Orange County Transportation Authority

Fuel Cell Electric Bus Progress Report

Data Period Focus: Feb. 2020 through Jul. 2021

Elizabeth Collins and Matthew Post

July 2022

NREL/TP-5700-83558
 Table of Contents
Introduction…………………………………………………………. 4
Fleet Profile………………………………………………………….. 5
Results Summary………………………………………............. 8
Evaluation Buses Specification……………….……………… 14
Infrastructure Description…………………………………….. 16
Data Summary………………………………………………………. 17
Fleet Mileage Accumulation……………….………… 20
Availability Analysis………………………………………. 23
Fuel Economy and Cost Analysis………………...... 30
Reliability—Miles Between Roadcall…………….. 38
Maintenance Cost Analysis…………………………… 40
Contacts…………………………………………………………………… 96
Acronyms and Abbreviations....................................... 97
Appendix: Fleet Summary Statistics ……………….……. 100

NREL | 2
 Introduction
This report presents early results from a deployment of fuel cell electric buses (FCEBs) operated by
Orange County Transportation Authority (OCTA) in Southern California. The ten FCEBs, produced by
New Flyer, feature an electric drive propulsion system powered by a Ballard fuel cell system. The
project team is collaborating with the U.S. Department of Energy (DOE) and DOE’s National
Renewable Energy Laboratory (NREL) to evaluate the buses in revenue service.
The goal of this evaluation is to compare the FCEB performance to that of conventional technology
and to track progress over time toward meeting the technical targets set by DOE and the
Department of Transportation (DOT). The FCEBs were delivered beginning in late-2019, and were
placed in service on February 9, 2020. The data period covers February 2020 through July 2021.
NREL collects data on ten 2016 model year compressed natural gas (CNG) buses as a baseline
comparison at OCTA.

Each NREL evaluation tracks data and performance results for a specific transit agency operating a specific manufacturer’s
technology design. Results from different OEM designs will vary and are not necessarily representative of a specific
technology. Results also will vary from agency to agency and even between facilities within the same agency. Readers
should keep this in mind when using these results for decision making.
NREL | 3
 Results Summary
Bus fleets: This evaluation includes ten 40-ft FCEBs built by New Flyer with an electric propulsion
system and a Ballard fuel cell system. The baseline buses are ten 2016 model year New Flyer 40-ft
CNG buses.
Bus use: OCTA’s average speed for its operation is around 13 mph. The agency reduced service in
March 2020 due to the COVID-19 pandemic.
Fuel economy and cost: The FCEBs had an average fuel economy of 8.39 miles per kilogram of
hydrogen, which equates to 9.48 mpdge. The CNG buses had an average fuel economy of 3.77
mpgge, which equates to 4.22 mpdge. The FCEB fuel economy was approximately 2.3 times that
of the CNG buses. Average hydrogen costs were $8.48/kg; CNG cost was $1.12/gge. The FCEBs
had an average fuel cost of $1.01 per mile. The fuel cost for the CNG buses averaged $0.36 per
mile.
Fuel use: During the data period, OCTA fueled its FCEB fleet more than 2,530 times with an
average fill amount of 20.17 kg. Daily dispensed hydrogen was 96 kg.
mpdge = miles per diesel gallon equivalent
mpgge = miles per gasoline gallon equivalent NREL | 4
 Results Summary (continued)
Availability: The average availability for the FCEB fleet was 62.5%. Most unavailable time for the
FCEBs was due to general bus-related problems followed by battery issues. This is not unusual for
a new design in its first deployment. OCTA is working with the OEM to identify the issues. The
availability for the fleet is expected to increase over time as these early issues are resolved. The
average availability for the fuel cell system was 94.9%. OCTA reports that its CNG bus availability
averages 80% or better.
Maintenance cost: The cost to maintain the buses in the data period was $0.46/mi for the FCEBs
and $0.66/mi for the CNG buses. Propulsion-system maintenance was $0.12 for the FCEBs
compared to $0.29 for the CNG buses.
Note that the FCEBs are under warranty and most repairs are covered by the OEM. Much of the
cost is labor to troubleshoot issues.

NREL | 5
 Fleet Profile
The Orange County Transportation Authority―OCTA
― is Orange County California’s transportation
agency, responsible for planning, financing and
coordinating the county’s freeway, street and rail
development, as well as managing countywide bus
and paratransit service, rail service, and the 91
Express Lanes. The agency’s 62 fixed bus routes
include local, community, express, and rail-
connection service. The service area for OCTA covers
34 cities and unincorporated Orange County,
California.

