-10 4:14 PM

Total r

1. Some refueling events not recorded/detected due to data noise or incompleteness.2. If tank level at fill was not available, a complete fill up was assumed.
National Renewable Energy Laboratory 63 Inno

CDP#42: Refueling by Time of Day

Refueling by Time of Day: DOE Fleet

9%

3

12

9

6

Total Fill3 % of fills b/t 6 AM & 6 PM: 89.7% Eve

1. Fills between 6 AM & 6 PM2. The outer arc is set at 12 % total Fill.3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

NREL CDP42

Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 64 Inno

CDP#43: Refueling by Day of Week

Sun Mon Tues Wed Thur Fri Sat 0

5

101520

Fills by Day of Week: DOE Fleet

% of Fills in a Day

NREL CDP43 Day

Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 65 Inno

Driving Start Time - Day: DOE Fleet

9%

3

12

9

6

Total Driving3 % of driving trips b/t 6 AM & 6 PM: 85.3% 

1. Driving trips between 6 AM & 6 PM2. The outer arc is set at 12 % total Driving.3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

% of NHTS trips b/t 6 AM & 6 PM: 81.5%

NREL CDP44

DN

Created: Mar-09-10 4:15 PM

2001 NHTS Data Includes ASCII.csv Source: http://nh

CDP#44: Driving Start Time – Day
National Renewable Energy Laboratory 66 Inno

Sun Mon Tues Wed Thur Fri Sat 0

2468

101214161820

Driving Trips by Day of Week: DOE Fleet

% of Driving Trips in a Day

NREL CDP45 Day

Created: Mar-09-10 4:15 PM

2001 NHTS Data Includes ASCII.csv Source: http://nh

CDP#45: Driving by Day of Week
National Renewable Energy Laboratory 67 Inno

0

1020304050

Time at Fuel Cell Stack Power Levels: DOE Fleet

Operating Time [%]

0-5%5-10%10-15%15-20%20-25%25-30%30-35%35-40%40-45%45-50%50-55%55-60%60-65%65-70%70-75%75-80%80-85%85-90%90-95% 95-1

% Max Fuel Cell Power (Gross)

All timeTime with 0 s

NREL CDP46

Created: Mar-09-10 4:21 PM

CDP#46: Fuel Cell System Operating 
National Renewable Energy Laboratory 68 Inno

0 5 10 15 20 

05

1015202530354045

Trip Frequency [%]

Trip Length [miles]

Trip Length: DOE Fleet

DONH

NREL CDP47

Created: Mar-09-10 4:16 PM

2001 NHTS Data Includes Car, TruASCII.csv Source: http://nhts.ornl.g

CDP#47: Trip Length
National Renewable Energy Laboratory 69 Inno

CDP#48: Primary Factors Affecting LeDemo Fleet Fuel Cell Degradation

DOE Fleet

High Current Time

Hot Starts

Starts/hour

Low Voltage Time

High Voltage Time

Cold Starts

Short Trips

0 Speed Trips

Hot Ambient Temp

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance. 

Created: Feb-21-08 9:32 AM

H*: Factor group associated with higL**: Factor group associated with low 

Due to differences among t

DOE Fleet Analysis results a

out and concrete conclusions 

to draw.

Individual team analyses (C

focused on patterns within 

C

NREL CDP48
National Renewable Energy Laboratory 70 Inno

CDP#49: Primary Factors Affecting LeDemo Team Fuel Cell Degradation

High Voltage Time

Low Current Time

Short Trips

Low Speed

Team 3

Team 4

Low Current Time

Long Trips

Warm Ambient Temp

Zero Speed

Current Transients

High Voltage Time

Low Current Time

Short Trips

Low Speed

Current Transients

1) On-going fuel cell degradation study using Partial Least Squares (PLS) 

regression model for each team’s Gen 1 fleet.

2) Teams’ PLS models have a high percentage of explained decay rate 

variance, but the models are not robust and results are scattered. 

