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Technical ReportNREL/TP-560-43049
April 2008
Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project
Spring 2008
Composite Data ProductsFinal Version February 29, 2008
Keith Wipke, Sam Sprik, and Jennifer Kurtz
NOTICEThis report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal 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 privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.
Available electronically at http://www.osti.gov/bridge
Available for a processing fee to U.S. Department of Energyand its contractors, in paper, from:U.S. Department of EnergyOffice of Scientific and Technical InformationP.O. Box 62Oak Ridge, TN 37831-0062phone: 865.576.8401fax: 865.576.5728email: mailto:[email protected]
Available for sale to the public, in paper, from:U.S. Department of CommerceNational Technical Information Service5285 Port Royal RoadSpringfield, VA 22161phone: 800.553.6847fax: 703.605.6900email: [email protected] ordering: http://www.ntis.gov/ordering.htm
Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste
3
Controlled Hydrogen Fleet and Infrastructure Demonstration and
Validation Project
Spring 2008 Composite Data Products
Final Version: February 29, 2008
Keith Wipke, Sam Sprik, Jennifer Kurtz
4
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2006 Target
2009 Target
Actual Operating Hours Accumulated To-Date Projected Hours to 10% Degradation
Max Hrs Accumulated (1)(2) Avg Hrs Accumulated (1)(3) Projection to 10% Degradation (4)(5)
Tim
e (H
ou
rs)
DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2007 Q4
Max ProjectionAvg Projection
Created: Feb-26-08 11:46 AM
(1) Range bars created using one data point for each OEM.(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 green bar represents an engineering judgment of the uncertainty due to data and methodology limitations. Projections will change as additional data are accumulated.
CDP#1: Hours Accumulated and Projected Hours to 10% Stack Voltage Degradation
5
Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0
50
100
150
200
250
300
Veh
icle
Ran
ge
(mile
s)
Vehicle Range1
2015 Target2009 Target
Created: Feb-15-08 7:37 AM
(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
6
Dyno (1) Window-Sticker (2) On-Road (3)(4)0
10
20
30
40
50
60
70
80
Fu
el E
con
om
y (m
iles/
kg H
2)
Fuel Economy
Created: Feb-15-08 7:17 AM
(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.
(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).
(4) Calculated from on-road fuel cell stack current or mass flow readings.
CDP#6: Fuel Economy
7
0
10
20
30
40
50
60
70
All OEMs
Eff
icie
nc
y (
%)
Fuel Cell System1 Efficiency2 at ~25% Net Power.
DOE Target
Created: Aug-29-06 4:09 PM
1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAEJ2615.
2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).Excludes power electronics and electric drive.
CDP#8: FC System Efficiency
8
Safety Reports - Vehicle Operation
0
1
2
3
2005
Q2
2005
Q3
2005
Q4
2006
Q1
2006
Q2
2006
Q3
2006
Q4
2007
Q1
2007
Q2
2007
Q3
2007
Q4
Nu
mb
er
of
Re
po
rts
Tank ScratchTraffic AccidentH2 Leak - During FuelingH2 Alarm - StackH2 Alarm - Fuel SystemH2 Alarm - Passenger Compartment
Created: 2/15/07 9AM
CDP#9: Safety Reports – Vehicles
9
350bar 700bar0
1
2
3
4
5
6
7
8
9
Wei
gh
t P
erce
nt
Hyd
rog
en (
%)
Weight Percent Hydrogen
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Feb-15-08 7:32 AM1Targets are set for advanced materials-based hydrogen storage technologies.
CDP#10: Storage Weight % Hydrogen
10
350bar 700bar0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
Mas
s H
2 p
er L
iter
(kg
/L)
Mass of Hydrogen Per Liter
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: Feb-15-08 7:32 AM1Targets are set for advanced materials-based hydrogen storage technologies.
CDP#11: Volumetric Capacity of H2 Storage
11
CDP#12: Vehicle Hydrogen Tank Cycle Life
0
2000
4000
6000
8000
10000
12000
All OEMs
Nu
mb
er
of
cy
cle
s
Hydrogen Tank Cycle Life
2015 DOE MYPP Target1
2010 DOE MYPP Target1
2007 DOE MYPP Target1
Created: 23-Feb-20061Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.