OCTA website: http://www.octa.net/default.aspx. NREL | 6

 Evaluation Buses
Vehicle System FCEB CNG FCEB
Number of buses 10 10
Bus manufacturer/model New Flyer, Xcelsior New Flyer, Xcelsior
Model year 2018 2016
Bus purchase cost* ($) 1.3 M 580,000
Length/width/height 41 ft/102 in./129.6 in. 40 ft/102 in./130.8 in.
Curb weight (lb.) 33,500 30,000
GVWR (lb.) 44,533 42,290
Hybrid system
Siemens ELFA2, Permanent
N/A
CNG
Electronic Motor, 210 kW
Ballard FCvelocity-HD85, Cummins Westport ISL G
Fuel cell or engine
85 kW 280 hp @ 2,200 rpm
A123 Systems, lithium-ion,
Energy storage N/A
100 kWh
Accessories Electric Electric and Mechanical
Gaseous hydrogen, 5 Type 4
CNG, 6 cylinders, * Cost includes OCTA equipment,
composite cylinders,
Fuel capacity Lincoln Composites such as information technology
Agility Fuel Solutions,
156 gge at 3,600 psi equipment.
37.5 kg at 5,000 psi NREL | 7
 Infrastructure Description
OCTA’s fueling station provides fuel to the FCEB fleet through liquid hydrogen delivery
and storage. The new station was built in 2019 – fully commissioned in April of that
year. The station includes an 18,000-gallon cryogenic storage tank. Two hydrogen
dispensers, installed in line with the CNG fueling island, allow the FCEBs to be handled
the same as the CNG bus fleet. Pre-cooling units operate at 10°C to help achieve a full
fill without overheating the tanks.

NREL | 8
 Data Summary
Data Item FCEB CNG
Number of buses 10 10
Data period 2/20–7/21 2/20–7/21
Number of months 18 18
Total mileage in data period 427,885 808,781
Average odometer 50,094 255,920
Average monthly mileage per bus 2,510 4,541
Total FCPPa hours 34,849 —
Availability (85% is target) 62.5 73
Fuel economy (FCEB mi/kg or CNG mpggeb) 8.39 3.77
Fuel economy (mpdgec) 9.48 4.22
Miles between roadcalls (MBRC) – busd 6,275 27,244
MBRC – propulsion system onlyd 8,964 38,920
MBRC – FC System onlyd 109,807 —
Total maintenance ($/mile) 0.46 0.66
Maintenance – propulsion system only ($/mile) 0.14 0.23
a FCPP= fuel cell power plant
b Miles per gasoline gallon equivalent.
c Miles per diesel gallon equivalent.
d MBRC for the FCEB data cumulative from the clean point of February 2020 through July 2020.
NREL | 9
FCEB Total Miles and Hours

Totals
Miles = 439,277
Hours = 34,849

NREL | 10
 Fleet Average Monthly Miles by Bus
Average Average
Bus Bus
Bus Miles Monthly Bus Miles Monthly
Months Months
Mileage Mileage
1111 48,444 18 2,691 5821 90,186 18 5,010
1112 34,002 18 1,889 5822 92,906 18 5,161
1113 46,449 18 2,580 5823 78,675 18 4,371
1114 49,018 18 2,723 5824 85,307 18 4,739
1115 39,565 18 2,198 5825 81,587 18 4,533
1116 52,477 18 2,915 5826 73,581 18 4,088
1117 49,621 18 2,757 5827 79,965 18 4,443
1118 44,929 18 2,496 5828 88,464 18 4,915
1119 37,420 13 2,878 5829 68,514 18 3,806
1120 37,302 18 2,072 5830 78,137 18 4,341
FCEB Fleet 439,227 175 2,510 CNG Fleet 817,321 180 4,541
Bus 1119 was being used for upgrade/testing during the early data period. Clean point is July 2020. NREL | 11
Average Monthly Miles

