hydrogen station data collection and analysis...2014 doe annual merit review and peer evaluation...
TRANSCRIPT
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Hydrogen Station Data Collection and Analysis
2014 DOE Annual Merit Review and Peer Evaluation Meeting
Sam Sprik, Jennifer Kurtz, Mike
Peters June 19, 2014: Washington, DC
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
Project ID# TV017
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Overview
Project start date: Oct 2011 Project end date: Sep 2014* Percent complete: ongoing
• Lack of current hydrogen refueling infrastructure performance and availability data
FY13 DOE Funding: $285k Planned FY14 DOE Funding: $200k Total Project Funding: $485k
Timeline
Budget
Barriers
• Hydrogen Frontier • CSULA • CARB • Shell • Proton OnSite • GTI • Linde
Partners
*Project continuation is determined annually by DOE
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Relevance: Meeting Vehicle Needs
• Location/Capacity/Utilization o Challenge: Stations need to provide coverage to meet the needs of vehicle drivers
in the pre-commercial stage as well as have hydrogen availability with minimal wait time
o Metrics: Station usage patterns and geographic locations • Fueling
o Challenge: Vehicles need to be fueled in an acceptable amount of time o Metrics: Fueling rates, times, amounts, back-to-back fills, communication...
• Maintenance/Availability o Challenge: Maintenance and other factors may cause station downtime and
increase cost o Metrics: Maintenance patterns, reliability and availability of stations
• Cost o Challenge: Hydrogen cost is dependent on several factors including where
produced, how delivered, efficiencies, and maintenance requirements o Metrics: Energy cost, maintenance cost…
• Station Timing o Challenge: Need enough lead time to build infrastructure to meet vehicle
demand o Metrics: Permitting time, building time, commissioning time…
Use metrics to clearly evaluate progress toward challenges
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Approach: Relationship to Other Tech Val Projects
Next Generation Hydrogen Infrastructure
Evaluation (FY13 – )
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Approach: FOA-626 (H2 Infrastructure Data)
Validation of Hydrogen Refueling Station Performance and Advanced Refueling Components • Objectives of FOA
o Provide H2 infrastructure data to NREL’s National Fuel Cell Technology Evaluation Center (NFCTEC) for analysis and aggregation
o Test, demonstrate, and validate hydrogen technologies in real-world environments
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Approach: FOA-626 Status (H2 Infrastructure Data)
• 4 awardees announced July 18, 2012
• All awards completed • Project kickoff Jan 2013 • Data starting to be
delivered to NREL’s NFCTEC
• Project to run for 4 years through 2 phases
• Will learn from state-of-the-art stations
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Approach: FOA-626 Winners Selected
Summary from press release (July 18, 2012) • California Air Resources Board (Sacramento, California)
o 1 station with natural gas to hydrogen, 180 kg of storage, and 60 kg of back-to-back fills in under an hour (DOE Award: $150,000)
• California State University and Los Angeles Auxiliary Services, Inc. (Los Angeles, California) o 1 station at CSULA with 24 hour public access and will fill up to 20 hydrogen
powered vehicles daily (DOE Award: $400,000) • Gas Technology Institute (Des Plaines, Illinois)
o 5 stations with their compressor technology, public access, and will analyze operational, transactional, safety, and reliability data (DOE Award: $400,000)
• Proton Energy Systems (Wallingford, Connecticut) o 2 stations that generate hydrogen from water through onsite solar-powered
electrolysis and will collect data on operation, maintenance and energy consumption (DOE Award: $400,000)
o Also, second project to deploy an advanced high-pressure electrolyzer at a station and nearly double the dispensing capacity of its storage tanks (DOE Award: $1 million)
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Approach: Analysis Objectives
Analyze operational data on existing hydrogen stations to provide status and feedback in the following areas: • Capacity • Utilization • Station build time • Maintenance/availability • Fueling • Geographic coverage
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Approach and Accomplishments: Milestones
• Quarterly data analysis (based on available data)
• Publication of composite data products
FY13 Q1 FY13 Q2 FY13 Q3 FY13 Q4
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Approach: Station Locations
58 Online 12 Future
3 mile radius
6 mile radius
• Maintain database of current stations in the U.S.
