spring 2011 composite data products arra material handling equipment
DESCRIPTION
Technical Report NREL/TP-5600-51577 April 2011. Spring 2011 Composite Data Products ARRA Material Handling Equipment J. Kurtz, K. Wipke, S. Sprik, T. Ramsden, C. Ainscough, G. Saur. Spring 2011 Composite Data Products ARRA Material Handling Equipment. - PowerPoint PPT PresentationTRANSCRIPT
NREL is a national laboratory of the U.S. Department of Energy, Office of EnergyEfficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Contract No. DE-AC36-08GO28308
Spring 2011 Composite Data ProductsARRA Material Handling Equipment
J. Kurtz, K. Wipke, S. Sprik, T. Ramsden, C. Ainscough, G. Saur
Technical Report NREL/TP-5600-51577April 2011
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.
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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.
Spring 2011 Composite Data ProductsARRA Material Handling Equipment
Jennifer Kurtz, Keith Wipke, Sam Sprik, Todd Ramsden, Chris Ainscough, Genevieve Saur
April 6th, 2011
TP-5600-51577
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-01Fuel Cell MHE Systems Deployed
2010 Q1 2010 Q2 2010 Q3 2010 Q40
50
100
150
200
250
300
350
400
14
122
35
40
131
35
40
131
60
76
172
136
206 206
308
Cu
mu
lati
ve S
yste
ms
1,2 D
eplo
yed
Fuel Cell Units Deployed - ARRA
Class IIIClass IIClass I
NREL cdparra_mhe_01
Created: Mar-10-11 2:18 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-02Fuel Cell System Operation Hours
0
2
4
6
8
10
12
0 200 400 600 8001000
12001400
16001800
20002200
24002600
28003000
>3000
% F
uel
Cel
l S
yste
ms
Cumulative Fuel Cell Operation Hours - ARRACombined Fleet Through 2010Q4
25% of FC Systems > 2360 Hours
FC SystemFleet Average FC System Hours
NREL cdparra_mhe_02
Created: Mar-09-11 6:49 PM Fuel Cell Operation Hours
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-03Fueling Events by Quarter
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40
2000
4000
6000
8000
10000
12000
14000
16000
Fueling Events By Quarter - ARRA
Nu
mb
er o
f F
ills
Cumulative Fuelings = 38,863
0
5
10
15
20
25
Cu
mu
lati
ve F
uel
ing
s [1
000]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_03
Created: Mar-21-11 3:29 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-04Hydrogen Dispensed by Quarter
2009Q1 2009Q2 2009Q3 2009Q4 2010Q1 2010Q2 2010Q3 2010Q40
1000
2000
3000
4000
5000
6000
7000
8000Hydrogen Dispensed By Quarter - ARRA
Hyd
rog
en D
isp
ense
d [
kg]
Cumulative Hydrogen Dispensed = 18,597 kg
0
1
2
3
4
5
6
7
8
9
10
Cu
mu
lati
ve A
mo
un
t [1
000
kg]
All Sites By QuarterCumulative By Site
NREL cdparra_mhe_04
Created: Mar-21-11 3:40 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-05Refueling Time of Day
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 240
200
400
600
800
1000
1200
1400
1600Refueling Time of Day - ARRA
Time of Day [hours]
Nu
mb
er o
f R
efu
elin
gs
NREL cdparra_mhe_05
Created: Mar-03-11 9:22 AM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-06Histogram of Fueling Times
0 1 2 3 4 5 6 7 8 9 100
1000
2000
3000
4000
5000
6000
Time (min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling TimesARRA Combined Fleet Through 2010Q4
38,795 Events Average = 1.83 min
NREL cdparra_mhe_06
Created: Mar-23-11 3:38 PM Fill data for class 1, 2, and 3 trucks
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-07Tank Pressure Level at Fueling
Tank Pressure At Fill: ARRA
FE16
%
NREL cdparra_mhe_07
Created: Mar-22-11 4:33 PM
1. Some refueling events not recorded/detected due to data noise or incompleteness.2. The outer arc is set at 30% total refuelings.3. Full Pressure is either 3600 psi or 5000 psi.
