1

Technical Report

NREL/TP-560-46679

September 2009

Controlled Hydrogen Fleet Infrastructure

Demonstration and Validation Project

Fall 2009

Composite Data Products

Final Version September 11, 2009

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

and
2

Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). 

The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government 

purposes.

Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any 

liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use 

would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, 

manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring by the Government or any agency thereof. The views 

and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency 

thereof. 
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

Fall 2009

Composite Data 

Products

September 11, 2009

Keith Wipke, Sam Sprik, 

Jennifer Kurtz, Todd 

Ramsden

Controlled Hydrogen Fleet and Infrastructure 

Demonstration and Validation Project
National Renewable Energy Laboratory 4 Innovation for Our Energy Future

CDP#1: Hours Accumulated and 

Projected Hours to 10% Stack Voltage Degradation

Gen1 Gen2 Gen1 Gen2 Gen1 Gen2 0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation

Time (Hours)

DOE Learning Demonstration Fuel Cell Stack Durability:

Based on Data Through 2009 Q2

Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Voltage Degradation (4)(5)(6)

Max Projection

Avg Projection

Created: Sep-09-09 10:48 AM

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% voltage degradation.

(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.

(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 against DOE targets,

 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 projection.

 The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and methodology limitations. 

 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 hours.
National Renewable Energy Laboratory 5 Innovation for Our Energy Future

Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5) 0

50

100

150

200

250

300

Vehicle Range (miles)

Vehicle Range1

2015 Target

2009 Target

 Gen 1

 Gen 2

Created: Aug-27-09 3:32 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 Innovation for Our Energy Future

CDP#3: Fuel Cell System Power Density, 

Including Hydrogen Storage

0

50

100

150

200

250

300

350

400

Power Density (W/L)

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

2010 and 2015 FreedomCAR Research Goal1

 Gen 1

 Gen 2

Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 stroage, but excludes power electronics, battery storage, and electric drive.
National Renewable Energy Laboratory 7 Innovation for Our Energy Future

0

50

100

150

200

250

300

350

400

Specific Power (W/kg)

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

2010 and 2015 FreedomCAR Research Goal1

 Gen 1

 Gen 2

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 electric drive.

CDP#4: Fuel Cell System Specific Power, 

Including Hydrogen Storage
National Renewable Energy Laboratory 8 Innovation for Our Energy Future

12 hr Equilibrium 12 hr Equilibrium 0

100

200

300

400

500

600

Time to Drive Away Time to Max FC Power

Time [s]

Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition1

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 o

C (soak duration not specified).

CDP#5: Fuel Cell Start Times from 

Sub-Freezing Soak Conditions
National Renewable Energy Laboratory 9 Innovation for Our Energy Future

Dyno (1) Window-Sticker (2) On-Road (3)(4) 0

10

20

30

40

50

60

70

80

Fuel Economy (miles/kg H

2

)

Fuel Economy

 Gen 1

 Gen 2

Created: Aug-27-09 3:32 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 Innovation for Our Energy Future

0

5

10

15

20

25

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%

>100%

% Max Fuel Cell Stack Voltage

All time

Time at low current

Created: Aug-14-09 4:47 PM

CDP#7: Fuel Cell Voltage
National Renewable Energy Laboratory 11 Innovation for Our Energy Future

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

10

20

30

40

50

60

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 25% Power

DOE Target at 100% Power

Gen 1 Efficiency Range

Gen 2 Efficiency Range

Created: Sep-02-09 11:27 AM

1

 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electric drive.

2

 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 extrapolated 

 due to steady state dynamometer cooling limitations.

CDP#8: FC System Efficiency
National Renewable Energy Laboratory 12 Innovation for Our Energy Future

0

1

2

3

Number of Reports

Safety Reports - Vehicle Operation

Tank Scratch

Traffic Accident

H2 Leak - During Fueling

H2 Alarm - Fuel System

H2 Alarm - Passenger Compartment

Created: Aug-10-09 3:08 PM

CDP#9: Safety Reports – Vehicles
National Renewable Energy Laboratory 13 Innovation for Our Energy Future

CDP#10: Storage Weight % Hydrogen

350bar 700bar 0

1

2

3

4

5

6

7

8

9

Weight Percent Hydrogen (%)

Weight Percent Hydrogen

2015 DOE MYPP Target1

2010 DOE MYPP Target1

2007 DOE MYPP Target1

Created: Aug-19-08 11:39 AM

1

Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 14 Innovation for Our Energy Future

CDP#11: Volumetric Capacity of H2 Storage

350bar 700bar 0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

Mass H2 per Liter (kg/L)

Mass of Hydrogen Per Liter

2015 DOE MYPP Target1

2010 DOE MYPP Target1

2007 DOE MYPP Target1

Created: Aug-19-08 11:39 AM

1

Targets are set for advanced materials-based hydrogen storage technologies.
National Renewable Energy Laboratory 15 Innovation for Our Energy Future

CDP#12: Vehicle Hydrogen Tank Cycle Life

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

Number of cycles

Hydrogen Tank Cycle Life1

All OEMs

2015 DOE MYPP Target2

2010 DOE MYPP Target2

2007 DOE MYPP Target2

 Gen 1

 Gen 2

Created: Sep-17-08 10:29 AM

1

Data reported reference NGV2, HGV2, or EIHP standards.