3) Factor groups associated with stacks that are opposite to the identified 

groups here are not specified.

H*

Starts/Hour

Zero Speed

Short Trips

Low Voltage Time

High Current Time

Current Transients

Cold Starts

Hot Ambient Temp

High Speed

H*

H*

H*

H*

H*: Factor group associated with hig

Created: Mar-09-09 9:06 AM C tdM 09 09

NREL CDP49
National Renewable Energy Laboratory 71 Inno

CDP#50: Refueling by Time of Night

Refueling by Time of Night: DOE Fleet

3%

3

12

9

6

Total Fill3 % of fills b/t 6 PM & 6 AM: 10.3% Eve

1. Fills between 6 PM & 6 AM2. The outer arc is set at 12 % total Fill.3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

NREL CDP50

Created: Mar-09-10 4:14 PM
National Renewable Energy Laboratory 72 Inno

Driving Start Time - Night: DOE Fleet

4%

3

12

9

6

Total Driving3 % of driving trips b/t 6 PM & 6 AM: 14.7% 

1. Driving trips between 6 PM & 6 AM2. The outer arc is set at 12 % total Driving.3. Some events not recorded/detected due to data noise or incompleteness.

PM AM

% of NHTS trips b/t 6 PM & 6 AM: 18.4%

NREL CDP51

DN

Created: Mar-09-10 4:15 PM

2001 NHTS Data Includes ASCII.csv Source: http://nh

CDP#51: Driving Start Time – Night
National Renewable Energy Laboratory 73 Inno

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 

0

100200300400500600700

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year Through 2009Q4

5 minute fill of5 kg at 350 bar

3 minute fill of5 kg at 350 bar

Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 16%2006 0.74 21%2007 0.81 26%2008 0.77 23%2009 0.77 22%

200520062007200820092006 MYPP Tech V2012 MYPP Tech V

NREL CDP52

Created: Mar-09-10 3:35 PM

CDP#52: Refueling Data by Year
National Renewable Energy Laboratory 74 Inno

02468

10

FC Energy by Power Levels: DOE Fleet

FC Energy [%]

0-5%5-10%10-15%15-20%20-25%25-30%30-35%35-40%40-45%45-50%50-55%55-60%60-65%65-70%70-75%75-80%80-85%85-90%90-95% 9

% Fuel Cell Power (Gross) of Max

NREL CDP53

Created: Mar-11-10 9:13 AM

CDP#53: Fuel Cell System Energy witPower Levels
National Renewable Energy Laboratory 75 Inno

0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-30days >30d

0

102030405060

Trip Frequency [%]

Time

Time between Trips: DOE Fleet

0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-

0

1020304050

% Trips

Time

0-60 min Breakdown: DOE Fleet

NREL CDP54

Created: Mar-09-10 4:16 PM

CDP#54: Time Between Trips
National Renewable Energy Laboratory 76 Inno

<-0.5 -0.5-0 0-0.5 0.5-1 1-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-4.5 4.5-5 

0

102030405060

Energy Consumed [kWh]

Trip Frequency [%]

Energy in Trip: DOE Fleet

Net batterycharge in trip

BatteryVehiclFC

NREL CDP55

Created: Mar-09-10 4:16 PM

CDP#55: Fuel Cell System Energy
National Renewable Energy Laboratory 77 Inno

0 5 10 15 20 25 30 35 

02468

101214161820

Trip Frequency [%]

Daily Distance [miles]

Daily Distance: DOE Fleet

DONH

NREL CDP56

Created: Mar-09-10 4:17 PM

Cumulative Frequency

@ 20 miles

DOE Fleet: 47.4%

NHTS: 27.2%

Cumulative 

@ 

DOE Fl

NH

2001 NHTS Data Includes Car, TruASCII.csv Source: http://nhts.ornl.g

CDP#56: Daily Driving Distance
National Renewable Energy Laboratory 78 Inno

CDP#57: H2 Storage System Mass and VolBreakdown

73%

24%

3%

Average Breakout of H2 Storage System Volum

3.26%

73%

23%

Average Breakout of H2 Storage System Mass

35% 56%

9%

H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)

