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Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Contract No. DE-AC36-08GO28308

Fall 2010 Composite Data Products

ARRA Material Handling Equipment

Quarter 3 of 2010

Composite Data Products

Final Version September 30, 2010

Jennifer Kurtz, Keith Wipke, Sam Sprik, and Todd Ramsden

Technical Report

NREL/TP-5600-49603

April 2011
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J. Kurtz, K. Wipke, S. 

Sprik, T. Ramsden

September 30th, 2010

Fall 2010 Composite Data Products

ARRA Material Handling Equipment
CDPARRA-MHE-01

Fuel Cell MHE Systems Deployed

National Renewable Energy Laboratory Innovation for Our Energy Future

2010 Q1 2010 Q2 0

20

40

60

80

100

120

140

160

180

200

220

 14

122

 35

 49

122 136

206

Cumulative Units Deployed

Fuel Cell Units Deployed - ARRA

Class III

Class II

Class I

NREL cdparra_mhe_01

Created: Sep-22-10 5:07 PM
CDPARRA-MHE-02

Fuel Cell Operation Hours

National Renewable Energy Laboratory Innovation for Our Energy Future

0

2

4

6

8

10

12

14

16

18

0

100

200

300400500600

700800900

100011001200

130014001500160017001800

1900200021002200

>2200

% Fuel Cell Stacks

Cumulative Fuel Cell Operation Hours - ARRA

65.9% FC Stacks > 1000 Hours

Min Fleet Average = 599 fuel cell hours

Max Fleet Average = 1338 fuel cell hours

NREL cdparra_mhe_02

Created: Sep-22-10 5:28 PM Fuel Cell Operation Hours
CDPARRA-MHE-03

Fueling Events by Quarter

National Renewable Energy Laboratory Innovation for Our Energy Future

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 0

2000

4000

6000

8000

10000

12000

14000

Fueling Events By Quarter - ARRA

Number of Fills

 Cumulative Fuelings = 13,329 

NREL cdparra_mhe_03

Created: Sep-22-10 5:55 PM
CDPARRA-MHE-04

Hydrogen Dispensed by Quarter

National Renewable Energy Laboratory Innovation for Our Energy Future

2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 0

1000

2000

3000

4000

5000

6000

Hydrogen Dispensed to Material Handling Equipment By Quarter - ARRA

Hydrogen Dispensed [kg]

 Cumulative Hydrogen Dispensed = 6,198 kg 

NREL cdparra_mhe_04

Created: Sep-30-10 3:39 PM
CDPARRA-MHE-05

Refueling Time of Day

National Renewable Energy Laboratory Innovation for Our Energy Future

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 0

100

200

300

400

500

600

700

800

Refueling Time of Day - ARRA

Time of Day [hours]

Number of Refuelings

NREL cdparra_mhe_05

Created: Sep-22-10 6:12 PM
CDPARRA-MHE-06

Histogram of Fueling Times

National Renewable Energy Laboratory Innovation for Our Energy Future

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

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

Time (min)

Number of Fueling Events

Histogram of Fueling Times

ARRA

 13,329 Events 

 Average = 1.93 min 

NREL cdparra_mhe_06

Created: Sep-22-10 6:40 PM Fill data for class 1, 2, and 3 trucks
CDPARRA-MHE-07

Tank Pressure Level at Fueling

National Renewable Energy Laboratory Innovation for Our Energy Future

Tank Pressure At Fill: ARRA

E F

28%

NREL cdparra_mhe_07

Created: Sep-22-10 6:18 PM

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

2. The outer arc is set at 40% total refuelings.

3. Full Pressure is either 3600 psi or 5000 psi.

Total refuelings1 Median Tank Pressure (At Fill) = 17% = 4106
CDPARRA-MHE-08

Operation Time between Fueling

National Renewable Energy Laboratory Innovation for Our Energy Future

0 2 4 6 8 10 12 0

100

200

300

400

500

600

700

 Average of 4.1 op hours between fills 

Operating Time Between Fuelings - ARRA

Operating Hours Between Fuelings1,2

Count

NREL cdparra_mhe_08

Created: Sep-30-10 3:39 PM Excludes Data > 12 hours

1) Some fueling events not recorded/detected

due to data noise or incompleteness.