2

Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.
National Renewable Energy Laboratory 16 Innovation for Our Energy Future

On-Site Natural Gas Reforming On-Site Electrolysis 0

10

20

30

40

50

60

70

80

2010 MYPP Target

2015 MYPP Target

2012 MYPP Target

2017 MYPP Target

Production Efficiency (LHV %)

Hydrogen Production Conversion Efficiency1

Average Station Efficiency

Quarterly Efficiency Data

Highest Quarterly Efficiency

Efficiency Probability Distribution2

Created: Sep-01-09 10:32 AM

1

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

process from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing. 2

The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency based on monthly conversion efficiency data

from the Learning Demonstration.

CDP#13: On-Site Hydrogen Production 

Efficiency
National Renewable Energy Laboratory 17 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

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

350 vs 700 bar Fills - All Light Duty Through 2009Q2

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 Count

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

350 bar 0.82 29% 17847

700 bar 0.62 3% 3792

350 bar

700 bar

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

Created: Aug-31-09 12:59 PM

CDP#14: Fueling Rates – 350 and 700 bar
National Renewable Energy Laboratory 18 Innovation for Our Energy Future

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

5

10

15

20

25

30

Segmented Trips/Hour Histogram: DOE Fleet

Trips/Hour*

Frequency [%]

*Trips/Hour based on 50 hour segments

spanning stack operating period Created: Aug-26-09 2:14 PM

CDP#16: Fuel Cell Stack Trips Per Hour 

Histogram
National Renewable Energy Laboratory 19 Innovation for Our Energy Future

0

1

2

3

4

5

6

7

8

9

10

0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 1750-2000

Stack Op Hour Groups

Trips/Hour*

Statistics of Trips/Hour vs Operating Hour: DOE Fleet

*Trips/Hour based on 50 hour segments

spanning stack operating period

Data Range

25th & 75th Percentiles

Group Median

Outlier

Created: Aug-26-09 2:14 PM

CDP#17: Statistics of Trips/Hour vs. 

Operating Hour
National Renewable Energy Laboratory 20 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

500

1000

1500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty Through 2009Q2

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

21854 Events

Average = 0.78 kg/min

24% >1 kg/min

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

Created: Aug-14-09 10:09 AM

CDP#18: Refueling Rates
National Renewable Energy Laboratory 21 Innovation for Our Energy Future

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

5

10

15

20

25

30

35

Time [min]

Trip Frequency [%]

Time Between Trips with Ambient Temperature: DOE Fleet

<0o

C

0-10o

C

10-24o

C

24-40o

C

>40o

C

Created: Aug-26-09 2:15 PM

CDP#19: Time Between Trips & Ambient 

Temperature
National Renewable Energy Laboratory 22 Innovation for Our Energy Future

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Severity

Total Infrastructure Safety Reports by Severity

and Report Type Through 2009 Q2

Alarms Only

Automatic System Shutdown

Electrical Issue

Equipment Malfunction

False Alarm/Mischief

H2 Release - Minor, NO Ignition

H2 Release - Significant, NO Ignition

Manual System Shutdown

Non-H2 Release

Site Power Outage

Structural Issue

System Trouble, not Alarm

Created: Sep-01-09 8:38 AM

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 – Infrastructure
National Renewable Energy Laboratory 23 Innovation for Our Energy Future

0 2 4 6 8 10 12 -30

-20

-10

0

10

20

30

40

50

60

1.4 % trips below 0 o

C

Max Op = 140.0 oF

Min Op = -5.8 oF

26.9 % trips above 28 o

C

Trip Frequency [%]

Temperature [

oC]

Average Ambient Trip Temperature: DOE Fleet

Created: Aug-14-09 4:47 PM

CDP#21: Range of Ambient Temperature

During Vehicle Operation
National Renewable Energy Laboratory 24 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

Number of Vehicles

Total Vehicle Hours

Vehicle Hours: All OEMs, Gen 1 and Gen 2

In Service

Retired

Total Vehicle Hours = 100,284

Through 2009 Q2

Created: Aug-26-09 04:13 PM

CDP#22: Vehicle Operating Hours
National Renewable Energy Laboratory 25 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