3.33%

72%

24%

H2 Mass (%)Pressure Vessel Mass (%)

Created: Aug-19-08 9:14 AM Balance of Plant Mass (%)

350 bar700 bar

Created: Aug 1

NREL CDP57
National Renewable Energy Laboratory 79 Inno

CDP#58: Fuel Cell System Power Den

0

100200300400500600700

Power Density (W/L)

FC System Power Density (W/L)

2010 and 2015 DOE MYPP Target1 

NREL CDP58

Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 80 Inno

CDP#59: Fuel Cell System Specific Po

0

100200300400500600700

Specific Power (W/kg)

FC System Specific Power (W/kg)

2010 and 2015 DOE MYPP Target1 

NREL CDP59

Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.
National Renewable Energy Laboratory 81 Inno

CDP#60: On-Site Hydrogen ProductioEfficiency vs. Capacity Utilization

0 10 20 30 40 50 60 70 80 

0

10203040506070

Production Capacity Utilization1 [%]

Production Conversion Efficiency

2

 [%]

Monthly Production Conversion Efficiency vs Utilization

Electrolysis DataElectrolysis Fit3Electrolysis Fit C

Natural Gas DataNatural Gas Fit3Natural Gas Fit C

NREL CDP60

Created: Mar-09-10 3:34 PM

1) 100% production utilization assumes operation 24 hrs a day, 7 days a week2) Production conversion efficiency is defined as the energy of the hydrogen out of the process (on a LHV basis) divided by the sum process from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, s3) High correlation with electrolysis data (R2 = 0.82) & low correlation with natural gas data (R2 = 0.060)
National Renewable Energy Laboratory 82 Inno

CDP#61: Refueling Station CompressEfficiency

On-Site Compression 

On-Site Compression Efficiency 0

102030405060708090

100

2010 MYPP Compression Target2015 MYPP Compression Target

Compression Efficiency (%)

On-Site Hydrogen Compression Efficiency1 and Energy Use

Average Station Compression EfficiencyQuarterly Compression Efficiency DataHighest Quarterly Compression EfficiencyAverage Station Compression EnergyQuarterly Compression Energy DataLowest Quarterly Compression Energy

NREL CDP61

Created: Mar-11-10 9:41 AM

1Consistent with the MYPP, compression efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the s

energy of the hydrogen output plus all other energy needed for the compression process. Data shown for on-site hydrogen production and stora

facilities only, not delivered hydrogen sites.

Compression Energy RequirOn average, 11.3% of the encontained in the hydrogen frequired for the compressioprocess.
National Renewable Energy Laboratory 83 Inno

CDP#62: Learning Demonstration VehGreenhouse Gas Emissions

0

100200300400500600700

WTW GHG Emissions (g CO2-eq/mi)

Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse Gas Emissions

Baseline Conventional Mid-Size Passenger Car2Baseline Conventional Mid-Size SUV2

Average WTW GHG Emissions (Learning Demo)Minimum WTW GHG Emissions (Learning Demo)WTW GHG Emissions (100% Renewable Electricity)WTW GHG Probability Based on Learning Demo3

NREL CDP62

Created: Mar-08-10 4:16 PM

On-Site Natural Gas Reforming On-Site Electrolysis(4)

1. Well-to-Wheels greenhouse gas emissions based on DOE's GREET model, version 1.8b. Analysis uses default GREET values except for FCV fuel e

production conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel economy data for all teaconversion efficiency values are the production efficiency data used in CDP #13.