Overall
• FCEB = 2,510
• CNG = 4,541

NREL | 12
 Availability Analysis
Availability, which is a measure of reliability, is presented as the percentage of days the buses are
actually available out of days that the buses are planned for passenger service. Buses available for
service may have been used in passenger service, training, or for special events, or they may have been
available but just not used. Buses unavailable for service may have had issues with the propulsion
system (fuel cell system, electric drive system), general bus maintenance, or undergoing scheduled
maintenance. Accidents are removed from the data—the bus is considered “not planned” during the
repair time.
The data presented are based on availability for morning pull-out and don’t necessarily reflect all-day
availability. Transit agencies typically have a target of 85% availability for their fleets to allow for time to
handle scheduled and unscheduled maintenance. For OCTA, NREL calculates availability based on the
planned service days, which are typically every day. OCTA provides daily bus availability for the FCEBs
and a reason for unavailability. Reasons for availability are based on the current open work orders. In
some cases, a bus is down for multiple reasons. For those days, the unavailability reason is split between
categories. For example, if a bus has open work orders for both general bus repair and PM, each
category would be credited for 0.5 unavailable days.
NREL presents availability as a monthly average trend and as overall availability. Unavailable time is
separated into several categories to show the primary reason for downtime.
NREL | 13
Availability/Unavailability Summary

Category FCEB # Days FCEB %

Planned work days 5,247
Days available 3,281 62.5
Days unavailable 1,966 37.5
Fuel cell system 269.4 5.1
Electric drive 8.0 0.2
Battery related 207.2 3.9
General bus maintenance 1073.4 20.5
Preventive maintenance (PM) 406.9 7.8
CNG baseline bus fleet availability is 80% or greater

NREL | 14
Monthly Availability

NREL | 15
FCEB Monthly Unavailability Reasons

NREL | 16
FCEB Overall Availability

NREL | 17
 Fuel Economy and Cost Analysis
OCTA provides individual fueling records for the FCEBs and CNG buses. CNG is typically
dispensed in units of gge. NREL uses these records to calculate the CNG fuel economy
in mpgge as well as mpdge. Hydrogen is tracked in kilograms; 1 kg of hydrogen has
essentially the same energy content as a gallon of gasoline. To compare the fuel
economy of the FCEBs to that of the baseline buses, NREL converts kg hydrogen to dge.
Conversions:
gge CNG * 0.895 = dge
kg H2 * 0.885 = dge

OCTA provides monthly cost of hydrogen per kg and CNG per therm.
The average cost of hydrogen during the evaluation period was $8.10/kg. The CNG fuel
cost for the data period was $1.22 per gge.

NREL | 18
 Fuel Economy by Bus
Diesel Fuel Fuel
Hydrogen Miles per
Bus Miles mi/kg gallon economy Bus Miles CNG (gge) CNG (dge) Economy
(kg) gge
Equiv. (mpdge) (mpdge)

1111 51,453 6,493.4 7.92 5,746.4 8.95 5821 89,045 22,055.3 4.04 19,739.5 4.51
1112 30,239 3,625.8 8.34 3,208.6 9.42 5822 92,668 23,900.2 3.88 21,390.7 4.33
1113 43,820 5,161.4 8.49 4,567.6 9.59 5823 78,524 23,335.7 3.36 20,885.5 3.76
1114 46,937 5,451.0 8.61 4,823.9 9.73 5824 84,309 20,763.4 4.06 18,583.2 4.54
1115 38,540 4,674.2 8.25 4,136.5 9.32 5825 80,859 21,845.8 3.70 19,552.0 4.14
1116 51,574 5,835.4 8.84 5,164.1 9.99 5826 73,682 19,545.2 3.77 17,492.9 4.21
1117 48,285 5,933.7 8.14 5,251.1 9.20 5827 78,809 20,579.5 3.83 18,418.6 4.28
1118 43,369 5,218.9 8.31 4,618.5 9.39 5828 87,069 22,330.4 3.90 19,985.7 4.36
1119 37,420 4,301.7 8.70 3,806.8 9.83 5829 66,013 18,516.0 3.57 16,571.8 3.98
1120 36,247 4,331.2 8.37 3,832.9 9.46 5830 77,805 21,386.6 3.64 19,141.0 4.06
FCEB Fleet 427,885 51,026.7 8.39 45,156.4 9.48 CNG Total 808,781 214,258.0 3.77 191,760.9 4.22

• FCEB fuel economy is 2.25 times that of the CNG buses.

NREL | 19
 Monthly Average Fuel Economy

*Average monthly high temperatures at John Wayne Airport in Santa Ana, CA. Data acquired from www.ncdn.noaa.gov NREL | 20
Monthly Average Fuel Cost Per Mile

Average fuel cost

• H2 = $8.44 /kg
• CNG = $1.25 /gge

Average cost per mile

• H2 = $1.01
• CNG = $0.33

NREL | 21
 Fleet Hydrogen Use
4000 30

3500
25
3000
20
Overall
Hydrogen Fuel (kg)