40

45

Number of Vehicles

Total Vehicle Miles

Vehicle Miles: All OEMs Combined, Gen 1 and 2

In Service

Retired

Total Vehicle Miles Traveled = 2,318,038

Through 2009 Q2

Created: Aug-26-09 04:13 PM

CDP#23: Vehicles vs. Miles Traveled
National Renewable Energy Laboratory 26 Innovation for Our Energy Future

2,318,038 

-

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 

Vehicle Miles Traveled

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

Created: Aug-26-09 04:13 PM

Through 2009 Q2

CDP#24: Cumulative Vehicle Miles Traveled
National Renewable Energy Laboratory 27 Innovation for Our Energy Future

60

49

-

20 

40 

60 

80 

100 

120 

140 

160 

Cumulative Vehicles Deployed/Retired1

Vehicle Deployment by On-Board Hydrogen Storage Type

700 bar on-road

350 bar on-road

Liquid H2 on-road

700 bar retired

350 bar retired

Liquid H2 retired

Created Feb-23-2009 1:20 PM (1) Retired vehicles have left DOE fleet and are no longer providing data to NREL Created Aug-26-2009 4:21 PM

140

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

CDP#25: Vehicle H2 Storage Technologies
National Renewable Energy Laboratory 28 Innovation for Our Energy Future

0

5

10

15

20

0

20

40

60

80

100

120

140

Number of Stations

Mass of Hydrogen 

(1000 kg)

Calendar Quarter

Cumulative Hydrogen Produced or Dispensed 

Through 2009 Q2

Cumulative Hydrogen

Number of Stations

Created 2009-Aug-27 1:09 pm

CDP#26: Cumulative H2 Produced or Dispensed
National Renewable Energy Laboratory 29 Innovation for Our Energy Future

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

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 (Data Range)

On-Site Electrolysis (Data Range)

Delivered (Data Range)

SAE J2719 APR2008 Guideline

Calculated Data

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#27: Hydrogen Quality Index
National Renewable Energy Laboratory 30 Innovation for Our Energy Future

0 2 4 6 8 10 12 14 16 18 20

Particulates 

μg/L

H2

 Fuel Constituents

Data Range SAE J2719 APR2008 Guideline Measured Less Than or Equal To (Detection Limited)

0 500 1000 1500 2000 2500 3000

(N2+He+Ar) 

He 

(Ar+N2) 

0 5 10 15 20 25 30 35 40

H2O 

Total HC 

O2 

CO2 

CO 

NH3 

μmol/mol (ppm)

0 10 20 30 40 50 60 70 80

Total S* 

nmol/mol (ppb)

Created: Aug-31-09 4:39 PM 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 31 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

10

20

30

40

50

60

70

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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

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

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 32 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

0.5

1

1.5

2

Total HC (

μmol/mol)(ppm)

Total HC (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 33 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

5

10

15

20

25

Total Halogenates (

μmol/mol)(ppm)

Total Halogenates (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 34 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

2

4

6

8

10

12

14

16

18

20

22

Particulate Concentration (

μg/L)

Particulate Concentration (μg/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:41 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 35 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

5

10

15

20

25

30

35

40

O

2

(μmol/mol)(ppm)

O2(μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 36 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

500

1000

1500

2000

2500

N

2 (

μmol/mol)(ppm)

N2 (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 37 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

500

1000

1500

2000

2500

3000

N

2+He+Ar (

μmol/mol)(ppm)

N2+He+Ar (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 38 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

5000

10000

15000

20000

25000

30000

Particulate Size (

μm)

Particulate Size (μm)

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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:41 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 39 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

50

100

150

200

250

300

He (

μmol/mol)(ppm)

He (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 40 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

5

10

15

H2O (

μmol/mol)(ppm)

H2O (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 41 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

0.05

0.1

0.15

0.2

Formic acid (

μmol/mol)(ppm)

Formic acid (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 42 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

0.02

0.04

0.06

0.08

0.1

Formaldehyde (

μmol/mol)(ppm)

Formaldehyde (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 43 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

0.2

0.4

0.6

0.8

1

CO (

μmol/mol)(ppm)

CO (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 44 Innovation for Our Energy Future

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

1

2

3

4

5

6

7

8

9

CO

2 (

μmol/mol)(ppm)

CO2 (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4
National Renewable Energy Laboratory 45 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

500

1000

1500

2000

2500

3000

Calcultated Total Constituents (

μmol/mol)(ppm)

Calcultated Total Constituents (μmol/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 Guideline

Calculated Data

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method
National Renewable Energy Laboratory 46 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

500

1000

1500

2000

2500

Ar+N

2 (

μmol/mol)(ppm)

Ar+N2 (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method
National Renewable Energy Laboratory 47 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