12
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
100
200
300
400
500
600
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty Through 2007Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Average = 0.79 % >1 = 24
2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target
Created: Feb-15-08 1:44 PM
CDP#18: Refueling Rates
13
0 20 40 60 80 100 120
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Total Infrastructure Safety Reports by Severityand Report Type Through 2007 Q4
Alarms OnlyAutomatic System ShutdownElectrical IssueEquipment MalfunctionFalse Alarm/MischiefH2 Release - Minor, NO IgnitionH2 Release - Significant, NO IgnitionNon-H2 ReleaseStructural IssueSystem Trouble, not Alarm
Created: Feb-15-08 1:24 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 – Infrastructure
14
-30
-20
-10
0
10
20
30
40
50
60
1.4oF
122.9oF
Deg
rees
Cel
siu
s
Ambient Temperature During Operation
All OEMs
Created: Feb-14-08 5:40 PM
CDP#21: Range of Ambient TemperatureDuring Vehicle Operation
15
Vehicle Hours: All OEMs Combined
0
2
4
6
8
10
12
14
16
18
0-150
150-300
300-450
450-600
600-750
750-900
900-1050
1050-1200
1200-1350
>1350
Total Vehicle Hours
Nu
mb
er o
f V
ehic
les
Through 2007 Q4
Created: Feb-15-08
Total Vehicle Hours = 52,268
CDP#22: Vehicle Operating Hours
16
Vehicle Miles: All OEMs Combined
0
2
4
6
8
10
12
14
16
0-35
00
3500
-700
0
7000
-105
00
1050
0-14
000
1400
0-17
500
1750
0-21
000
2100
0-24
500
2450
0-28
000
2800
0-31
500
>3150
0
Total Vehicle Miles
Nu
mb
er o
f V
ehic
les
Total Miles Traveled = 1,105,440
Through 2007 Q4
Created: Feb-15-08
CDP#23: Vehicles vs. Miles Traveled
17
Cumulative Vehicle Miles Traveled: All OEMs
-
200,000
400,000
600,000
800,000
1,000,000
1,200,000
2005
Q2
2005
Q3
2005
Q4
2006
Q1
2006
Q2
2006
Q3
2006
Q4
2007
Q1
2007
Q2
2007
Q3
2007
Q4
Ve
hic
le M
iles
Tra
ve
led
Created: Feb-15-08
CDP#24: Cumulative Vehicle Miles Traveled
18
On-Board Hydrogen Storage Methods
-
10
20
30
40
50
60
70
80
90
100
2005
Q2
2005
Q3
2005
Q4
2006
Q1
2006
Q2
2006
Q3
2006
Q4
2007
Q1
2007
Q2
2007
Q3
2007
Q4
Cu
mu
lati
ve V
ehic
les
Dep
loye
d
Liquid H2
700 bar tanks
350 bar tanks
Created Feb-08-2008 8:57AM
92
CDP#25: Vehicle H2 Storage Technologies
19
Cumulative Hydrogen Produced or Dispensed Through 2007 Q4
0
5
10
15
20
25
30
35
40
45
50
2005
Q2
2005
Q3
2005
Q4
2006
Q1
2006
Q2
2006
Q3
2006
Q4
2007
Q1
2007
Q2
2007
Q3
2007
Q4
Calendar Quarter
Mas
s o
f H
ydro
gen
(kg
) (t
ho
usa
nd
s)
0
2
4
6
8
10
12
14
16
Nu
mb
er o
f S
tati
on
s
Cumulative Hydrogen
Number of Stations
Created Feb-28-08
CDP#26: Cumulative H2 Produced or Dispensed
20
99.7399.7499.7599.7699.7799.7899.7999.8
99.8199.8299.8399.8499.8599.8699.8799.8899.8999.9
99.9199.9299.9399.9499.9599.9699.9799.9899.99
100
Hyd
rog
en F
uel
Qu
alit
y In
dex
(%
)
Hydrogen Fuel Quality Index Sampled from Stations(1)
Data RangeDataSAE J2719
Created: Feb-15-08 2:10 PM(1) Includes sampling from both electrolysis and reforming
CDP#27: Hydrogen Purity Scatter Plot
21
0 1 2 3 4 5 6 7 8 9 10
Particulates
g/L
H2 Impurities
Data Range SAE J2719 Measured Less Than or Equal To (Detection Limited)
0 500 1000 1500 2000 2500 3000
(N2 + He + Ar)
0 5 10 15 20 25 30 35 40
H20 Total HC
O2 CO2 CO
NH3
mol/mol (ppm)
0 10 20 30 40 50 60 70 80 90 100
Total S*
nmol/mol (ppb)Created: Feb-15-08 2:10 PM *Calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).