Total refuelings1 = 10100Median Tank Pressure (At Fill) = 27%
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-08Operation Time between Fueling
0 2 4 6 8 10 120
200
400
600
800
1000
1200
Average: 5.0 hours
Operating Time Between Fuelings - ARRACombined Fleet Through 2010Q4
Operating Hours Between Fuelings1,2
Co
un
t
Range of0
2
4
6
8
Site Averages
Ave
rag
e O
p H
rs b
etw
een
Fu
elin
gs
NREL cdparra_mhe_08
Created: Mar-22-11 10:26 AM Excludes Data > 12 hours
1) Some fueling events not recorded/detecteddue to data noise or incompleteness.2) Data indicative of actual use and does notrepresent the max capability of the systems.
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-09Histogram of Fueling Rates
0 0.2 0.4 0.6 0.8 1 1.20
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Avg Fuel Rate (kg/min)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling RatesARRA Combined Fleet Through 2010Q4
38,795 Events Average = 0.33 kg/min
Range of0
0.1
0.2
0.3
0.4
0.5
Site Averages
Ave
rag
e F
uel
ing
Rat
es
NREL cdparra_mhe_09
Created: Mar-24-11 9:50 AM Fill data for class 1, 2, and 3 trucks
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-10Histogram of Fueling Amounts
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20
1000
2000
3000
4000
5000
6000
Amount Fueled (kg)
Nu
mb
er o
f F
uel
ing
Eve
nts
Histogram of Fueling AmountsARRA Combined Fleet Through 2010Q4
Average = 0.48 kg
NREL cdparra_mhe_10
Created: Mar-23-11 3:35 PM Fill data for class 1, 2, and 3 trucks
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-11Fuel Cell Operation Hours by Quarter
2010 Q1 2010 Q2 2010 Q3 2010 Q40
20000
40000
60000
80000
100000
120000
To
tal O
per
atio
n H
ou
rs
Fuel Cell Operation Hours by Quarter - ARRA
Total Hours = 307,433
0
20
40
60
80
100
120
140
160
180
Cu
mu
lati
ve F
leet
Ho
urs
[10
00]
All FleetsIndividual Fleet
NREL cdparra_mhe_11
Created: Mar-30-11 3:46 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-12Fuel Cell System Maintenance by Category
10%10%
11%
12%
14%
Number of EventsTotal Events = 1149
83% were unscheduled
6%
9%
11%11%
22%
6%
13%
Labor HoursTotal Hours = 1676
87% were unscheduled
THERMAL MANAGEMENT
SENSORS
ENERGY STORAGE SYSTEM
PREVENTATIVE MAINTENANCE
ELECTRICAL
FUEL SYSTEM
CONTROL ELECTRONICS
UPGRADE
SOFTWARE
OTHER
AIR SYSTEM
MISC
NREL cdparra_mhe_12
Created: Mar-30-11 4:58 PM
Fuel Cell System Maintenance By Category - ARRAAll ARRA Sites Thru 2010Q4
MISC includes the following categories:FC STACK
MANUFACTURING DEFECTVALVES
ACTUATORSSERVICE
OPERATOR PROTOCOL
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-13Fuel Cell System Scheduled and Unscheduled Maintenance by Category
0 20 40 60 80 100 120 140 160
MISCAIR SYSTEM
OTHERSOFTWARE
UPGRADECONTROL ELECTRONICS
FUEL SYSTEMELECTRICAL
PREVENTATIVE MAINTENANCEENERGY STORAGE SYSTEM
SENSORSTHERMAL MANAGEMENT
Fuel Cell System Maintenance Scheduled vs. Unscheduled - ARRANumber of Maintenance Events by Category
Number of Events
Total Events = 114983% were unscheduled Scheduled
Unscheduled
0 50 100 150 200 250 300 350 400
MISC
FC STACK
SOFTWARE
CONTROL ELECTRONICS
SENSORS
AIR SYSTEM
FUEL SYSTEM
PREVENTATIVE MAINTENANCE
ELECTRICAL
THERMAL MANAGEMENT
ENERGY STORAGE SYSTEM
Number of Labor Hours by Category
Hours
Total Hours = 167687% were unscheduled Scheduled
Unscheduled
NREL cdparra_mhe_13
Created: Mar-30-11 4:58 PM
MISC includes the following categories:FC STACK
MANUFACTURING DEFECTVALVES
ACTUATORSSERVICE
OPERATOR PROTOCOL
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-14Average Fuel Cell System Maintenance by Quarter
0
50
100
150
200
250
300
350
400
450Maintenance Events
# o
f E
ven
ts
10Q
1
10Q
2
10Q
3
10Q
4
0
100
200
300
400
500
600
700
Maintenance Hours
Ho
urs
10Q
1
10Q
2
10Q
3
10Q
4
ScheduledUnscheduledOperator
NREL cdparra_mhe_14
Created: Mar-30-11 4:58 PM
Average Fuel Cell System Quarterly Maintenance -ARRA
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-15Operating Time at Fuel Cell Voltage Levels