2. Baseline conventional passenger car and light duty truck GHG emissions are determined by GREET 1.8b, based on the EPA window-sticker fuel ec

gasoline mid-size passenger car and mid-size SUV, respectively. The Learning Demonstration fleet includes both passenger cars and SUVs.3. The Well-to-Wheels GHG probability distribution represents the range and likelihood of GHG emissions resulting from the hydrogen FCV fleet base

economy data and monthly conversion efficiency data from the Learning Demonstration.4. On-site electrolysis GHG emissions are based on the average mix of electricity production used by the Learning Demonstration production sites, wgrid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are higelectricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied from the U.S. average emissions would be 1330 g/mile.
National Renewable Energy Laboratory 84 Inno

13%

13%

18%

22%

By Number of Events

Total Number of Events = 2491

20%

By Labo

Total Hou

system control & safetycompressorreformerelectrolyzerdispenserothervalves & pipingelectricalstorage

NREL CDP63

Created: Mar-10-10 10:31 AM

Hydrogen Fueling Station Maintenance

CDP#63: Hydrogen Fueling Station Maintenance by System
National Renewable Energy Laboratory 85 Inno

5% 3%

34%

58%

Fuel Cell Vehicle Events (11574)

18%

8%

50%

Fuel Cell Vehicle Labor (1

Vehicle (non-powertrain)Fuel Cell SystemPowertrainBattery

4%

10%

12%

13%

23%

39%

Fuel Cell System Events (3916)

< 1%

27%

28%

Fuel Cell System Labor (

Thermal ManagementAir SystemControls, Electronics, SensorsFuel SystemFuel Cell StackOther

NREL CDP64

Created: Mar-10-10 10:34 AM

Fuel Cell Vehicle Maintenance Events and Labor Hours

CDP#64: Fuel Cell Vehicle MaintenancSystem
National Renewable Energy Laboratory 86 Inno

0246

8

101214

HWFET Cycle

US06 Cycle

UDDS Cycle

1015 Cycle

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 

Percent Idle in Trip

% Idle

Trip Frequency [%]

NREL CDP65

Created: Mar-09-10 4:17 PM

CDP#65: Percent Idle in Trip with Comparison to Standard Drive Cycles 
National Renewable Energy Laboratory 87 Inno

0 5 10 15 20 25 30 35 40 45 50 55 60 65 

0

5

10152025303540

Speed [mph]

Operation Time [%]

Fuel Cell Vehicle Speed

DOE Fleet Speed

DOE Fleet Idle1015 Cycle (14.1 mph avg)UDDS Cycle (19.6 mph avg)HWFET Cycle (48.0 mph avg)US06 Cycle (48.2 mph avg)

NREL CDP66

Created: Mar-09-10 4:17 PM

CDP#66: FCV Speed with Comparison Standard Drive Cycles
National Renewable Energy Laboratory 88 Inno

05

10152025303540

Stack Count

Fuel Cell Stack Operation Hours: Gen1

Gen1

0 200 400 600 800 100012001400160018002000

Gen1 Hours

24% of stacks in operation

In Op1Retired2Other3

05

10152025303540

Stack Count

Fuel Cell Stack Operation Ho

Gen2

0 200 400 600 800 1000120014001600

Gen2 Hours

34% of stacks i

NREL CDP67

Created: Mar-23-10 10:39 AM

1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because  Some project teams concluded in Fall/Winter 2009

CDP#67: Fuel Cell Stack Operation Ho
National Renewable Energy Laboratory 89 Inno

0 5 10 15 20 25 30 35 40 0

5

1015202530

Stack Count

% FC Power Drop

FC Power Drop During Operation Period: Gen1

Gen1

60% of In Op stackshave > 10% power drop

In Op1Retired2Other3

0 5 10 15 20 25 30 

05

1015202530

Stack Count

% FC Power Drop

FC Power Drop During Operation 

Gen2

85% of In Ohave > 10% 

NREL CDP68

Created: Mar-23-10 10:39 AM

1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because  Some project teams concluded in Fall/Winter 2009

CDP#68: Power Drop During Fuel CelOperation Period
National Renewable Energy Laboratory 90 Inno

3040

5060708090

100110120130

 0 100 200 300 400 500 600 700 800 900 1000110012001300140015001600170018

Stack Op Hour Segments(2)

% Power(1)

Max Fuel Cell Power Loss vs Op Hours: Gen1

1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.

