*Preliminary results in the above graphs include eight months of data from March through October 2005

50

40

30

20

10

0

Cumulative Fueling Rate Histogram: VTA Station

4.543.532.5

Fueling Rate (kg/min)

21.51

Number of Occurences

About 55 kg useful fuel on the bus – fast rate required for reasonable fill time DOE Target(light-duty): 1kg H2/min

4.50

4.00

3.50

3.00

Miles per Gallon

(Diesel Equivalent)

Mar-05

Apr-05

May-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Average Fuel Economy

FCBs have 13% lower energy equivalent fuel 

economy compared to diesel (FCB 3.45, Diesel 3.95)

Diesel Bus Fuel Cell Bus

5,000

4,000

3,000

2,000

1,000

0

Mar-05

Apr-05

May-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Miles

Average Miles Accumulated per Bus by Month

Diesel Bus Fuel Cell Bus

25,000

20,000

15,000

10,000

5,000

0

1,600

1,200

800

400

0

Miles

FC Hours

Nov-04

Dec-04

Jan-05

Feb-05

Mar-05

Apr-05

May-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Total Miles and FC Hour Accumulation

Totals for all FCBs - more than 19,000 miles and 1,400 FC hours

Fuel Cell Hours

Cumulative Mileage

Start of Revenue Service

Overview

Timeline 

Evaluations typically 

cover two years of data

Start date determined 

by bus delivery

International 

collaboration ongoing

Budget

FY06: $288 K

FY05: $338 K 

FY04: $238 K

Technology Validation Barriers

A. Vehicles 

B. Storage 

C. Hydrogen fueling infrastructure 

D. Maintenance and training 

E. Codes and standards

 Validate FC and hydrogen technologies in transit applications

- Provide feedback for HFCIT Program R&D

- Provide “lessons learned” on implementing next generation FC systems into 

transit operations 

 Harmonize data collection efforts with other FC bus demonstrations worldwide 

(in coordination with FTA and other U.S. and international partners)

- Establish a common template for collecting and sharing data between programs

- Leverage resources by gathering data and comparing a larger statistical set of vehicles 

(eight - U.S., 30 - Europe) 

Objectives

Approach

 Evaluations

- Collect and analyze operational data on FCBs in 

service (using diesel or CNG as baseline)

• Vehicle specifications, use, and duty-cycle

• Fluid consumption (fuel, oil, water, etc.)

• Maintenance records (scheduled and unscheduled)

• Facility descriptions and costs

• Fleet experience with buses and infrastructure

• Detailed data similar to light-duty demonstrations

 Evaluations: Working with transit fleets to evaluate FCBs in service

- Santa Clara VTA – Completed preliminary data report; data collection continues

- Hickam AFB – Data collection in progress

 International collaboration

- Coordinating committee for working group

- Third International FCB Workshop; led breakout session on 

“data sharing sensitivities”

Overview of Technical Accomplishments/Progress

 International collaboration

- International FCB 

Working Group

• Define common data 

set to collect and share

• Workshop now an 

IPHE recognized event

Ongoing FCB Evaluations

Hickam AFB, Honolulu, HI

Vehicles

- One ElDorado 30-ft bus

• Enova battery-dominant hybrid 

FC system, Hydrogenics 20kW FC

- One step van

• Enova hybrid FC system, 

Hydrogenics 60kW FC 

Status

- Hydrogen fueling available 

in late 2005

- Bus operating on shuttle 

route around base

- Expect permanent fueling 

onsite in early 2006

- Step van in service as maintenance support vehicle

Remainder of FY06

Data analysis and draft final report on VTA evaluation

Data analysis and draft preliminary data 

report on Hickam AFB evaluation

Collect more technical data on FCBs and infrastructure to 

complement DOE controlled fleet demo

Report informational data on international FCB 

demos and finalize list of operational and 

performance data

FY07

 Publish final report on VTA evaluation

 Publish preliminary data report on Hickam AFB

Feed early results back into HFCIT Program R&D

Continue collection and analysis of technical data on 

buses and infrastructure for all fleets

 Attend Fourth International FCB Workshop

Begin sharing operational and performance data with 

international FCB demos

Progress

International 

Collaboration

Third workshop held in 

Vancouver, BC, December 2005

Reported status of 

informational data collection

- Request sent to 20 cities; 

11 responses to date

Breakout sessions

- Data sharing sensitivities

- Policy/business case for FCBs

- Issues with H2 infrastructure

Planning Fourth International 

FCB Workshop for Yokohama, 

Japan, October 2006

Workshop now an 

IPHE recognized event

Alameda Contra-Costa 

Transit Agency, Oakland, CA

AC Transit is demonstrating three Van Hool 40-ft buses 

with a UTC FC and an ISE Corp hybrid system

The hydrogen fueling station was designed and built by 

Chevron. The station features a natural gas reformer that 

can produce 150 kg H2 per day 

The buses were put into revenue service in March 2006. 