CDP #28: Hydrogen Impurities Scatter Plot
22
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
50
100
150
200
250
300
350
400
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2007Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.94 36%Non-Comm 0.66 20%
CommNon-Comm2006 Tech Val Milestone2010 MYPP Adv Storage Materials Target
Created: Feb-27-08 11:26 AM
CDP#29: Fueling Rates – Communication and Non-Communication Fills
23
0 20 40 60 80 100 120 140 160
AdjustmentCheck Only
OtherRepair
Replacement
Maintenance: Average Labor Hours Per Station Since InceptionThrough 2007 Q4
ScheduledUn-Scheduled
0 5 10 15 20 25 30 35
AdjustmentCheck Only
OtherRepair
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: Feb-13-08 4:54 PM
CDP#30: Infrastructure Maintenance
24
Online Stations
0
2
4
6
8
10
12
14
16
2005Q2
2005Q3
2005Q4
2006Q1
2006Q2
2006Q3
2006Q4
2007Q1
2007Q2
2007Q3
2007Q4
Reporting Period
Nu
mb
er
of
Sta
tio
ns
Created Feb-15-08
CDP#31: Number of Reporting Stations
25
Infrastructure Hydrogen Production Methods
0
1
2
3
4
5
DeliveredCompressed H2
Natural Gas On-siteReforming
Electrolysis Delivered Liquid H2
Production Technology
# o
f S
tati
on
s
Created Feb-15-08
CDP#32: Infrastructure Hydrogen Production Methods
26
0 10 20 30 40 50 60 70 80 90 1000
1
2
3
4
5
6
7
8
9
10
11
12Range Histogram: All OEMs
Percentage of chassis dyno range1 b/w refuelings
Per
cen
tag
e o
f R
efu
elin
gs
0 10 20 30 40 50 60 70 80 90 1000
25
50
75
100
Cu
mu
lati
ve P
erce
nta
ge
Created: Feb-15-08 9:20 AM
Total refuelings2 = 10991
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.
CDP#33: Percentage of Theoretical Range Traveled Between Refuelings
27
0 10 20 30 40 50 60 70 80 90 100
Vehicle Range Factors
Percentage of chassis dyno range1.
All
OE
Ms
Win
do
w-S
tick
er 2
On
-Ro
ad 3
Dyn
o 1
Created: Feb-15-08 9:20 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).3. Using fuel economy from on-road data (excluding trips > 1 mile, consistent with other data products).
CDP#34: Effective Vehicle Range
28
2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 2007Q2 2007Q3 2007Q40
5
10
15
Reporting Period
Nu
mb
er o
f S
tati
on
s
Infrastructure Safety Trend and Online Stations Through 2007 Q4
Number of Online StationsAvg Refuelings Between Safety Reports
Created: Feb-15-08 1:24 PM
0
50
100
150
200
250
Nu
mb
er o
f R
efu
elin
gs
713
3441
114125 129
43
67
114
89
CDP#35: Average Refuelings Between Infrastructure Safety Reports
29
2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 2007Q2 2007Q3 2007Q40
5
10
15
20
25
Reporting Period
Nu
mb
er o
f R
epo
rts
Type of Infrastructure Safety Reports by Quarter Through 2007 Q4
IncidentNear MissNon-EventStations OnlineAvg # Reports/Station
Created: Feb-15-08 1:24 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#36: Type of Infrastructure Safety Report By Quarter
30
0 20 40 60 80 100 120
Non-Event
Near Miss
Incident
Number of Reports
Sev
erit
y
Primary Factors of Infrastructure Safety ReportsThrough 2007 Q4
Calibration/Settings/ Software ControlsDesign FlawEnvironment (Weather, Power Disruption, Other)Inadequate Training, Protocol, SOPInadequate/ Non-working EquipmentMaintenance RequiredMischief, Vandalism, SabotageNew Equipment MaterialsNot Yet DeterminedOperator/Personnel Error
Created: Feb-15-08 1:24 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 Infrastructure Safety Reports
31
0 2 4 6 8 10 12 14 16 18 200
200
400
600
800
1000
1200
1400
Time (min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling TimesAll Light Duty Through 2007Q4
Average = 3.43 % <5 = 87
Created: Feb-15-08 1:44 PM
CDP#38: Refueling Times
32
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 50
50
100
150
200
250
300
350
Amount Fueled (kg)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling AmountsAll Light Duty Through 2007Q4
