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.

Performance & Reliability of Fuel Cell Systems in the Field

Fuel Cell End Users’ Forum

Chris Ainscough, Jennifer Kurtz, Keith Wipke, Sam Sprik, Leslie Eudy, Genevieve Saur, Todd Ramsden

February 4th, 2013

This presentation does not contain any proprietary, confidential, or otherwise restricted information

V2, 4/5/12

2

Outline

• Combined Results • Light Duty Vehicle results from the U.S.

DOE Learning Demonstration Project: 2004 – 2012

• American Recovery & Reinvestment Act (ARRA) fuel cell backup power & material handling and systems.

https://powerpedia.energy.gov/w/images/7/77/DOE_Seal_Color_Hi-Res.jpg

3

CDPs

DDPs

Public

Composite Data Products (CDPs) • Aggregated data across multiple systems,

sites, and teams • Publish analysis results every six months

without revealing proprietary data2

Detailed Data Products (DDPs) • Individual data analyses

• Identify individual contribution to CDPs • Shared every six months only with the

partner who supplied the data1

1) Data exchange may happen more frequently based on data, analysis, & collaboration 2) Results published via NREL Tech Val website, conferences, and reports (http://www.nrel.gov/hydrogen/proj_learning_demo.html)

Project Approach Supporting Both DOE/Public as Well as Technology Developers

Results

Bundled data (operation & maintenance/safety) delivered

to NREL quarterly

Internal analysis completed quarterly

4

Combined Results

5

Fuel Cell Deployment mAp

0

25

50

75

100

125

Material Handling Equipment (14 Sites and 684 FC Units)Backup Power (316 Sites and 335 FC Units)Stationary (2 Sites and 4 FC Units)APU (1 Sites and 1 FC Units)Bus (9 Sites and 16 FC Units)Car (22 Sites and 22 FC Units)

NREL cdp_XApp_02Created: Oct-31-12 2:48 PM

Number of FCUnits in

State/Site

Deployments we track

6

Fueling Rates

Rate typically scales with the on-board fuel capacity. Larger capacity requires faster fueling.

7

Fueling Times

Fast fueling (< 3 minutes) is a key parameter to the value proposition in MHE. It is a key differentiator between fuel cell and battery electric vehicles. The latter can take up to 20 hours on a level 1 charger or 8 hours on level 2.

8

Light Duty Vehicles

9

2nd Generation Vehicles Demonstrated Technology Improvements Over Gen 1

Generation 1 Vehicles • FC not freeze-capable • ~2003 stack technology • Storage: liquid H2 & 350

and 700 bar • Range: 100-200 miles • Efficiency: 51-58% at ¼

power

Generation 2 Vehicles • FC freeze-capable • ~2007-2009 stack tech. • Storage: All 700 bar

• Range: 200-250 miles • Efficiency: 53-59% at ¼

power • Longer FC durability

10

7

12

6

0

5

10

15

20

25

Num

ber o

f Sta

tions

Reporting Period

Cumulative Stations

Continuing Outside of ProjectRetired StationsCurrent Project Stations

NREL cdp_fcev_31Created Dec-9-11 9:15 AM

Infrastructure Status: Out of 25 Project Stations, 13 Are Still Operational* (6 outside of DOE project)

Jan-31-2012

2 Online 3 Future

54 Online 15 Future

6 Online

SF Bay Area

DC to New York

3 Online

Detroit Area

Los Angeles Area

16 Online 11 Future

3 mile radius

6 mile radius

12

7

6

**

** Funded by state of CA or others, outside of this project

* CDP station status is as of 9/30/11

11

Total of 99 CDPs Published, Including 40 Winter 2011 CDPs

Only selected highlights (mostly from the last year) will be covered

12

Project Achieved Both Technical Goals; Outside Analysis Used for Cost Evaluation

Vehicle Performance Metrics Gen 1 Vehicle Gen 2 Vehicle 2009 Target After 2009Q4

Fuel Cell Stack Durability 2,000 hours Max Team Projected Hours to

10% Voltage Degradation 1,807 hours 2,521 hours --

Average Fuel Cell Durability Projection 821 hours 1,062 hours 1,748 hours

Max Hours of Operation by a Single FC Stack to Date 2,375 hours 1,261 hours 1,582 hours