A preliminary 

data report 

should be 

available in 

late 2006

Coordinated FCB Evaluations Under Other Funding

SunLine Transit Agency 

Thousand Palms, CA

SunLine is demonstrating a Van Hool 40-ft bus with a 

UTC FC and an ISE Corp hybrid system. The bus started revenue service in December 2005. A preliminary 

data report should be available in late 2006.

The hydrogen station features a natural gas reformer 

by HyRadix.

Future Work

Summary

FCBs are all in service and data collection is ongoing

- Some preliminary data now available to industry

Bus duty-cycle allows fast accumulation of miles/FC hours

- Some buses have accumulated over 17,000 miles

- On track to achieve well over 1,000 FC hours/bus by 

end of demo

 Fuel economy results show need for hybridization

Collecting performance and cost data on conventional 

technology establishes a baseline for tracking progress

- Use of prototype FCBs is much less than standard buses

- High cost for maintaining current generation prototype 

technology

Warranty costs not included in totals

Preliminary Costs

FCBs Diesel Buses

Number of Vehicles Three Five

Data Period 3/05-10/05 3/05-10/05

Fuel Use 5,469 kg 41,474 gal

Base Fleet Mileage 16,708 163,619

Fuel Costs

Fleet Miles/kg 3.05

Representative Fleet 

MPG (energy equiv) 3.45 3.95

Average Fuel Cost $8.56/kg $2.02/gal

Fuel Cost per Mile $2.80 $0.51

Maintenance Costs

Total Cost per Mile $4.26 $0.59

Propulsion System 

Related (maintenance 

cost per mile)

$3.06 $0.21

Bus Specifications

Vehicle System Cerone Depot

FCBs Diesel Buses

Number of Buses Three Five

Bus Manufacturer 

and Model Gillig low-floor Gillig low-floor

Model Year 2004 2002

Length/Width/Height 40 ft/102 in/144 in 40 ft/102 in/120 in

GVWR/Curb Weight 40,600 lb/34,100 lb 39,600 lb/27,300 lb

Wheelbase 284 in 284 in

Passenger Capacity 37 seated or 29 seated and 

two wheelchairs, five standing

38 seated or 31 seated and 

two wheelchairs, 43 standing

Engine Manufacturer 

and Model Two Ballard FC modules P5-2 Cummins ISL (8.9 liter)

Rated Power 150 kW each (300 kW total) 280 bhp @ 2,200 rpm

Rated Torque 790 lb-ft @ 1,350 rpm (1250 Nm) 900 lb-ft @ 1,300 rpm

Accessories Mechanical Mechanical

Emissions Equipment None Diesel oxidation catalyst

Fuel Capacity Approx. 55 kg hydrogen at 5,000 psi 115 gal 

VTA Fueling Station

Air Products

Liquid H2 storage

Dispenses compressed H2

Preliminary Data Results: Santa Clara VTA – San Jose, CA

Reliability: Miles 

Between Road Calls

Diesel buses – 9,019 MBRC total; 

11,424 MBRC propulsion 

related only

FCBs – 983 MBRC total; 

1,044 MBRC propulsion 

related only

Collaborations

United States International

FTA

NAVC

HCATT

CaFCP

Unviersity of Hawaii

 EC

Premia

ECTOS

CUTE

STEP

NRCan

UNDP-GEF

Partners

Operating Fleets

AC Transit 

Santa Clara VTA 

SunLine 

Hickam AFB

Manufacturers/

Systems Integrators

Enova Systems 

Gillig/Ballard 

Van Hool /ISE Corp 

FC Suppliers

Ballard Hydrogenics 

UTC Power

H2 Infrastructure

Air Products Chevron

In-Use Bus Evaluation

Comparison of FCBs to diesel baseline

- Three model year 04 buses with 

non-hybrid FC system by Ballard 

Power Systems

- Five model year 02 diesel buses 

(Cummins ISL with DPF)

 FCBs’ limitations

- Added service (between 

scheduled diesel buses)

- During the week only 

- Driver and mechanic availability

Diesel buses randomly dispatched

Average speed 14.5 mph

The information contained in this poster is subject to a government license; NREL/PO-540-39662; 2006 DOE Hydrogen, Fuel Cells & Infrastructure Technologies Program Review, Washington, D.C., May 16-19, 2006.

Technology Validation: Fuel Cell Bus Evaluations Leslie Eudy • National Renewable Energy Laboratory • May 17, 2006 • Project ID # TVP-7