0 10 20 30 40 50 60 70 80 90 100 >1000
5
10
15
20
25
30
% Rated Max Fuel Cell Voltage
% F
uel
Cel
l Op
erat
ing
Tim
e
Operating Time at Fuel Cell Voltage Levels - ARRA
NREL cdparra_mhe_15
Created: Mar-22-11 4:41 PM
1
1) 100% max fuel cell voltage is approximately open-circuit voltage
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-16Operating Time at Fuel Cell Current Levels
0 10 20 30 40 50 60 70 80 90 1000
5
10
15
20
25
30
% Rated Max Fuel Cell Current
% F
uel
Cel
l Op
erat
ing
Tim
e
Operating Time at Fuel Cell Current Levels - ARRA
NREL cdparra_mhe_16
Created: Mar-22-11 4:41 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-17Operating Time at Fuel Cell Power Levels
0 10 20 30 40 50 60 70 80 90 100 >1000
5
10
15
20
25
% Rated Max Fuel Cell Power
% F
uel
Cel
l Op
erat
ing
Tim
e
Operating Time at Fuel Cell Power Levels - ARRA
NREL cdparra_mhe_17
Created: Mar-22-11 4:41 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-18Infrastructure Maintenance by Category
9%
10%
13%23%
31%
Number of EventsTotal Events = 363
87% were unscheduled
8%
8%
10%
13% 35%
20%
Labor HoursTotal Hours = 2427
87% were unscheduled
H2 production unit
compressor
preventative maintenance
dispenser
system control & safety
valves & piping
MISC
NREL cdp_mhe_18
Created: Mar-18-11 9:20 AM
Infrastructure Maintenance By CategoryAll Sites Thru 2010Q4
MISC includes the following categories:Data collection
electricalother
storage
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-19Infrastructure Scheduled & Unscheduled Maintenance by Category
0 20 40 60 80 100 120
MISC
valves & piping
system control & safety
dispenser
preventative maintenance
compressor
H2 production unit
Infrastructure Maintenance Scheduled vs. UnscheduledNumber of Maintenance Events by Category
Number of Events
Total Events = 36387% were unscheduled Scheduled
Unscheduled
0 100 200 300 400 500 600 700 800 900
MISC
valves & piping
system control & safety
dispenser
preventative maintenance
H2 production unit
compressor
Number of Labor Hours by Category
Hours
Total Hours = 242787% were unscheduled Scheduled
Unscheduled
NREL cdp_mhe_19
Created: Mar-18-11 9:20 AM
MISC includes the following categories:Data collection
electricalother
storage
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-20Infrastructure Maintenance by Quarter
0
50
100
150Maintenance Events
# o
f E
ven
ts
10Q
1
10Q
2
10Q
3
10Q
4
0
100
200
300
400
500
600
700
Maintenance Hours
Ho
urs
10Q
1
10Q
2
10Q
3
10Q
4
ScheduledUnscheduled
NREL cdp_mhe_20
Created: Mar-18-11 9:20 AM
Average Infrastructure Site Quarterly Maintenance
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-21Average Daily Hydrogen Dispensed by Location
Average Daily Hydrogen Dispensed by Location - ARRA
1-10
11-20
21-30
31-40
41-50
51-60
61-70
71-80
81-90
91-100
>100
NREL cdparra_mhe_21
Created: Mar-10-11 10:45 AM
18597 kg Hydrogen Dispensed
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-22Average Daily Dispensing Operations by Site
Hydrogen Use0
10
20
30
40
Avg
Dai
ly k
g
Hydrogen Use0
0.2
0.4
0.6
0.8
1
Avg
Dai
ly k
g/s
yste
m
Fill Frequency0
20
40
60
80
100
Avg
Dai
ly f
ills
Fill Frequency0
0.5
1
1.5
Avg
Dai
ly f
ills/
syst
em
NREL cdparra_mhe_22
Created: Mar-09-11 6:50 PM
Average Daily Dispensing Operations by Site - ARRA
Shaded areas represent the min and max site average hydrogen use and fill frequency
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-23Average Daily Fuel Cell Operation Hours per Fleet
A B C D E0
1
2
3
4
5
6
7
8
9
10
Fleet
Ho
urs
Average Daily Fuel Cell Operation Hours per System - ARRA
25th and 75th PercentileMedian
NREL cdparra_mhe_23
Created: Mar-24-11 11:50 AM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-24Average Daily Fuel Cell Operation Hours per System
0 1 2 3 4 5 6 7 8 9 10 11 120
2
4
6
8
10
Hours of Operation Per Day
Day
s o
f O
per
atio
n [
%]
Fuel Cell System Operation Hours Per Day
0 1 2 3 4 5 6 7 8 9 10 11 120
2
4
6
8
10
Average Hours of Operation Per Day
Fu
el C
ell S
yste