2) Data indicative of actual use and does not

represent the max capability of the systems.
CDPARRA-MHE-09

Histogram of Fueling Rates

National Renewable Energy Laboratory Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 0

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

ARRA

 13,329 Events 

 Average = 0.27 kg/min 

NREL cdparra_mhe_09

Created: Sep-22-10 6:41 PM Fill data for class 1, 2, and 3 trucks
CDPARRA-MHE-10

Histogram of Fueling Amounts

National Renewable Energy Laboratory Innovation for Our Energy Future

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0

200

400

600

800

1000

1200

1400

1600

1800

2000

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling Amounts

ARRA

 Average = 0.47 kg 

NREL cdparra_mhe_10

Created: Sep-22-10 6:41 PM Fill data for class 1, 2, and 3 trucks
CDPARRA-MHE-11

Fuel Cell Operation Hours by Quarter

National Renewable Energy Laboratory Innovation for Our Energy Future

2010 Q1 2010 Q2 0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

Total Operation Hours

Fuel Cell Operation Hours by Quarter - ARRA

52613

96433

Total Hours = 149,046

NREL cdparra_mhe_11

Created: Sep-23-10 3:37 PM
CDPARRA-MHE-12

Fuel Cell System Maintenance by Category

National Renewable Energy Laboratory Innovation for Our Energy Future

10%

13%

14%

23%

24%

Number of Events

Total Events = 789

73% were unscheduled

9%

17%

13%

28%

20%

Labor Hours

Total Hours = 1165

69% were unscheduled

Controls, Electronics, Sensors

Preventative maintenance

Thermal management

Energy Storage System

Fuel System

Other

Electrical

Operator Error

Air System

FC Stack

Scheduled equip upgrade

Air system

NREL cdparra_mhe_12

Created: Sep-22-10 7:00 PM

Forklift Maintenance By Category - ARRA
CDPARRA-MHE-13

Fuel Cell System Scheduled and Unscheduled Maintenance by Category

National Renewable Energy Laboratory Innovation for Our Energy Future

0 20 40 60 80 100 120 140 160 180 200

Air system Scheduled equip upgrade

FC Stack Air System Operator Error

Electrical

Other Fuel System Energy Storage System

Thermal management

Preventative maintenance Controls, Electronics, Sensors

Fuel Cell System Maintenance Scheduled vs. Unscheduled - ARRA 

Number of Maintenance Events by Category

Number of Events

Total Events = 789

71% were unscheduled Scheduled

Unscheduled

0 50 100 150 200 250 300 350

Air system Scheduled equip upgrade

FC Stack Air System Operator Error

Electrical

Other Fuel System Energy Storage System

Thermal management

Preventative maintenance Controls, Electronics, Sensors

Number of Labor Hours by Category

Hours

Total Hours = 1165

68% were unscheduled Scheduled

Unscheduled

NREL cdparra_mhe_13

Created: Sep-30-10 11:45 AM
CDPARRA-MHE-14

Average Fuel Cell System Maintenance by Quarter

National Renewable Energy Laboratory Innovation for Our Energy Future

10Q1 10Q2 0

1

2

3

4

5

6

Average FC Maintenance Events

Average # of Events per System

10Q1 10Q2 0

1

2

3

4

5

6

Average FC Maintenance Hours

Average Hours per System

Operator Error (Unscheduled)

Unscheduled

Scheduled

NREL cdparra_mhe_14

Created: Sep-30-10 3:27 PM

Average Fuel Cell System Quarterly Maintenance - ARRA
CDPARRA-MHE-15

Operating Time at Fuel Cell Voltage Levels

National Renewable Energy Laboratory Innovation for Our Energy Future

0 10 20 30 40 50 60 70 80 90 100 >100 0

5

10

15

20

25

30

35

40

% Rated Max Fuel Cell Voltage

% Fuel Cell Operating Time

Operating Time at Fuel Cell Voltage Levels - ARRA

NREL cdparra_mhe_15

Created: Sep-30-10 12:03 PM

1

1) 100% max fuel cell voltage is approximately open-circuit voltage
CDPARRA-MHE-16