Driving Range 250 miles

Adjusted Dyno (Window Sticker) Range 103-190 miles 196-254 miles --

Median On-Road Distance Between Fuelings 56 miles 81 miles 98 miles

Fuel Economy (Window Sticker) 42 – 57 mi/kg 43 – 58 mi/kg no target --

Fuel Cell Efficiency at ¼ Power 51 – 58% 53 – 59% 60% --

Fuel Cell Efficiency at Full Power 30 – 54% 42 – 53% 50% --

Infrastructure Performance Metrics 2009 Target After 2009Q4

H2 Cost at Station (early market)

On-site natural gas reformation

$7.70 – $10.30/kg

On-site Electrolysis

$10.00 – $12.90/kg

$3/gge --

Average H2 Fueling Rate 0.77 kg/min 1.0 kg/min 0.65 kg/min

Outside of this project, DOE independent panels concluded at 500 replicate stations/year: Distributed natural gas reformation at 1500 kg/day: $2.75-$3.50/kg (2006) Distributed electrolysis at 1500kg/day: $4.90-$5.70 (2009)

Outside review panel

1)

2)

3)

13

0 50 100 150 200 250 3000

5

10

Perc

enta

ge o

f Ref

uelin

gs

Distance between refuelings [Miles]2

Distance Driven Between Refuelings: All OEMs

Gen1Gen2After 2009Q4

NREL cdp_fcev_80

1. Some refueling events are not detected/reported due to data noise or incompleteness.2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the vehicle.

Gen1 Refuelings1 = 18941 Median distance between refuelings = 56 Miles Gen2 Refuelings1 = 6870 Median distance between refuelings = 81 Miles

Created: Dec-13-11 3:57 PM

Refuelings after 2009Q41 = 9937 Median distance between refuelings = 98 Miles

RANGE: Results Show Significant Improvement in Real-World Driving Range Between 3 Sets of Vehicles

+45% improvement Gen 1 to Gen 2

+75% improvement in real-world driving

range with latest adv. tech. vehicles

Note: Actual range possible >200 miles

2

2

2

14

0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

5

10

15

20

25Fuel Cell Stack4 Operation Hours

FC S

tack

s [%

]

Operation Hours

25% of FC Stacks > 937 hoursM

edia

n (6

20 h

ours

)

In Service1

Retired2

Not in Service3

NREL cdp_fcev_86Created: Dec-15-11 12:32 PM

1) Stacks that are in service and accumulating operation hours.2) Stacks retired due to low-performance or catastrophic failure.3) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performancerelated issues or c)removed from DOE program.4) Only includes systems operating after 2009Q4.

Evaluated FC Durability Data from FCEVs After 2009Q4 – Fuel Cell Stack Operation Hours and Max Power Degradation

Some stacks operated over 1,400 hours, but half were still below 600 hours

0

20

40

60

80

100

120

0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments2

% P

ower

1

Max Fuel Cell Stack3 Power Degradation Over Operation

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 3 points in segment.3) Only includes systems operated after 2009Q4.

Data Range25th & 75th PercentilesGroup MedianOutlier

NREL cdp_fcev_90Created: Jan-10-12 10:29 AM

Median power differencefrom 0 hour segment to1300 hour segment = -18.2%

Recent data from stacks shows knee

in FC power degradation curve

at ~200 hours

15

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000102030405060

Fuel Cell Stacks4 Projected Hours to 10% Voltage Degradation

1,74

8

FC S

tack

s [%

]

Time 0 Fit (In Service)Time 0 Fit (Retired or Not in Service)2

Weighted Average (Fleet)

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000102030405060

2,26

1

Projected Hours to 10% Voltage Degradation 1,3

FC S

tack

s [%

]

Steady Operation Fit (In Service)5

Steady Operation Fit (Retired or Not in Service)2, 5Weighted Average (Fleet)

NREL cdp_fcev_87Created: Jan-10-12 10:28 AM

1) Projection using field data, calculated at high stack current, from operation hour 0 or a steady operation period. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.4) Only includes systems operating after 2009Q4.5) Not all stacks have a steady operation fit which is calculated from data after 200 hr break-in period. The steady operation starting hour is an approximation of the period after initial break-in where degradation levels to a more steady rate.