1

2

3

4

5

6

NH3 (

μmol/mol)(ppm)

NH3 (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4 Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

50

100

150

200

Ar (

μmol/mol)(ppm)

Ar (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method
National Renewable Energy Laboratory 48 Innovation for Our Energy Future

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. 0

1

2

3

4

5

6

NH3 (

μmol/mol)(ppm)

NH3 (μmol/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 Guideline

Measured

Less Than or Equal To (Detection Limited)

Created: Aug-31-09 4:40 PM

Data is from Learning Demonstration and California Fuel Cell Partnership testing

Year 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, and Year 4 is 2008Q3-2009Q2

Year 1 Year 2 Year 3 Year 4

CDP#28 Supplemental: Hydrogen 

Constituents by Year and Production Method
National Renewable Energy Laboratory 49 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

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

Comm vs Non-Comm Fills - All Light Duty Through 2009Q2

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 

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

Comm 0.92 36%

Non-Comm 0.66 13%

Comm

Non-Comm

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

Created: Sep-02-09 11:32 AM

CDP#29: Fueling Rates Communication and 

Non-Communication Fills
National Renewable Energy Laboratory 50 Innovation for Our Energy Future

0 50 100 150 200 250

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since Inception

Through 2009 Q2

Scheduled

Un-Scheduled

0 5 10 15 20 25 30 35 40

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Number of Events Per Station Since Inception

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

# of Events

Hours

Comparison of Scheduled/Un-Scheduled Maintenance

Created: Aug-17-09 12:25 PM

CDP#30: Infrastructure Maintenance
National Renewable Energy Laboratory 51 Innovation for Our Energy Future

0

5

10

15

20

25

Number of Stations

Reporting Period

Online Stations

Existing Stations

Retired Stations

Created Aug-27-09 1:03pm

CDP#31: Number of Online Stations
National Renewable Energy Laboratory 52 Innovation for Our Energy Future

0

1

2

3

4

5

6

7

8

Delivered 

Compressed H2

Natural Gas On-site 

Reforming

Electrolysis Delivered Liquid H2

# of Stations

Production Technology

Infrastructure Hydrogen Production Methods 

Existing Stations

Retired Stations

Created Aug-27-09 1:03pm

CDP#32: Infrastructure Hydrogen Production 

Methods
National Renewable Energy Laboratory 53 Innovation for Our Energy Future

CDP#33: Percentage of Theoretical Range 

Traveled Between Refuelings

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

1

2

3

4

5

6

7

8

9

10

11

12

Range Histogram: All OEMs

Percentage of chassis dyno range1

 b/w refuelings

Percentage of Refuelings

0 10 20 30 40 50 60 70 80 90 1000

25

50

75

100

Cumulative Percentage

Created: Aug-26-09 9:40 AM

Total refuelings2 = 22470

1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPA

adjusted) and usable fuel on board.

2. Some refueling events are not detected/reported due to data noise or incompleteness.
National Renewable Energy Laboratory 54 Innovation for Our Energy Future

0 10 20 30 40 50 60 70 80 90 100

Gen1

Gen2

Vehicle Range Factors

Percentage of chassis dyno range1

.

All OEMs

Window-Sticker 

2 Window-Sticker 

2

On-Road 3 On-Road 3

Dyno 1

Created: Aug-31-09 9:26 AM

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 55 Innovation for Our Energy Future

05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q2 0

2

4

6

8

10

12

14

16

18

20

22

Reporting Period

Number of Stations

Infrastructure Safety Trend and Number of Stations Through 2009 Q2

Number of Stations

Avg Refuelings Between Safety Reports

Created: Sep-01-09 8:40 AM

0

100

200

300

400

500

600

Avg # of Refuelings Between Safety Reports

7 11

32 34

88 102 115

47

68

124

101

57 54

73

51

146

530

CDP#35: Average Refuelings Between 

Infrastructure Safety Reports
National Renewable Energy Laboratory 56 Innovation for Our Energy Future

05Q2 05Q3 05Q4 06Q1 06Q2 06Q3 06Q4 07Q1 07Q2 07Q3 07Q4 08Q1 08Q2 08Q3 08Q4 09Q1 09Q2 0

5

10

15

20

25

30

35

40

45

50

Reporting Period

Number of Reports

Type of Infrastructure Safety Reports by Quarter Through 2009 Q2

Incident

Near Miss

Non-Event

Number of Stations

Avg # Reports/Station

Created: Sep-01-09 8:40 AM

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 Report 

By Quarter
National Renewable Energy Laboratory 57 Innovation for Our Energy Future

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Severity

Primary Factors of Infrastructure Safety Reports

Through 2009 Q2

Calibration/Settings/ Software Controls

Design Flaw

Electrical Power to Site

Environment (Weather, Power Disruption, Other)