• Sync data with Alt Fuels Data Center (AFDC)
• Station coverage
Los Angeles Area Hydrogen Station Location Data Available through AFDC Mobile App (iPhone)
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Accomplishment: Infrastructure Data Templates
Templates enable collection of similar data from all the stations Aggregated results from data collected Templates distributed to project partners for data collection and feedback Templates provided to CEC for inclusion in Hydrogen Station Program Opportunity Notices (PONs)
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Approach: Station Data (Continual Collection)
• H2 produced or delivered by month • On-site efficiency, conversion efficiency,
compression energy, storage and dispensing energy • Maintenance • Safety • Hydrogen quality • Fueling • Cost of non-H2 energy for compression, dispensing,
conversion • Cost items (by month)
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Approach: Station Data (Site Summary)
• Station description • Production capacity • Dispensing capacity • Survivability (max/min temperature) • Nominal pre-cooling temp and SAE 2601 type • Storage type(s) and capacities and at what pressure(s) • Number of dispensers at what pressure(s) • Compressor(s) information • Time to design, permit, construct, and commission • Footprints: storage, production, dispensing
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NREL’s National Fuel Cell Technology Evaluation Center
Approach: National Fuel Cell Technology Evaluation Center (NFCTEC)
CDPs
DDPs
Composite Data Products (CDPs) • Aggregated data across multiple systems, sites, and teams • Publish analysis results without revealing proprietary data every 6 months2
Detailed Data Products (DDPs) • Individual data analyses • Identify individual contribution to CDPs •Only shared with partner who supplied data every 6 months1
1) Data exchange may happen more frequently based on data, analysis, and collaboration 2) Results published via NREL Tech Val website, conferences, and reports
Results
Internal analysis completed quarterly
Bundled data (operation & maintenance/safety)
delivered to NREL quarterly
Confidential Public
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Accomplishment: Analysis
• NREL Fleet Analysis Toolkit (NRELFAT) o Developed first under fuel cell vehicle
Learning Demonstration o Restructured architecture and interface to
effectively handle new applications and projects and for analyses flexibility
o Leverage analysis already created • Publish results
o Detailed and composite results o Target key stakeholders such as fuel cell
and hydrogen community and end users
Leveraged analysis code from previous projects and created new code useful for other projects such as material handling equipment.
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Accomplishments
• Analyzed data for station(s) providing data through CY2013Q4
• Visited several current stations • Published new Fall 2013 and Spring 2014 CDPs • Tracked current stations in database and synced with
Alt Fuels Data Center database of stations
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Spring 2014 Composite Data Products
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CDP-INFR-01 Hydrogen Dispensed by Quarter
0
1
2
3
4
5
6
2009Q12009Q2
2009Q32009Q4
2010Q12010Q2
2010Q32010Q4
2011Q12011Q2
2011Q32011Q4
2012Q12012Q2
2012Q32012Q4
2013Q12013Q2
2013Q32013Q4
Hydrogen Dispensed By QuarterH
ydro
gen
Dis
pens
ed [1
,000
kg]
Cumulative Hydrogen Dispensed = 43,821 kg
0
5
10
15
20
25
Cum
ulat
ive
Am
ount
[1,0
00 k
g]
All Sites By QuarterCumulative By Site
NREL cdp_infr_01Created: Apr-07-14 4:28 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-02 Histogram of Fueling Rates
0 0.5 1 1.5 2 2.5 30
0.5
1
1.5
2
2.5
3
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Rates
3 minute fill of5 kg
13,978 EventsAverage = 0.55 kg/min