Projected Fuel Stack Durability to 10% Voltage Degradation; Two Fits

Using all data from t0

Fitting after first 200 hours

Average projections

Gen 1: 821 Gen 2: 1,062 Recent: 1,748

Many stacks have projections that we

limit to 2X to minimize extrapolation

16

Infrastructure Safety

0

10

20

30

40

50

Num

ber o

f Rep

orts

Type of Infrastructure Safety Reports by Quarter Through 2011 Q3

05Q2

05Q3

05Q4

06Q1

06Q2

06Q3

06Q4

07Q1

07Q2

07Q3

07Q4

08Q1

08Q2

08Q3

08Q4

09Q1

09Q2

09Q3

09Q4

10Q1

10Q2

10Q3

10Q4

11Q1

11Q2

11Q3

IncidentNear MissNon-EventAvg # Reports/Station

NREL cdp_fcev_36Created: Dec-15-11 3:36 PM

Reporting PeriodAn 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

Positive Trend. No incidents since 09Q1

17

5%

5%

6%

8%

9%

9%12%

21%

21%

Classified Events = 1,095160% unscheduled

multiplesystems 0

misc 190

entiresystem 203

classifiedevents1

1095

Event Count

9%

11%

6%

14%

16%

29%

Total Hours = 6,57050% unscheduled

electricalsoftwarehydrogen compressorsensorsvalvesair systemdispenserfittings&pipingcontrol electronicsH2 storage

NREL cdp_fcev_94

MISC includes the following failure modes: purifier, nitrogen system, feedwater system,seal, safety, reformer, electrolyzer, thermal management, other

2. Includes data from stations operating after 2009 Q4. Forlegacy results refer to CDP #63.

Created: Jan-17-12 1:53 PM

Infrastructure Maintenance By Equipment Type2

Infrastructure Maintenance: Equipment

Among hydrogen-specific equipment, compressors are a leading cause of maintenance.

18

Backup Power

19

Reliability: 99.5% successful starts

0

20

40

60

80

100

120

140

160

180

200

220

Star

ts

Starts by Month

07/09

08/09

09/09

10/09

11/09

12/09

01/10

02/10

03/10

04/10

05/10

06/10

07/10

08/10

09/10

10/10

11/10

12/10

01/11

02/11

03/11

04/11

05/11

06/11

07/11

08/11

09/11

10/11

11/11

12/11

01/12

02/12

03/12

04/12

05/12

06/12

Calendar Month

1526 of 1533 Starts Successful (99.5%)52% Conditioning Starts

StartsConditioning1 StartSuccessful Start

0

15

30

45

60

75

90

105

120

135

150

Rep

ortin

g FC

Sys

tem

s

NREL cdp_bu_04

Created: Sep-13-12 6:37 PM 1) FC system conditioning is an automated operation for regularsystem checks; activitated after long periods of no operation.

20

21

Material Handling Equipment

22

MHE Operation Status

*Through June 2012

Key Operation Metric CDPARRA-MHE-# Units in Operation

(100 Class 1, 62 Class 2, 172 Class 3) 490* 01

Hours Accumulated 1,248,384 hrs* 11

25% of FC Systems > 5,260 hrs* 02

FC Systems Average > 6 hours Daily 66%* 24

Hydrogen Dispensed 141,500 kg* 04

Hydrogen Fills 197,991* 03

Average Fill Amount 0.6 kg/fill* 10

Average Fill Time 2.3 min/fill* 06

Average Op Time between Fill 4.7 hrs* 08

The majority of sites have delivered liquid hydrogen. 2 of the 8 sites are greenfield sites. 4 sites have more than one class of MHE in operation.

23

Annualized Total Cost of Ownership per Unit Identifies Key Cost Advantages are Dependent on Deployment Size

CDP Ref #: 58

Fuel

Infra.

Hardware

Warehouse Space

Fueling Labor

Maint.

Results assume replacements as needed and do not reflect technology generation improvements or other productivity improvements such as constant power, emissions, and cold environment. FC costs include current tax credit of $3,000/kW or 30% of purchase price. Data source: ARRA & DLA project partner questionnaire & fuel cell performance data.