ms
[%]
Average Daily Fuel Cell System Operation Hours
48.7% Fuel Cell SystemsAverage > 6 Hours Daily
NREL cdparra_mhe_24
Created: Mar-22-11 1:03 PM
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-25Infrastructure Safety Reports by Quarter
2010 Q1 2010 Q2 2010 Q3 2010 Q40
5
10
15
20
25
30
Nu
mb
er o
f R
epo
rts
Infrastructure Safety Reports By Quarter
Incident2
Near Miss1
NREL cdp_mhe_25
Created: Mar-10-11 2:09 PM
1) Near Miss is an event that under slightly different circumstances could have become an incident -unplanned H2 release insufficient to sustain a flame
2) 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 uses as common fuels)
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-26Fuel Cell System Safety Reports by Quarter
2010 Q1 2010 Q2 2010 Q3 2010 Q40
5
10
15
20
25
30
35
40
45
50
Nu
mb
er o
f R
epo
rts
Fuel Cell System Safety Reports by Quarter - ARRA
Incident2
Near Miss1
NREL cdparra_mhe_26
Created: Mar-29-11 2:34 PM
1) Near Miss is an event that under slightly different circumstances could have become an incident -unplanned H2 release insufficient to sustain a flame
2) 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 uses as common fuels)
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-27Fuel Cell System Safety Reports by Severity and Type
0 10 20 30 40 50 60
Incident
Near Miss
Number of Reports
Sev
erit
y
Fuel Cell System Safety Reports by Severity - ARRA and Report Type 2010Q4
Electrical IssueH2 Release - Minor, NO IgnitionH2 Release - Significant, NO Ignition
NREL cdparra_mhe_27
Created: Mar-29-11 2:35 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
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-28Fuel Cell System Reliability Growth by Site for Quarter
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-29Fuel Cell System Reliability Growth by Top 4 Categories
0
0.5
1
1.5
2
2.5
3
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
ENERGY STORAGE SYSTEM
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
THERMAL MANAGEMENT
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
OPERATOR PROTOCOL
Failure Rate Increasing
Failure Rate Decreasing
Fleet
0
0.5
1
1.5
2
2.5
3
Average Vehicle Operating Hours
Sh
ape
Par
amet
er (
)*
SENSORS
Failure Rate Increasing
Failure Rate Decreasing
Fleet
NREL cdp_mhe_29
Created: Apr-05-11 4:40 PM *IEC 61164 *IEC 61164 *IEC 61164 *IEC 61164
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-30Fuel Cell System Mean Time Between Failure
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-31Fuel Cell System Mean Time Between Scheduled Maintenance
0 1000 2000 3000 4000 5000 60000
2
4
6
8
10
12
14
16
18
20
Unit MTBSM1
% o
f u
nit
s
Individual Unit MTBSM1 All Sites
0 1000 2000 3000 4000 5000 60000
2
4
6
8
10
Unit MTBPM2
% o
f u
nit
s
Individual Unit MTBPM2 All Sites
0 1000 2000 3000 4000 5000 60000
2
4
6
8
10
Unit MTBU3
% o
f u
nit
s
Individual Unit MTBU3 All Sites
NREL cdp_mhe_31
Created: Apr-05-11 1:41 PM
1Mean Time Between Scheduled Maintenance. Includes Preventative and Upgrades
2Mean Time Between PreventativeMaintenance
3Mean Time Between Upgrade
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-32 Site Operation Hours and Voltage Durability
Site Max Op Hours(1) Site Ave Op Hours(1)0
2000
4000
6000
8000
10000
4842
3959
Max of Site Projections59519
Ave of Site Projections53002
Ho
urs
Operation Hours and Projected Hours to 10% Voltage Drop(2-4)
NREL cdp_mhe_32
Created: Mar-24-11 10:55 AM
(1) Range bars created using one data point for each fleet. Some stacks have accumulated hours beyond 10% voltage degradation.(2) 10% voltage drop level is a DOE metric for assessing fuel cell performance.(3) Projections using field data and calculated at a high stack current.(4) 10% voltage drop is NOT an indication of an OEM's end-of-life criteria and projections do not address catastrophic stack failure.(5) Each site has one voltage projection value that is the weighted average of the site's fuel cell stack projections.