Average = 2.25
Created: Feb-15-08 1:44 PM
CDP#39: Refueling Amounts
33
Tank Levels: DOE Fleet
15%
FE
Created: Feb-27-08 10:51 AM
Total refuelings1 = 13085
1. Some refueling events not recorded/detected due to data noise or incompleteness.
Median Tank Level = 39% at Fill
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.
CDP#40: H2 Tank Level at Refueling
34
FE
Tank Level Medians: DOE Fleet, All Vehicles
Created: Feb-27-08 10:51 AM
Total refuelings1 = 13085
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.
CDP#41: Refueling Tank Levels - Medians
35
Refueling by Time of Day: DOE Fleet
9%
3
12
9
6
Created: Feb-27-08 10:51 AM
Total Fill3 Events = 11356% of fills b/t 6 AM & 6 PM: 86.5%
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
CDP#42: Refueling by Time of Day
36
Sunday Monday Tuesday Wednesday Thursday Friday Saturday0
5
10
15
20
Fills by Day of Week: DOE Fleet
% o
f F
ills
in a
Day
Day
Created: Feb-27-08 10:51 AM
CDP#43: Refueling by Day of Week
37
Driving Start Time - Day: DOE Fleet
9%
3
12
9
6
DOE FleetNHTS
Created: Feb-27-08 10:51 AM
Total Driving3 Events = 139968% of driving trips b/t 6 AM & 6 PM: 88.7%
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%
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
38
Sunday Monday Tuesday Wednesday Thursday Friday Saturday0
5
10
15
20
Driving Trips by Day of Week: DOE Fleet
% o
f D
rivi
ng
Tri
ps
in a
Day
Day
DOE Fleet
NHTS
Created: Feb-27-08 10:51 AM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#45: Driving by Day of Week
39
0
5
10
15
20
25
30
35
40
45
50
%Time at Power Levels v2: DOE Fleet
% T
ime
at P
ow
er L
evel
0-5%
5-10
%
10-1
5%
15-2
0%
20-2
5%
25-3
0%
30-3
5%
35-4
0%
40-4
5%
45-5
0%
50-5
5%
55-6
0%
60-6
5%
65-7
0%
70-7
5%
75-8
0%
80-8
5%
85-9
0%
90-9
5%
95-1
00%
>100%
% Fuel Cell Power (Gross) of MaxCreated: Feb-27-08 12:04 PM
17.6%-47.9% of operating time at idle(Vehicle Speed = 0 & F.C. Power > 0)
CDP#46: Fuel Cell System Operating Power
40
0 5 10 15 20 250
5
10
15
20
25
30
35
40
45
Fre
qu
ency
(%
)
Trip Length (miles)
Trip Length: DOE Fleet
DOE FleetNHTS
Created: Feb-27-08 11:56 AM
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#47: Trip Length
41
CDP#48: Primary Factors Affecting Learning Demo Fleet Fuel Cell Degradation
DOE Fleet
High Current TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot 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 stacksL**: 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 TimeHot StartsStarts/hour
Low Voltage TimeHigh Voltage Time
Cold StartsShort Trips
0 Speed TripsHot 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 stacksL**: 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.
42
CDP#49: Primary Factors Affecting Learning Demo Team Fuel Cell Degradation
Team 1
High Voltage TimeHigh Current TimeHot Ambient Temp
Short TripsStarts/hour
Team 2
Team 3
Team 4
Hot StartsStarts/hour
High Voltage TimeLow Current Time
Idle TimeCold Starts
Warm Ambient TempLong Trips
High Voltage TimeLow Current Time
Hot StartsIdle Time
Short TripsStarts/hour
1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for each team.
2) Teams’ PLS models have a high percentage of explained decay rate variance, but the models are not robust and results are scattered.