Gen1 Data Range 25th & 75th 

Group MediOutlier

NREL CDP69

Created: Mar-23-10 10:39 AM

CDP#69: Max Fuel Cell Power DegradGen 1
National Renewable Energy Laboratory 91 Inno

3040

5060708090

100110120130

 0 100 200 300 400 500 600 700 800 900 1000110012001300140015001600170018

Stack Op Hour Segments(2)

% Power(1)

Max Fuel Cell Power Loss vs Op Hours: Gen2

1) Normalized by fleet median value at 200 hours.2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.

Gen2 Data Range 25th & 75th 

Group MediOutlier

NREL CDP70

Created: Mar-23-10 10:39 AM

CDP#70: Max Fuel Cell Power DegradGen 2
National Renewable Energy Laboratory 92 Inno

0-200 400 600 800 1000 1200 1400 1600 1800 2000 

05

1015202530

27% Gen1 > 2000 projected hrs17% Gen2 > 2000 projected hrs

Projected Hours

% Stacks

Durability: Projected Hours to Low Fuel Cell Power Limit

Gen1 (> 200 operation hrs)

Gen1 (< 200 operation hrs)Gen2 (> 200 operation hrs)Gen2 (< 200 operation hrs)

NREL CDP71

Created: Mar-23-10 10:39 AM

1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning D2. Acceptable low vehicle performance limit will be determined by retail customer expectations.3. Power projection method based on the voltage degradation techniques, but uses max fuel cell power instead of voltaghigh current.4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and hours greater than 200 the degradation rate tends to flatten out.

CDP#71: Projected Hours to OEM Low Operation Limit
National Renewable Energy Laboratory 93 Inno

CDP#72: Difference Between Tank anAmbient Temperature Prior to Refueli

-20 0 20 4

-20-10

0

102030405060

Ambient Air Temperature [de

Tank Temperature [deg C]

Tank vs. Ambient Air Temps Prior to 

-40 -20 0 20 40 0

500

100015002000

Delta Temperature [deg C]

Count

Delta Temperature: Tank minus Ambient

Delta Temp HistogramNormal Distribution Fit

00.020.040.060.08

Density

Mean= -3.751Std Dev= 6.129

NREL CDP72

Created: Mar-11-10 10:24 AM

-This CDP created in support of SAE J2601 related to refueling

-Temperatures are prior to refueling and exclude data within 4 hours of a previous fill-The plot to the left excludes ambient temperatures less than -5 deg C
National Renewable Energy Laboratory 94 Inno

10 15 20 25 

0

200400600

800

100012001400160018002000

Fuel Cell Stack Projected Hours as a Function of Voltage Drop

% Voltage Drop

Projected Hours2,3

Gen 1 Average ProjectionsGen 1 Average Projection to 10% Voltage Degradation1Gen 2 Average ProjectionsGen 2 Average Projection to 10% Voltage Degradation1

NREL CDP73

Created: Mar-23-10 10:40 AM

(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(2) Projections using on-road data -- degradation calculated at high stack current.(3) Curves generated using the Learning Demonstration average of each individual fleet average at various voltage degradation (4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.(6) All OEM Gen 2 average fleet projections are higher than Gen1 projections, however due to less operation data for Gen 2, these projections are limited by demonstrated operation hours to minimize extrapolations.

CDP#73: Fuel Cell Stack Projected Hoa Function of Voltage Drop
National Renewable Energy Laboratory 95 Inno

0 2 4 6 8 10 12 14 16 18 20

05

101520

Cycle Per Mile

Trip Frequency [%]

Number of Cycles1 per Trip Mile

0 2 4 6 8 10 12 14 1

0

102030405060

Cycle Per Min

Trip Frequency [%]