False Alarm

Inadequate Training, Protocol, SOP

Inadequate/ Non-working Equipment

Maintenance Required

Mischief, Vandalism, Sabotage

New Equipment Materials

Not Yet Determined

Operator/Personnel Error

System Manually Shutdown

Created: Sep-01-09 8:38 AM

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 Infrastructure 

Safety Reports
National Renewable Energy Laboratory 58 Innovation for Our Energy Future

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

500

1000

1500

2000

2500

3000

Time (min)

Number of Fueling Events

Histogram of Fueling Times

All Light Duty Through 2009Q2

Average = 3.26 min

86% <5 min

 2006 MYPP Tech Val Milestone (5 kg in 5 min at 350 bar)

 2012 MYPP Tech Val Milestone (5 kg in 3 min at 350 bar)

Created: Aug-14-09 10:40 AM

CDP#38: Refueling Times
National Renewable Energy Laboratory 59 Innovation for Our Energy Future

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

100

200

300

400

500

600

700

800

900

Amount Fueled (kg)

Number of Fueling Events

Histogram of Fueling Amounts

All Light Duty Through 2009Q2

Average = 2.14 kg

Created: Aug-14-09 10:40 AM

CDP#39: Refueling Amounts
National Renewable Energy Laboratory 60 Innovation for Our Energy Future

CDP#40: H2 Tank Level at Refueling

Tank Levels: DOE Fleet

14%

E F

Created: Aug-26-09 9:40 AM

Total refuelings1 = 24859

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

Median Tank Level (At Fill) = 41%

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 61 Innovation for Our Energy Future

CDP#41: Refueling Tank Levels - Medians

E F

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

Created: Aug-26-09 9:40 AM

Total refuelings1 = 24859

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 62 Innovation for Our Energy Future

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: 90.2% Events = 20939

1. Fills between 6 AM & 6 PM

2. The outer arc is set at 12 % total Fill.

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

AM PM

Created: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 63 Innovation for Our Energy Future

CDP#43: Refueling by Day of Week

Sun Mon Tues Wed Thur Fri Sat 0

5

10

15

20

Fills by Day of Week: DOE Fleet

% of Fills in a Day

Day

Created: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 64 Innovation for Our Energy Future

Driving Start Time - Day: DOE Fleet

9%

3

12

9

6

Total Driving3 % of driving trips b/t 6 AM & 6 PM: 85.6% Events = 273900

1. Driving trips between 6 AM & 6 PM

2. 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%

DOE Fleet

NHTS

Created: Aug-25-09 2:28 PM

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#44: Driving Start Time – Day
National Renewable Energy Laboratory 65 Innovation for Our Energy Future

Sun Mon Tues Wed Thur Fri Sat 0

2

4

6

8

10

12

14

16

18

20

Driving Trips by Day of Week: DOE Fleet

% of Driving Trips in a Day

Day

DOE Fleet

NHTS

Created: Aug-25-09 2:28 PM

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#45: Driving by Day of Week
National Renewable Energy Laboratory 66 Innovation for Our Energy Future

0

10

20

30

40

50

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%

95-100%

>100%

% Max Fuel Cell Power (Gross)

All time

Time with 0 speed

Created: Aug-26-09 2:15 PM

CDP#46: Fuel Cell System Operating Power
National Renewable Energy Laboratory 67 Innovation for Our Energy Future

0 5 10 15 20 25 0

5

10

15

20

25

30

35

40

45

Trip Frequency [%]

Trip Length [miles]

Trip Length: DOE Fleet

DOE Fleet

NHTS

Created: Sep-04-09 12:13 PM

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#47: Trip Length
National Renewable Energy Laboratory 68 Innovation for Our Energy Future

CDP#48: Primary Factors Affecting Learning 

Demo 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 high decay rate fuel cell stacks

L**: Factor group associated with low decay rate fuel cell stacks

Due to differences among teams, the 

DOE Fleet Analysis results are spread 

out and concrete conclusions are difficult 

to draw.

Individual team analyses (CDP#49) 

focused on patterns within a fleet.

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 high decay rate fuel cell stacks

L**: Factor group associated with low decay rate fuel cell stacks

Due to differences among teams, the 

DOE Fleet Analysis results are spread 

out and concrete conclusions are difficult 

to draw.