14% >1 kg/min2% >1.67 kg/min
Reference Line at 1 kg/min2012 MYPP Tech Val Milestone
NREL cdp_infr_02Created: Apr-24-14 11:43 AM | Data Range: 2009Q1-2013Q4
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CDP-INFR-03 Histogram of Fueling Times
0 2 4 6 8 10 12 14 16 18 200
0.5
1
1.5
Time (min)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Times
Average = 5.58 min
50% <5 min19% <3 min
Reference Line at 5 min 2012 MYPP Tech Val Milestone (5 kg in 3 min)
NREL cdp_infr_03Created: Apr-24-14 11:47 AM | Data Range: 2009Q1-2013Q4
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CDP-INFR-04 Histogram of Fueling Amounts
0 1 2 3 4 5 6 70
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Amount Fueled (kg)
Num
ber o
f Fue
ling
Even
ts [1
,000
]Histogram of Fueling Amounts
Average = 2.46 kg
NREL cdp_infr_04Created: Apr-07-14 4:31 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-05 Dispensed Hydrogen per Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
Dis
pens
ed H
ydro
gen
[% o
f tot
al]
Day of Week
Dispensed Hydrogen per Day of Week
0
10
20
30
40
33 kg/day avg
Dai
ly A
vera
ge [k
g]
All StationsIndividual Stations
NREL cdp_infr_05Created: Apr-07-14 4:32 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-06 Station Capacity Utilization
1 2 3 4 50
20
40
60
80
100
120
140
160
180
200
Station (Sorted By Increasing Station Capacity)
Cap
acity
Util
izat
ion
1 [%]
Station Capacity Utilization
57.8%
Maximum Daily Utilization
Maximum Quarterly Utilization2
Average Daily Utilization2
NREL cdp_infr_06Created: Apr-07-14 4:33 PM | Data Range: 2009Q1-2013Q4
Note: The focus for early stationsis geographic coverage
1Station nameplate capacity reflects a variety of system design consderations including system capacity, throughput, system reliability and durability, and maintenance. Actual daily usage may exceed nameplate capacity.2Maximum quarterly utilization considers all days; average daily utilization considers only days when at least one filling occurred
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CDP-INFR-07 Station Usage
1 2 3 4 50
5
10
15
20
25
30
35
40
Station (Sorted By Increasing Station Capacity)
Fills
Per
Day
1
Station Usage
Maximum Daily Fills
Average Daily Fills2
NREL cdp_infr_07Created: Apr-07-14 4:33 PM | Data Range: 2009Q1-2013Q4
Note: The focus for early stationsis geographic coverage
1Excludes hydrogen fills of < 0.5 kg2Average daily fills considers only days when at least one fill occurred
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CDP-INFR-08 Time Between Fueling
<0 0 2 4 6 8 10 12 14 16 18 200
2
4
6
8
10
12
Si
mul
tane
ous
Fills
Back-to-Back Fills
8 % of fills are within 0-5 minutes of each other71 % of fills have more than 20 minutes between them14017 Total Fills
Time Between Fuelings* [min]
# of
Fue
lings
[% o
f tot
al]
Histogram of Time Between Fuelings
All Sites CombinedIndividual Sites
200 250 300 350 400 450 500 550 600 650 700 750 800 850 9000
100
200
300
400Final Pressures for Fills with <5 Minutes in Between
# of
Fue
lings
Final Pressure [bar]
Previous FillNext Fill
NREL cdp_infr_08Created: Apr-07-14 4:34 PM | Data Range: 2009Q1-2013Q4 *Time is from end of fill to start of next fill.
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CDP-INFR-09 Fueling Final Pressures
200 250 300 350 400 450 500 550 600 650 700 750 800 850 9000
1
2
3
4
5
6
7
450
bar*
350 bar Fills (200 to 450 bar) 700 bar Fills ( > 450 bar)
Final Pressure [bar]
% o
f Fue
ling
Even
tsFueling Final Pressures
Avg Final Pressure = 346 bar% of Fills > 350 bar = 46%Number of Fills = 3880
Avg Final Pressure = 722 bar% of Fills > 700 bar = 60%Number of Fills = 9894
AverageNominal
NREL cdp_infr_09Created: Apr-24-14 2:09 PM | Data Range: 2009Q1-2013Q4 *The line at 450 bar separates 350 bar fills from 700 bar fills. It is slightly over
the allowable 125% of nominal pressure (437.5 bar) from SAE J2601.