Number of Cycles1 per Trip M

Gen1 Gen2 0

10203040

Cycle per Mile

Range of Fleet Average Cycle1 per Mile

Gen1 

1234567

Cycle per Min

Range of Fleet Average Cycle1 

NREL CDP74

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack vo

CDP#74: Fuel Cell Transient Cycle CoMile and per Minute
National Renewable Energy Laboratory 96 Inno

CDP#75: Fuel Cell Transient Voltage aTime Change
National Renewable Energy Laboratory 97 Inno

05

101520

253035

DownUp SlowUp SlowDown SlowDownUp DownSSUp

Frequency [%]

Transient Cycle1 Count by Category2

0 5 10 15 20 25 30 35 40 0

5

1015202530

dV/dt

Frequency [%]

DownUp Cycle1 dV/dT

0 5 10 15 20 25 

0

1020304050

dV/dt

Frequency [%]

SlowUp Cycl

0 5 10 15 20 25 30 35 40 0

1020304050

dV/dt

Frequency [%]

SlowDown Cycle1 dV/dT

0 5 10 15 20 25 30 35 40 0

102030405060

dV/dt

Frequency [%]

SlowDownUp Cycle1 dV/dT

0 5 10 15 20 25 

0

20406080

100

dV/dt

Frequency [%]

DownSSUp Cy

NREL CDP76

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage

2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 sec SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack vo

CDP#76: Fuel Cell Transient Rate by CCategory
National Renewable Energy Laboratory 98 Inno

05

101520

253035

DownUp SlowUp SlowDown SlowDownUp DownSSUp

Frequency [%]

Transient Cycle1 Count by Category2

05

101520

-34

-30

-26

-22

-18

-14

-10

-6

-226

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]

Frequency [%]

DownUp Cycle1 dV

05

101520

-34

-30

-26

-22

-18

-14

-10

-6

-22

% Voltage Change [%M

Frequency [%]

SlowUp Cy

02468

1012

-34

-30

-26

-22

-18

-14

-10

-6

-226

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]

Frequency [%]

SlowDown Cycle1 dV

02468

1012

-34

-30

-26

-22

-18

-14

-10

-6

-226

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]

Frequency [%]

SlowDownUp Cycle1 dV

05

101520

-34

-30

-26

-22

-18

-14

-10

-6

-22

% Voltage Change [%M

Frequency [%]

DownSSUp C

NREL CDP77

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage

2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 sec SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack volt

CDP#77: Fuel Cell Transient Voltage Changes by Cycle Category
National Renewable Energy Laboratory 99 Inno

05

101520253035

DownUpSlowUp SlowDown SlowDownUp DownSSUp

Cycle Frequency [%]

Transient Cycle Count by Category4

Total<LoV Level2>HiV Level3

t

V

Example

0 2 4 6 8 10 12 14 1

0

1020304050607080

Count per Mile

Trip Frequency [%]

Cycles1 Outside of Voltage L

<>

NREL CDP78

Created: Mar-22-10 4:46 PM

1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) The low voltage level is 70% Max Stack Voltage3) The high voltage level is 90% Max Stack Voltage4) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.

CDP#78: Fuel Cell Transient Cycles Oof Specified Voltage Levels
National Renewable Energy Laboratory 100 Inn

0 5 10 15 20 25 30 35 40 45 50 0

24

68

1012141618

% Time

Trip Frequency [%]

Percent of Trip Time at Steady State

NREL CDP79

Created: Mar-22-10 4:46 PM 1) SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.

CDP#79: Percentage of Trip Time at SState
National Renewable Energy Laboratory 101 Inn

0 50 100 150 200 250 

05

10

Percentage of Refuelings

Distance between refuelings [Miles]2

Distance Driven Between Refuelings: All OEMs

NREL CDP80

Created: Mar-23-10 10:53 AM

Total Refuelings1 = 25811

 Gen1 Refuelings = 18941 Median distance between refuelings = 56 M Gen2 Refuelings = 6870 Median distance between refuelings = 81 M

1. Some refueling events are not detected/reported due to data noise or incompleteness.2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the vehicle.

CDP#80: Miles Between Refuelings