Individual team analyses (CDP#49) 

focused on patterns within a fleet.
National Renewable Energy Laboratory 69 Innovation for Our Energy Future

CDP#49: Primary Factors Affecting Learning 

Demo Team Fuel Cell Degradation

Team 1

High Voltage Time

Low Current Time

Short Trips

Low Speed

Team 2

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 high decay rate fuel cell stacks

Created: Mar-09-09 9:06 AM
National Renewable Energy Laboratory 70 Innovation for Our Energy Future

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: 9.8% Events = 20939

1. Fills between 6 PM & 6 AM

2. The outer arc is set at 12 % total Fill.

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

PM AM

Created: Aug-26-09 9:40 AM
National Renewable Energy Laboratory 71 Innovation for Our Energy Future

Driving Start Time - Night: DOE Fleet

3%

3

12

9

6

Total Driving3 % of driving trips b/t 6 PM & 6 AM: 14.4% Events = 273900

1. Driving trips between 6 PM & 6 AM

2. 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%

DOE Fleet

NHTS

Created: Aug-25-09 2:28 PM

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#51: Driving Start Time – Night
National Renewable Energy Laboratory 72 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

50

100

150

200

250

300

350

400

450

500

Avg Fuel Rate (kg/min)

Number of Fueling Events

Histogram of Fueling Rates

All Light Duty by Year Through 2009Q2

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 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 0.79 26%

2005

2006

2007

2008

2009

2006 MYPP Tech Val Milestone

2012 MYPP Tech Val Milestone

Created: Aug-14-09 3:32 PM

CDP#52: Refueling Data by Year
National Renewable Energy Laboratory 73 Innovation for Our Energy Future

0

2

4

6

8

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%

95-100%

>100%

% Fuel Cell Power (Gross) of Max

Cumulative %

0

20

40

60

80

100

Created: Aug-26-09 2:15 PM

CDP#53: Fuel Cell System Energy within 

Power Levels
National Renewable Energy Laboratory 74 Innovation for Our Energy Future

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

10

20

30

40

50

60

Trip Frequency [%]

Time

Time between Trips: DOE Fleet

0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-60 min 0

10

20

30

40

50

% Trips

Time

0-60 min Breakdown: DOE Fleet

Created: Aug-14-09 5:36 PM

CDP#54: Time Between Trips
National Renewable Energy Laboratory 75 Innovation for Our Energy Future

<-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 >5 0

10

20

30

40

50

60

Energy Consumed [kWh]

Trip Frequency [%]

Energy in Trip: DOE Fleet

Net battery

charge in trip

Battery

Vehicle Motor

FC

Created: Aug-26-09 2:15 PM

CDP#55: Fuel Cell System Energy
National Renewable Energy Laboratory 76 Innovation for Our Energy Future

0 5 10 15 20 25 30 35 40 0

2

4

6

8

10

12

14

16

18

20

22

Trip Frequency [%]

Daily Distance [miles]

Daily Distance: DOE Fleet

DOE Fleet

NHTS

Created: Sep-04-09 12:13 PM

Cumulative Frequency

@ 20 miles

DOE Fleet: 48.4%

NHTS: 27.2%

Cumulative Frequency

@ 40 miles

DOE Fleet: 68.1%

NHTS: 52.9%

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips

ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001

CDP#56: Daily Driving Distance
National Renewable Energy Laboratory 77 Innovation for Our Energy Future

CDP#57: H2 Storage System Mass and Volume 

Breakdown

Average Breakout of H2 Storage System Volume

73%

24%

3%

Average Breakout of H2 Storage System Mass

3.26%

23%

73%

9%

35% 56%

H2 Volume (%)

Pressure Vessel Volume (%)

Balance of Plant Volume (%)

72%

3.33%

24%

H2 Mass (%)

Pressure Vessel Mass (%)

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

350 bar

700 bar
National Renewable Energy Laboratory 78 Innovation for Our Energy Future

CDP#58: Fuel Cell System Power Density

0

100

200

300

400

500

600

700

Power Density (W/L)

FC System Power Density (W/L)

2010 and 2015 DOE MYPP Target1 Gen 1

 Gen 2

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 79 Innovation for Our Energy Future

CDP#59: Fuel Cell System Specific Power

0

100

200

300

400

500

600

700

Specific Power (W/kg)

FC System Specific Power (W/kg)

2010 and 2015 DOE MYPP Target1 Gen 1

 Gen 2

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 80 Innovation for Our Energy Future

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

10

20

30

40

50

60

70

Production Capacity Utilization1 [%]

Production Conversion Efficiency

2 [%]

Monthly Production Conversion Efficiency vs Utilization

Electrolysis Data

Electrolysis Fit3

Electrolysis Fit Confidence

Natural Gas Data

Natural Gas Fit3

Natural Gas Fit Confidence

Created: Aug-27-09 4:42 PM

1) 100% production utilization assumes operation 24 hrs a day, 7 days a week

2) Production conversion efficiency is defined as the energy of the hydrogen out of the process (on a LHV basis) divided by the sum of the energy into the production