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CDP-INFR-10 Cumulative Number of Stations
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CDP-INFR-11 Hydrogen Stations by Type
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CDP-INFR-12 Fueling Rates 350 Vs. 700 bar
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
200
400
600
800
1000
1200
1400
Avg Fuel Rate (kg/min)
Num
ber o
f Fue
ling
Even
ts
Histogram of Fueling Rates350 vs 700 bar Fills
3 minute fill of5 kg
Fill Type Avg %>1 %>1.67 Count------------- ---------- ------- --------- --------350 bar 0.43 4 1% 3117700 bar 0.64 22 3% 7265
350 bar700 barReference Line at 1 kg/min2012 MYPP Tech Val Milestone
NREL cdp_infr_12Created: Apr-07-14 4:36 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-13 Number of Fueling Events per Hour
0 5 10 15 20 250
10
20
30
40
50
60
Number of Fuelings in an Hour
Freq
uenc
y [%
of t
otal
]
Number of Fuelings Per Hour
NREL cdp_infr_13Created: Apr-07-14 4:38 PM | Data Range: 2009Q1-2013Q4
Average: 1.9 per hourMedian: 1.0 per hourMax: 23.0 per hour
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CDP-INFR-14 Hydrogen Dispensed per Hour
0 10 20 30 40 50 600
2
4
6
8
10
12
14
Amount Fueled in an Hour [kg]
Freq
uenc
y [%
of t
otal
]
Hydrogen Dispensed Per Hour
NREL cdp_infr_14Created: Apr-07-14 4:39 PM | Data Range: 2009Q1-2013Q4
Average: 4.4 kgs per hourMedian: 3.2 kgs per hourMax: 50.9 kgs per hour
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CDP-INFR-15 Number of Fills by Time of Day
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 240
1
2
3
4
5
6
7
8
9
Number Included19,698 fills
Number of Fueling Events per Time of Day
Time of Day [hours]
Tota
l Num
ber o
f Fill
s [%
of T
otal
]
NREL cdp_infr_15Created: Apr-28-14 3:17 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-16 Fueling Amounts per Time of Day
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 240
1
2
3
4
5
6
7
8
Amount Included45,732 kg
Fueling Amounts per Time of Day
Time of Day [hours]
Tota
l Dis
pens
ed [%
of T
otal
]
0
10
20
30
40
50
60
70
Max
and
Avg
Dis
pens
ed [k
g]
TotalMaxAverage
NREL cdp_infr_16Created: Apr-07-14 4:41 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-17 Fueling Rates by Amount Filled
0 0.5 1 1.5 2 2.50
500
1000
1500
2000
2500
Average Fuel Rate [kg/min]
Num
ber o
f Fue
ling
Even
ts
Histrogram of Fueling Rates by Amounts
0 to 0.5 kg0.5 to 1 kg1 to 2 kg2 to 4 kg4 to 6 kgReference Line at 1 kg/min2012 MYPP Tech Val Milestone
NREL cdp_infr_17Created: Apr-07-14 11:43 AM | Data Range: 2009Q1-2013Q4
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CDP-INFR-18 Fueling Amount vs. Time to Fill
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CDP-INFR-19 Hydrogen Dispensed by Month
0
200
400
600
800
1000
1200
1400
2009
2010
2011
2012
2013
2014
Mon
thly
Am
ount
[kg]
Hydrogen Dispensed By Month
NREL cdp_infr_19Created: Apr-07-14 4:43 PM | Data Range: 2009Q1-2013Q4
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CDP-INFR-20 Number of Fills by Month
0
100
200
300
400
500
600
2009
2010
2011
2012
2013
2014
Mon
thly
Num
ber o
f Fill
s
Number of Fills By Month
NREL cdp_infr_20Created: Apr-08-14 9:22 AM | Data Range: 2009Q1-2013Q4
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CDP-INFR-21 Maintenance by Equipment Type
5%
6%
7%
9%
18%
19%
20%
Total Events = 1,9471
39% unscheduled
entiresystem 46
multiplesystems 155
misc 372
classifiedevents1 1374
Event Count
14%
23%
6%
14%
31%
Total Hours = 19,08119% unscheduled
hydrogen compressor
dispenser
safety
thermal management
reformer
electrolyzer
feedwater system
sensors
software
fuel system
air system
NREL cdp_infr_21Created: Apr-10-14 4:20 PM | Data Range: 2009Q1-2013Q4
Maintenance by Equipment Type
MISC includes the following failure modes: seal, nitrogen system, storage,valves, electrical, purifier, control electronics, fittings&piping, other
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CDP-INFR-22 Maintenance Labor Hours Breakdown
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0
5
10
15
20
25
30
35
Labor Hours Per Event
Freq
uenc
y (%
of t
otal
)
Infrastructure Maintenance Labor Hours Breakdown
NREL cdp_infr_22
0
10
20
30
Sites
Even
t Lab
or (h
rs)
Maximum and Mean Event Labor Hoursfor each site.