Class III Annualized Cost • $11,700 FC • $12,400 Battery

Analysis inputs are averages per category, some key inputs are: • 58 FC lifts • 333 days per year, 2.5

shifts per day (2,100 pedal hours per year)

• 3 min per hydrogen fill & 10 min per battery change out

24

MHE Availability

90

91

92

93

94

95

96

97

98

99

100

% A

vaila

bilit

y

MHE Availability - ARRA & DLA1

Jan-1

0

Feb-1

0

Mar-1

0

Apr-1

0

May-1

0

Jun-1

0Ju

l-10

Aug-1

0

Sep-1

0

Oct-1

0

Nov-1

0

Dec-1

0

Jan-1

1

Feb-1

1

Mar-1

1

Apr-1

1

May-1

1

Jun-1

1Ju

l-11

Aug-1

1

Sep-1

1

Oct-1

1

Nov-1

1

Dec-1

1

MonthlyMean

NREL cdp_mhe_54

Created: Mar-26-12 4:19 PM

1. Availability is calculated as follows: Availability starts at 100% for each vehicle on each calendar day. If the vehicle has a maintenance record on a given day, unavailable hours are subtracted from availability. The number of unavailable hours is calculated according to the following schedule: A. Unavailable hours = 21 hours if maintenance hours is blank or > 6 hours. B. Unavailable hours = if maintenance hours are between 4 and 6 hours. C. Unavailable hours = the actual maintenance hours if it is less than 4 hours. D. If maintenance hours are > 21 , the rules A-C above are applied recursively to any remainder above 21 hours.

Mean Availability: 98 %

25

Reliability - Fuel Cell System

0 500 1000 1500 2000 2500 3000 3500 4000 4500 50000

10

20

30

40

Unit MTBF1 (Hours)

Perc

ent o

f Uni

ts

Unit MTBF by Operating Hours

17%

17%

18%20%

27%19%

15%

16% 16%

19%

15%26%

28%

26%

19% 13%

13%

13%

13% 13%

13%

13%

13%

AIR SYSTEMCONTROL ELECTRONICSELECTRICALENERGY STORAGE SYSTEMFUEL SYSTEMSENSORSSOFTWARETHERMAL MANAGEMENT

NREL cdp_mhe_30

Created: Mar-26-12 4:17 PM

1Mean Time Between Failure

Class 1 Class 2 Class 3

Equipment Categories for Units with MTBF

26

Reliability - Infrastructure

Compressor

Feedwater

Dispenser

Infrastructure consistently delivering 250 and 350 bar fills even though the majority of the sites have a MTBF of 25 days or less.

27

Deep Dive: Hydrogen Leaks

6%6%

6%

16%

18%

47%

Classified Events = 491100% unscheduled

misc 0

classified1

events49

Event Count

7%

8%

5%

18%

25%

39%

Total Hours = 442100% unscheduled

hydrogen compressor

fittings&piping

dispenser

valves

seal

reformer

NREL cdp_mhe_51

Created: Mar-14-12 3:11 PM

Hydrogen Leaks By Equipment Category: Infrastructure

28

Deep Dive: Hydrogen Compressors

5%9%

9%

14%

17%

21%

26%

Classified Events = 137198% unscheduled

misc 45

classified1

events137

Event Count

12%

7%

14%

22%

36%

Total Hours = 1,57297% unscheduled

metal fatigue

excessive noise

hydrogen leak

pressure low

temperature high

inspect trouble alarm or report

fluid leak_non_hydrogen

NREL cdp_mhe_52

Created: Mar-09-12 2:07 PM

Hydrogen Compressor Failures By Mode

MISC includes the following failure modes: cavitation, debris infiltration, failed closed,flow high, manufacturing defect, moisture infiltration, operator protocol, preventative

maintenance, maintenance error, upgrade, replace failed parts, other

29

Hydrogen Compressors: Improving Reliability

• DOE & NREL have begun an accelerated test program to evaluate H2 compressor failures & solutions in more detail.

• NREL provides the test facilities and labor. Compressor partners provide test articles.

30

Technical Summary – What We’ve Learned

Light Duty Vehciles • 183 Vehicles:

• 154,000 hours • 3.6M miles • 500K trips

• 25 Stations: • 152,000 kg produced/dispensed • 33K fuelings

• Met DOE target of 2000 hours stack durability • Met DOE target of 250 mile driving range.

31

Technical Summary – What We’ve Learned Fuel Cell Backup Power • Operating reliability in 15 states with

99.5% successful starts. • Maximum continuous run time of 29

hours due to an unplanned grid outage.

Fuel Cell Material Handling Equipment • Operating with an average availability

of ~98% at 8 end-user facilities. • Most systems operate at least 6 hours

a day. • Cost of ownership comparison

between fuel cell and battery MHE indicate significant cost savings cost for refueling labor and infrastructure space but much greater cost for hydrogen infrastructure and fuel.