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

3) High correlation with electrolysis data (R2

 = 0.86) & low correlation with natural gas data (R2 = 0.034)

CDP#60: On-Site Hydrogen Production 

Efficiency vs. Capacity Utilization
National Renewable Energy Laboratory 81 Innovation for Our Energy Future

On-Site Compression Energy 0

5

10

15

20

25

30

35

40

45

50

Compression Energy (MJ/kg)

On-Site Compression Efficiency 0

10

20

30

40

50

60

70

80

90

100

2010 MYPP Compression Target

2015 MYPP Compression Target

Compression Efficiency (%)

On-Site Hydrogen Compression Efficiency1

 and Energy Use

Average Station Compression Efficiency

Quarterly Compression Efficiency Data

Highest Quarterly Compression Efficiency

Average Station Compression Energy

Quarterly Compression Energy Data

Lowest Quarterly Compression Energy

Created: Aug-27-09 4:14 PM

1

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

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

facilities only, not delivered hydrogen sites.

Compression Energy Requirement:

On average, 11.0% of the energy

contained in the hydrogen fuel is

required for the compression

process.

CDP#61: Refueling Station Compressor 

Efficiency
National Renewable Energy Laboratory 82 Innovation for Our Energy Future

0

100

200

300

400

500

600

700

WTW GHG Emissions (g CO2-eq/mi)

Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse Gas Emissions1

Baseline Conventional Mid-Size Passenger Car2

Baseline 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

Created: Sep-08-09 4:21 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 economy, hydrogen

production conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel economy data for all teams (as used in CDP #6);

conversion 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 economy of a conventional

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 based on window-sticker fuel

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, which includes both

grid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are highly dependent on

electricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied from the U.S. average grid mix, average GHG

emissions would be 1245 g/mile.

CDP#62: Learning Demonstration Vehicle 

Greenhouse Gas Emissions
National Renewable Energy Laboratory 83 Innovation for Our Energy Future

14%

14%

19%

21%

By Number of Events

Total Number of Events = 2291

22%

12%

17%

20%

By Labor Hours

Total Hours = 11119

system control & safety

compressor

reformer

electrolyzer

dispenser

other

valves & piping

electrical

storage

Created: Aug-17-09 2:56 PM

Hydrogen Fueling Station Maintenance

CDP#63: Hydrogen Fueling Station 

Maintenance by System
National Renewable Energy Laboratory 84 Innovation for Our Energy Future

5% 3%

33%

58%

Fuel Cell Vehicle Events (11075)

19%

7%

49%

24%

Fuel Cell Vehicle Labor (11849 hours)

Vehicle (non-powertrain)

Fuel Cell System

Powertrain

Battery

4%

10%

11%

13%

24%

38%

Fuel Cell System Events (3704)

< 1%

28%

27% 11%

12%

21%

Fuel Cell System Labor (5856 hours)

Thermal Management

Air System

Controls, Electronics, Sensors

Fuel System

Fuel Cell Stack

Other

Created: Aug-18-09 2:25 PM

Fuel Cell Vehicle Maintenance Events and Labor Hours

CDP#64: Fuel Cell Vehicle Maintenance by 

System
National Renewable Energy Laboratory 85 Innovation for Our Energy Future

0

2

4

6

8

10

12

14

HWFET CycleUS06 CycleUDDS Cycle1015 Cycle

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Percent Idle in Trip

% Idle

Trip Frequency [%]

Created: Sep-08-09 3:29 PM

CDP#65: Percent Idle in Trip with 

Comparison to Standard Drive Cycles 
National Renewable Energy Laboratory 86 Innovation for Our Energy Future

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

5

10

15

20

25

30

35

40

Speed [mph]

Operation Time [%]

Fuel Cell Vehicle Speed

DOE Fleet Speed

DOE Fleet Idle

1015 Cycle (14.1 mph avg)

UDDS Cycle (19.6 mph avg)

HWFET Cycle (48.0 mph avg)

US06 Cycle (48.2 mph avg)

Created: Sep-09-09 7:39 AM

CDP#66: FCV Speed with Comparison to 

Standard Drive Cycles
National Renewable Energy Laboratory 87 Innovation for Our Energy Future

0

5

10

15

20

25

30

35

40

45

Stack Count

Fuel Cell Stack Operation Hours: Gen1

Gen1

0-200

400600800

100012001400160018002000

Gen1 Hours >2000

32% of stacks in operation

In Op1

Retired2

Other3

0

5

10

15

20

25

30

35

40

45

Stack Count

Fuel Cell Stack Operation Hours: Gen2

Gen2

0-200

400600800

100012001400160018002000

Gen2 Hours >2000

65% of stacks in operation

In Op1

Retired2

Other3

Created: Sep-09-09 10:48 AM

1) Stack currently accumulating hours

2) Stack removed for low performance

3) Stack not currently accumulating hours, but not removed because of low performance