2500
Daily kg Hydrogen: 95.56

kg per fill
2000 15
H2 kg/fill: 20.17
1500
10
1000
5
500

0 0

Hydrogen dispensed Average kg/fill

NREL | 22
 Roadcall Analysis
A roadcall or revenue vehicle system failure is defined as a failure of an in-service bus that causes
the bus to be replaced on route or causes a significant delay in schedule. If the problem with the
bus can be repaired during a layover and the schedule is kept, this is not considered a roadcall.
The analysis described here includes only roadcalls that were caused by “chargeable” failures.
Chargeable roadcalls include systems that can physically disable the bus from operating on route,
such as interlocks (doors, air system), engine, or things that are deemed to be safety issues if
operation of the bus continues. They do not include roadcalls for things such as problems with
radios, fareboxes, or destination signs.
The transit industry measures reliability as mean distance between failures, also documented as
MBRC. NREL tracks MBRC by total roadcalls, propulsion-related roadcalls, and fuel cell (FC)
system-related roadcalls. Total roadcalls includes all chargeable roadcalls. “Propulsion-related
roadcall” is a subset of total roadcalls and includes all roadcalls due to propulsion-related systems
including the FC system (or engine for a conventional bus), electric drive, fuel, exhaust, air intake,
cooling, non-lighting electrical, transmission systems, and hydraulics. The FC system-related
roadcalls, a subset of the propulsion-related roadcalls, and MBRC are included for the FCEBs.
NREL | 23
Cumulative MBRC

FCEB CNG
Bus MBRC 6,275 27,244
Propulsion
8,964 38,920
MBRC
FC system
109,807 N/A
MBRC

NREL | 24
 Maintenance Analysis
NREL collects all work orders for the evaluation buses to calculate a maintenance cost per mile. Costs for
accident-related repairs which are extremely variable from bus to bus, were eliminated from the analysis.
Warranty costs are not included in the cost-per-mile calculations because those costs are covered in the
capital cost of the buses. For consistency, NREL uses a constant $50 per hour. This does not reflect an
average rate for OCTA. Cost per mile is calculated as follows:
Cost per mile = [(labor hours * 50) + parts cost)] / mileage
NREL calculates total cost per mile, scheduled maintenance cost per mile, and unscheduled maintenance
cost per mile. NREL also categorizes maintenance cost by system to provide insight into which systems have
the most costs for each technology. Parts for scheduled maintenance, such as filters and fluids, are included
in the specific system categories. For example, oil and oil filters are included in the power plant (engine)
subsystem parts costs, while air filters are included in the air intake subsystem parts costs.
The propulsion system costs are of particular interest. Propulsion-related vehicle systems include the
exhaust, fuel, engine, FC system, battery modules, electric propulsion, air intake, cooling, non-lighting
electrical, transmission systems, and hydraulics. These systems have been separated to highlight
maintenance costs most directly affected by the advanced propulsion system changes for the buses.
NREL | 25
 Maintenance Analysis Results
Labor Total Cost per Labor Total Cost per
Bus Mileage Parts ($) Bus Mileage Parts ($)
hours Mile ($) hours Mile ($)
1111 48,444 5,578.48 373.9 0.50 5821 90,186 24,839.74 648.0 0.63
1112 34,002 3,175.58 297.0 0.53 5822 92,906 38,808.85 860.3 0.88
1113 46,449 5,592.92 426.8 0.58 5823 78,675 22,583.38 537.5 0.63
1114 49,018 4,677.07 368.5 0.47 5824 85,307 19,072.31 650.5 0.60
1115 39,565 4,502.45 248.8 0.43 5825 81,587 19,720.90 642.0 0.64
1116 52,477 3,913.35 343.6 0.40 5826 73,581 18,225.86 600.7 0.66
1117 49,621 5,871.03 378.0 0.50 5827 79,965 20,996.82 596.8 0.64
1118 44,929 2,859.72 309.3 0.41 5828 88,464 16,921.16 678.6 0.57
1119 37,420 1,988.18 252.2 0.39 5829 68,514 26,166.63 579.0 0.80
1120 37,299 1,574.54 272.8 0.41 5830 78,137 21,033.76 498.8 0.59
FCEB Fleet 439,224 39,733.32 3,270.8 0.46 CNG Fleet 817,321 228,369.41 6,292.1 0.66

Note: the FCEBs are under warranty, while the CNG buses are not under warranty.