Operating Time at Fuel Cell Current Levels

National Renewable Energy Laboratory Innovation for Our Energy Future

0 10 20 30 40 50 60 70 80 90 100 110 0

5

10

15

20

25

30

% Rated Max Fuel Cell Current

% Fuel Cell Operating Time

Operating Time at Fuel Cell Current Levels - ARRA

NREL cdparra_mhe_16

Created: Sep-23-10 4:39 PM
CDPARRA-MHE-17

Operating Time at Fuel Cell Power Levels

National Renewable Energy Laboratory Innovation for Our Energy Future

0 10 20 30 40 50 60 70 80 90 100 >100 0

5

10

15

20

25

30

% Rated Max Fuel Cell Power

% Fuel Cell Operating Time

Operating Time at Fuel Cell Power Levels - ARRA

NREL cdparra_mhe_17

Created: Sep-23-10 4:39 PM
CDPARRA-MHE-21

Average Daily Hydrogen Dispensed by Location

National Renewable Energy Laboratory Innovation for Our Energy Future

Average Daily Hydrogen Dispensed by Location - ARRA

1-10

11-20

21-30

31-40

41-50

51-60

61-70

71-80

81-90

91-100

>100

NREL cdparra_mhe_21

Created: Sep-30-10 3:29 PM

6321 kg Hydrogen Dispensed
CDPARRA-MHE-22

Average Daily Dispensing Operations by Site

National Renewable Energy Laboratory Innovation for Our Energy Future

Hydrogen Use 0

10

20

30

40

Avg Daily kg

Hydrogen Use 0

0.2

0.4

0.6

0.8

1

Avg Daily kg/system

Fill Frequency 0

20

40

60

80

100

Avg Daily fills

Fill Frequency 0

0.5

1

1.5

Avg Daily fills/system

NREL cdparra_mhe_22

Created: Sep-23-10 5:03 PM

Average Daily Dispensing Operations by Site - ARRA

Shaded areas represent the min and max site average hydrogen use and fill frequency
CDPARRA-MHE-23

Average Daily Fuel Cell Operation Hours per Fleet

National Renewable Energy Laboratory Innovation for Our Energy Future

A B C 0

1

2

3

4

5

6

7

8

9

10

Fleet

Hours

Average Daily Fuel Cell Operation Hours per Fleet - ARRA

25th and 75th Percentile

Median

NREL cdparra_mhe_23

Created: Sep-09-10 7:37 PM
CDPARRA-MHE-24

Average Daily Fuel Cell Operation Hours per System

National Renewable Energy Laboratory Innovation for Our Energy Future

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

5

10

15

20

25

30

Average Daily Fuel Cell Operation Hours

% Fuel Cell Systems

Average Daily Fuel Cell Operation Hours per System - ARRA

50.4% Fuel Cell Systems Average 5-7 Hours Daily

NREL cdparra_mhe_24

Created: Sep-09-10 5:51 PM
CDPARRA-MHE-26

Fuel Cell System Safety Reports by Quarter

National Renewable Energy Laboratory Innovation for Our Energy Future

2010 Q1 2010 Q2 0

1

2

3

4

5

6

Number of Reports

Fuel Cell System Safety Reports by Quarter - ARRA

Incident2

Near Miss1

NREL cdparra_mhe_26

Created: Sep-23-10 3:07 PM

1) Near Miss is an event that under slightly different circumstances could have become an incident

 -unplanned H2 release insufficient to sustain a flame

2) 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 uses as common fuels)
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Fall 2010 Composite Data Products ARRA Material Handling 

Equipment: Quarter 3 of 2010, Final Version September 30, 2010

5a. CONTRACT NUMBER

DE-AC36-08GO28308

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J. Kurtz, K. Wipke, S. Sprik, and T. Ramsden

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NREL/TP-5600-49603

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ARHY.1001

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This presentation summarizes Fall 2010 composite data products ARRA material handling equipment.

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composite data products; fuel cells; fuel cell system maintenance; fuel cell operation

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