*excluded outlier
MeanMax
NREL cdp_infr_22Created: Apr-24-14 3:04 PM | Data Range: 2009Q1-2013Q4
>24
92% of repairs require less than the mean of 11.1 hours of labor.Median labor hours: 2.8
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CDP-INFR-23 Equipment Category Repair Time
0123456789
101112
AIR SYSTEM
CONTROL ELECTRONICS
DISPENSER
ELECTRICAL
ELECTROLYZER
ENTIRE SYSTEM
FEEDWATER SYSTEM
FITTINGS&PIPIN
G
FUEL SYSTEM
HYDROGEN COMPRESSOR
MULTIPLE SYSTEMS
NITROGEN SYSTEM
OTHER
PURIFIER
REFORMER
SAFETYSEAL
SENSORS
SOFTWARE
STORAGE
THERMAL MANAGEMENT
VALVES
Rep
air L
abor
Tim
e (H
ours
)
Equipment Category Repair Time
NREL cdp_infr_23Created: Apr-10-14 4:20 PM | Data Range: 2009Q1-2013Q4
75% Percentile
Median
25% Percentile
Mean
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CDP-INFR-24 Failure Modes for Top Equipment Categories
0 50 100 150 200 250 300 350
HYDROGEN COMPRESSOR
DISPENSER
SAFETY
THERMAL MANAGEMENT
Event Count
20%*
19%*
18%*
9%*
FLUID LEAK_NON_HYDROGEN
HYDROGEN LEAK
IMPROPER INSTALLATION
INSPECT TROUBLE ALARM OR REPORT
MANUFACTURING DEFECT
REPLACE FAILED PARTS
SOFTWARE BUG
MISC
SCHEDULED (PREV MAINT, UPGRADES)
0 1000 2000 3000 4000
HYDROGEN COMPRESSOR
DISPENSER
SAFETY
THERMAL MANAGEMENT
Labor Hours
31%*
14%*
6%*
23%*
NREL cdp_infr_24Created: Apr-28-14 2:33 PM | Data Range: 2009Q1-2013Q4
Failure Modes for Top Equipment Categories
* Percentage of total events or hours.
MISC includes the following failure modes: flow low, inspect trouble alarm or report,other, out of calibration, pressure high, software bug, other
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0
1
2
3
4
5
H2O = 22*
H2O = 400*
H2O = 97*
H2O = 20*
H2O = 52*
H2O = 6.2*
H2O = 55*
HC = 2.2*
HC = 7.5*
CO = 2.7*
HC = 8*
CO = 4.5*
CO2 = 1.2*
2009
Q1
2009
Q2
2009
Q3
2009
Q4
2010
Q1
2010
Q2
2010
Q3
2010
Q4
2011
Q1
2011
Q2
2011
Q3
2011
Q4
2012
Q1
2012
Q2
2012
Q3
2012
Q4
2013
Q1
2013
Q2
2013
Q3
2013
Q4
Num
ber o
f Sam
ples
Rep
orte
dH2 Quality
NREL cdp_infr_25Created: Apr-24-14 4:13 PM | Data Range: 2009Q1-2013Q4
23 of 33 samples ( 70%) met the SAEJ2719 guidelines. Consecutivesamples may be for a single issue.
*Values are in micromole/mole. Only values that exceed SAE J2719 guideline are shown in text.
CDP-INFR-25 H2 Quality
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Collaborations
• Station Operators o Gas Technologies Institute (GTI) o Linde o Hydrogen Frontier o Shell o California State University Los Angeles (CSULA) o Proton OnSite
• Organizations o California Fuel Cell Partnership (CaFCP) o California Air Resources Board (CARB) o California Energy Commission (CEC) o H2USA – Station Working Group
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Collaborations: CaFCP Working Group
• Participate in CaFCP working group meetings and station implementation team toward: o Developing recommendations for future stations o Staying current with California hydrogen activities
and needs
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Future CDPs Planned
• Separate out fueling events (rates, etc.) by topic (as data allow) o Pre-cooling temp o Amount filled o Simultaneous fueling o Back-to-back
• Maintenance o Frequency, MTBF, most frequent, most costly…
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Proposed Future Work • Add stations to the analysis as they come online
• FOA Station Status • Proton OnSite upgrades to Wallingford station (2014Q3) • Proton OnSite 2nd station (2014Q3) • GTI reporting on new Linde stations (2014Q4) • CARB Station measurement upgrades and data (2014Q3)
• Create new CDPs that describe the current state of pre-commercial stations
• Provide feedback on infrastructure status to stakeholders, continue collaborations, and seek feedback on important metrics
• Feed shortfalls back to developers, and track consumer behavior
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Project Summary
• Relevance: Hydrogen stations need to be able to meet vehicle needs.
• Approach: Analyze station operational data, building upon tools and capabilities from Learning Demo.
• Accomplishments and Progress: Updated database of stations and completed analysis of current station data.
• Collaborations: Currently working with station operators and California organizations.
• Future Work: As new stations open and provide data, NREL will add them to the analysis to get a good picture of the current state of hydrogen infrastructure.