CDP#67: Fuel Cell Stack Operation Hours
National Renewable Energy Laboratory 88 Innovation for Our Energy Future

0-5 10 15 20 25 30 35 40 >40 0

5

10

15

20

25

30

Stack Count

% FC Power Drop

FC Power Drop During Operation Period: Gen1

Gen1

68% of In Op stacks

have > 10% power drop

In Op1

Retired2

Other3

0-5 10 15 20 25 30 35 40 >40 0

5

10

15

20

25

30

Stack Count

% FC Power Drop

FC Power Drop During Operation Period: Gen2

Gen2

95% of In Op stacks

have > 10% power drop

In Op1

Retired2

Other3

Created: Sep-09-09 10:48 AM

1) Stack currently accumulating hours

2) Stack removed for low performance

3) Stack not currently accumulating hours, but not removed because of low performance

CDP#68: Power Drop During Fuel Cell Stack 

Operation Period
National Renewable Energy Laboratory 89 Innovation for Our Energy Future

30

40

50

60

70

80

90

100

110

120

130

 0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000

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 4 points in segment.

Gen1 Data Range

25th & 75th Percentiles

Group Median

Outlier

Created: Sep-09-09 10:48 AM

CDP#69: Max Fuel Cell Power Degradation –

Gen 1
National Renewable Energy Laboratory 90 Innovation for Our Energy Future

30

40

50

60

70

80

90

100

110

120

130

 0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000

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 4 points in segment.

Gen2 Data Range

25th & 75th Percentiles

Group Median

Outlier

Created: Sep-09-09 10:48 AM

CDP#70: Max Fuel Cell Power Degradation –

Gen 2
National Renewable Energy Laboratory 91 Innovation for Our Energy Future

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

5

10

15

20

25

30

27% Gen1 > 2000 projected hrs

9% 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)

Created: Sep-09-09 10:48 AM

1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning Demonstration.

2. 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 voltage at a specific

high current.

4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operation

hours greater than 200 the degradation rate tends to flatten out.

CDP#71: Projected Hours to OEM Low Power 

Operation Limit
National Renewable Energy Laboratory 92 Innovation for Our Energy Future

-20 0 20 40 60 -20

-10

0

10

20

30

40

50

60

Ambient Air Temperature [deg C]

Tank Temperature [deg C]

Tank vs. Ambient Air Temps Prior to Refueling

Frequency

50

100

150

200

250

-40 -20 0 20 40 0

1000

2000

Delta Temperature [deg C]

Count

Delta Temperature: Tank minus Ambient

Delta Temp Histogram

Normal Distribution Fit

0

0.05

0.1

Density

Mean= -3.896

Std Dev= 5.775

Created: Sep-09-09 11:11 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

CDP#72: Difference Between Tank and 

Ambient Temperature Prior to Refueling
National Renewable Energy Laboratory 93 Innovation for Our Energy Future

10 15 20 25 30 0

200

400

600

800

1000

1200

1400

1600

1800

2000

Fuel Cell Stack Projected Hours as a Function of Voltage Drop

% Voltage Drop

Projected Hours

2,3

Gen 1 Average Projections

Gen 1 Average Projection to 10% Voltage Degradation1

Gen 2 Average Projections

Gen 2 Average Projection to 10% Voltage Degradation1

Created: Sep-11-09 8:57 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 levels.

(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 Hours as 

a Function of Voltage Drop
F1147-E(10/2008)

REPORT DOCUMENTATION PAGE Form Approved

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PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ORGANIZATION.

1. REPORT DATE (DD-MM-YYYY)

September 2009

2. REPORT TYPE

Technical Report

3. DATES COVERED (From - To)

4. TITLE AND SUBTITLE

Controlled Hydrogen Fleet and Infrastructure Demonstration and 

Validation Project: Fall 2009; Composite Data Products, Final 

Version September 11, 2009

5a. CONTRACT NUMBER

DE-AC36-08-GO28308

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S)

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

5d. PROJECT NUMBER

NREL/TP-560-46679

5e. TASK NUMBER

FC087810

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

National Renewable Energy Laboratory

1617 Cole Blvd.

Golden, CO 80401-3393

8. PERFORMING ORGANIZATION

REPORT NUMBER

NREL/TP-560-46679

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR'S ACRONYM(S)

NREL

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13. SUPPLEMENTARY NOTES

14. ABSTRACT (Maximum 200 Words)

Graphs of composite data products produced by DOE's Controlled Hydrogen Fleet and Infrastructure Demonstration 

and Validation project through September 2009.

15. SUBJECT TERMS

hydrogen; hydrogen demonstration; hydrogen validation

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