Aggregated data showcases performance over the last two

years in MHE and backup power.

Performance results address a need for published results on

the technology status.

Data analyses develop as systems operate and based on the key performance areas in

the markets.

32

More information available

• www.nrel.gov/hydrogen/proj_tech_validation.html • or search for “NREL CDP”

Link to sunburst

http://www.nrel.gov/hydrogen/media/demo/source/sunburst.html

33

Backup Slides

34

Cumulative Mileage

3,590,828

-

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

4,000,000

Vehi

cle

Mile

s Tr

avel

ed

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

Created: Dec-13-11 03:23 PM

Through 2011 Q3

NREL cdp_fcev_24

35

0 5 10 15 20 25 300

1

2

3

4

Site MTBF1 (Days)

Cou

nt o

f Site

s

Site MTBF (Calendar Days In Operation): Infrastructure2

NREL cdp_fcev_98Created: Jan-09-12 4:26 PM 1. Cumulative Mean Time Between Failure 2. Includes data from stations operating after 2009 Q4.

Infrastructure Maintenance: MTBF

Lifetime cumulative MTBF < 25 days, but improving at 5 of 7 stations.

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Shap

e Pa

ram

eter

( β)1

Overall Site Reliability Growth: Infrastructure3

Site: 1 Site: 2 Site: 3 Site: 4 Site: 5 Site: 6 Site: 7

1. IEC 61164:2004(E)., Reliability Growth - Statistical Test and Evaluation Methods, IEC. 2004.

2.% change in instantaneous MTBF

3. Includes data from stations operating after 2009 Q4.

Entire historyLast 20% of eventsFirst 120 Days

NREL cdp_fcev_97Created: Jan-09-12 4:23 PM

Sites Sorted by Increasing Age (Calendar Days)

Failu

re R

ate

Incr

easi

ngFa

ilure

Rat

e D

ecre

asin

g

Instantaneous MTBF improved for 5 of 7 sites for the last 20% of events.

12%2 522%2

43%2

127%2

-64%2 -20%2

379%2

36

Cost of Ownership: Backup power Fuel Cell* Diesel Battery Reliability + o + Capital Cost ($/kW) - + ++ Extended Run Time ++ ++ -- Emissions ++ - ++ Noise + + ++ Environmental ~ - ~ Weight + - - Efficiency + - ++ Annual Fuel Cost + - ++ Annual Maintenance Cost + - ++ Maintenance Frequency ++ - ? Refurbishment + + -- Conditioning Tests + - ~ Operation Lifetime + ++ --

Gathering data on: • Site Description • System Description • System Requirements • Capital Cost • Operating & Maintenance

Cost • Operating Lifetime for fuel cells, batteries, and generators

*Tax credit $3,000/kW or 30% total

Performance and Reliability of Fuel Cell Systems in the FieldOutlineProject Approach Combined ResultsDeployments we trackFueling RatesFueling TimesLight Duty Vehicles2nd Generation Vehicles Demonstrated Technology Improvements Over Gen 1Infrastructure StatusTotal of 99 CDPs Published, �Including 40 Winter 2011 CDPsProject Achieved Both Technical Goals; �Outside Analysis Used for Cost EvaluationRANGE: Results Show Significant Improvement in �Real-World Driving Range Between 3 Sets of VehiclesEvaluated FC Durability Data from FCEVs After 2009Q4 – �Fuel Cell Stack Operation Hours and Max Power DegradationProjected Fuel Stack Durability to 10% Voltage Degradation; Two FitsInfrastructure SafetyInfrastructure Maintenance: EquipmentBackup PowerReliability: 99.5% successful startsMaterial Handling EquipmentMHE Operation StatusAnnualized Total Cost of Ownership per Unit Identifies Key Cost �Advantages are Dependent on Deployment SizeMHE AvailabilityReliability - Fuel Cell SystemReliability - InfrastructureDeep Dive: Hydrogen LeaksDeep Dive: Hydrogen CompressorsHydrogen Compressors: Improving ReliabilityTechnical Summary – What We’ve LearnedTechnical Summary – What We’ve LearnedMore information availableBackup SlidesCumulative MileageInfrastructure Maintenance: MTBFCost of Ownership: Backup power