H*
L**
High Voltage TimeLow Current Time
Idle Time
Low Voltage TimeCold Starts
Hot Ambient TempShort TripsStarts/hour
H*
H*
H*
H*
L**
L**
H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks
Created: Feb-27-08 12:17 PM
Team 1
High Voltage TimeHigh Current TimeHot Ambient Temp
Short TripsStarts/hour
Team 2
Team 3
Team 4
Hot StartsStarts/hour
High Voltage TimeLow Current Time
Idle TimeCold Starts
Warm Ambient TempLong Trips
High Voltage TimeLow Current Time
Hot StartsIdle Time
Short TripsStarts/hour
1) On-going fuel cell degradation study using Partial Least Squares (PLS) regression model for each team.
2) Teams’ PLS models have a high percentage of explained decay rate variance, but the models are not robust and results are scattered.
H*
L**
High Voltage TimeLow Current Time
Idle Time
Low Voltage TimeCold Starts
Hot Ambient TempShort TripsStarts/hour
H*
H*
H*
H*
L**
L**
H*: Factor group associated with high decay rate fuel cell stacksL**: Factor group associated with low decay rate fuel cell stacks
Created: Feb-27-08 12:17 PM
43
Refueling by Time of Night: DOE Fleet
5%
3
12
9
6
Created: Feb-27-08 10:51 AM
Total Fill3 Events = 11356% of fills b/t 6 PM & 6 AM: 13.5%
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
CDP#50: Refueling by Time of Night
44
Driving Start Time - Night: DOE Fleet
3%
3
12
9
6
DOE FleetNHTS
Created: Feb-27-08 10:51 AM
Total Driving3 Events = 139968% of driving trips b/t 6 PM & 6 AM: 11.3%
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%
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
45
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
50
100
150
200
250
300
350
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesAll Light Duty by Year Through 2007Q4
5 minute fill of5 kg at 350 bar
3 minute fill of5 kg at 350 bar
Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 17%2006 0.72 20%2007 0.86 28%
2005200620072006 Tech Val Milestone2010 MYPP Adv Storage Materials Target
Created: Feb-27-08 11:39 AM
CDP#52: Refueling Data by Year
46
0
2
4
6
8
10% Energy by Power levels: DOE Fleet
% E
ner
gy
0-5%
5-10
%
10-1
5%
15-2
0%
20-2
5%
25-3
0%
30-3
5%
35-4
0%
40-4
5%
45-5
0%
50-5
5%
55-6
0%
60-6
5%
65-7
0%
70-7
5%
75-8
0%
80-8
5%
85-9
0%
90-9
5%
95-1
00%
>100%
% Fuel Cell Power (Gross) of Max
Cu
mu
lati
ve %
0
20
40
60
80
100
Created: Feb-27-08 12:04 PM
CDP#53: Fuel Cell System Energy within Power Levels
47
0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-30days >30days0
10
20
30
40
50
60
% T
rip
s
Time
Time between Trips: DOE Fleet
0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-60 min0
10
20
30
40
50
60
% T
rip
s
Time
0-60 min Breakdown: DOE Fleet
Created: Feb-27-08 11:56 AM
CDP#54: Time Between Trips
48
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 >50
5
10
15
20
25
30
35
40Trip Energy: DOE Fleet
% T
rip
s
Energy Consumed [kWh]Created: Feb-27-08 12:04 PM
# of Trips: 150221
CDP#55: Fuel Cell System Energy
49
0 5 10 15 20 25 30 35 400
5
10
15
20
25
Fre
qu
ency
(%
)
Daily Distance (miles)
Daily Distance: DOE Fleet
DOE FleetNHTS
Created: Feb-27-08 11:56 AM
Cumulative Frequency@ 20 miles
DOE Fleet: 50.9%NHTS: 27.2%
Cumulative Frequency@ 40 miles
DOE Fleet: 69.9%NHTS: 52.9%
2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001
CDP#56: Daily Driving Distance
50
Average Breakout of H2 Storage System Volume
73%
24%
3%
Average Breakout of H2 Storage System Mass
73%
23%
3.26%
350 bar
55%35%
10%
H2 Volume (%)Pressure Vessel Volume (%)Balance of Plant Volume (%)
26%
3.45%
71%
H2 Mass (%)Pressure Vessel Mass (%)Balance of Plant Mass (%)
700 bar
Created: Feb-15-08 6:53 AM
CDP#57: H2 Storage System Mass and Volume Breakdown