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-33 Fuel Cell Stack Voltage Durability as a Function of Voltage Drop Levels
10 15 20 25 300
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Fuel Cell Stack Durability as a Function of Voltage Drop4
% Voltage Drop
Pro
ject
ed H
ou
rs2,
3
25th/75th Quartile Projections3,5
Average Fleet Projection1,5
Max Fleet Projection1,5
NREL cdp_mhe_33
Created: Mar-24-11 10:55 AM
(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life cri teria.(2) Projections using field data and calculated at high stack current.(3) 25th and 75th percentiles spans the range of stack projection. The included stacks satisfy a minimum number of operation hours and weighting factor.(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) Each site has one voltage projection value that is the weighted average of the sites's fuel cell stack projections.
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-34 Fuel Cell Stack Power Degradation over Time
0
20
40
60
80
100
120
0 200 400 600 800 1000120014001600180020002200240026002800300032003400360038004000Stack Op Hour Segments(2)
% P
ow
er(1
)
Max Fuel Cell Stack Power Degradation Over Operation
1) Normalized by fleet maximum power.2) Each segment point is median FC power (+-100 hrs). Box not drawn if fewer than 3 points in segment.
Data Range25th & 75th PercentilesGroup MedianOutlier
NREL cdp_mhe_34
Created: Mar-24-11 10:56 AM
Median power differencefrom 0 hour segment to3800 hour segment = -12.2%
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-35Dispensed Hydrogen by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
5
10
15
20
25Refueling by Day of Week
% o
f F
ills
in a
Day
DayNREL cdparra_mhe_35
Created: Mar-10-11 9:35 AM
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-37Fuel Cell System Downtime
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 180
20
40
60
80
100
120
Average of 2.3 hours of downtimefrom refueling each month
Refueling Downtime1 (in hours) per Month
Fre
qu
ency
[M
on
ths]
Refueling Downtime Per Material Handling Unit
Fleet Averages
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150
20
40
60
80
Average of 2.5 hours of downtimefrom refueling per 100 hours of operation
Refueling Downtime (in hours) per 100 Operational Hours
Fre
qu
ency
[U
nit
s]
Fleet Averages
NREL cdparra_mhe_37
Created: Mar-10-11 10:21 AM
1 Refueling downtime represents total refueling time from "drive-up" to "drive-away" not only hydrogen gas dispensing time
Note: Some refueling events not recorded/included due to data noise or incompleteness
NATIONAL RENEWABLE ENERGY LABORATORY
CDPARRA-MHE-40Site Summary
Forklift Units (I,II,III) 0,26,72 0,14,0 35,0,0 25,0,0 45,14,2 0,36,100 40,0,0 0,25,70Operation
Shifts per Day 2 2 3 1-2 3 2 2 3Hours per Shift 8-10 9.5 8 10 8 8-10 8 8Days per Week 6 N/A N/A 7 7 6 6 6
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-41Infrastructure Safety Categories
0 2 4 6 8 10 12 14 16
Incident
Near Miss
Number of Reports
Sev
erit
y
Infrastructure Safety Reports by Severity - All Sites and Report Type 2010Q4
Alarms OnlyEquipment MalfunctionH2 Release - Minor, NO IgnitionNon-H2 ReleaseOther 1 (user defined)Structural Issue
NREL cdp_mhe_41
Created: Mar-09-11 2:26 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
NATIONAL RENEWABLE ENERGY LABORATORY
CDP-MHE-42Amount of Hydrogen Dispensed by Day of Week
Sun Mon Tues Wed Thur Fri Sat0
2
4
6
8
10
12
14
16
18
20
Dis
pen
sed
Hyd
rog
en [
% o
f to
tal]
Day of Week
Dispensed Hydrogen per Day of Week
0
5
10
15
20
25
30
35
40
45
50
Ave
rag
e kg
All SitesIndividual Site
NREL cdparra_mhe_42
Created: Mar-29-11 4:19 PM