NREL | 26
Scheduled and Unscheduled Maintenance Cost

NREL | 27
Parts and Labor Maintenance Cost

NREL | 28
 Maintenance Cost by System
The vehicle systems include the following:
• Propulsion-related systems—Repairs for exhaust, fuel, engine, electric motors, fuel cell
modules, battery modules, propulsion control, non-lighting electrical (charging, cranking, and
ignition), air intake, cooling, hydraulics, and transmission
• Cab, body, and accessories—Includes body, glass, and paint repairs following accidents; cab
and sheet metal repairs on seats and doors; and accessory repairs such as hubodometers and
radios
• PMI (preventive maintenance inspections)—Labor for preventive maintenance
• Brakes
• Frame, steering, and suspension
• Heating, ventilation, and air conditioning (HVAC)
• Lighting
• Axles, wheels, and drive shaft
• Air system, general
• Tires
NREL | 29
 Maintenance Cost per Mile by System
FCEB CNG Color coding:
Highest cost
System Cost per Percent of Cost per Percent of
Mile ($) Total (%) Mile ($) Total (%)
Second highest cost
Propulsion-related 0.119 25.8 0.288 43.4
Cab, body, and accessories 0.173 37.4 0.170 25.6
PMI 0.096 20.7 0.070 10.5
Third highest cost
Brakes 0.008 1.8 0.066 9.9
Frame, steering, and suspension 0.011 2.3 0.012 1.8
HVAC 0.007 1.5 0.011 1.7
Lighting 0.004 0.8 0.006 0.9
Air, general 0.036 7.9 0.029 4.4
Axles, wheels, and drive shaft 0.006 1.3 0.011 1.7
Tires 0.003 0.6 0.001 0.1
Total 0.462 100 0.664 100

• For the FCEB fleet, the systems with the highest cost were propulsion-related; cab, body, and accessories; and
PMI. For the CNG fleet, the systems with the highest cost were also propulsion-related; cab, body, and
accessories; and PMI.
• Overall costs for the FCEBs are similar to that of the CNG buses.
NREL | 30
Maintenance Cost by System: FCEBs

NREL | 31
Maintenance Cost by System: CNG Buses

NREL | 32
 Propulsion-Related Maintenance Costs by Subsystem
Maintenance System FCEB CNG Maintenance System FCEB CNG
Mileage 439,224 817,321 Non-Lighting Electrical Parts cost ($) 315.50 34,256.73
Total Propulsion- Parts cost ($) 15,868.70 136,716.19 System (General Electrical, Labor hours 131.0 185.0
Related Systems Labor hours 731.5 1,974.3 Charging, Cranking, Total cost ($) 6,865.50 43,506.73
(Total of all systems in Total cost ($) 52,443.70 235,428.69 Ignition) Total cost ($) per mile 0.016 0.053
table) Total cost ($) per mile 0.119 0.288 Parts cost ($) 1,079.23 3,323.65
Parts cost ($) 0.00 5,753.34 Labor hours 0.0 31.0
Labor hours 0.0 55.5 Air Intake System
Exhaust System Total cost ($) 1,079.23 4,873.65
Total cost ($) 0.00 8,528.34 0.002 0.006
Total cost ($) per mile
Total cost ($) per mile 0.000 0.010
Parts cost ($) 344.59 4,064.72
Parts cost ($) 116.50 18,737.30
Labor hours 33.0 246.8
Labor hours 120.0 720.5 Cooling System
Fuel System Total cost ($) 1,994.59 16,402.22
Total cost ($) 6,116.50 54,762.30
Total cost ($) per mile 0.014 0.067 Total cost ($) per mile 0.005 0.020
Parts cost ($) 12,999.46 19,058.42 Parts cost ($) 0.00 51,510.46
Powerplant System Labor hours 1.0 118.0
Labor hours 259.0 615.5 Transmission System
(Fuel Cell System for Total cost ($) 50.00 57,410.46
Total cost ($) 25,949.46 49,833.42
FCEBs) Total cost ($) per mile 0.000 0.070
Total cost ($) per mile 0.059 0.061
Parts cost ($) 1,013.42 0.00 Parts cost ($) 0.00 11.57
Electric Propulsion Labor hours 187.5 0.0 Labor hours 0.0 2.0
Hydraulic System
System Total cost ($) 10,388.42 0.00 Total cost ($) 0.00 111.57
Total cost ($) per mile 0.024 0.000 Total cost ($) per mile 0.000 0.000
Parts cost include items regularly replaced as part of scheduled maintenance. Scheduled parts make up 90% of the FC System parts NREL | 33
 Contacts

NREL
Matthew Post
Phone: 303-275-3829
Email: [email protected]

Orange County Transportation Authority

Cliff Thorne
Phone: 714-560-9975
Email: [email protected]

NREL | 34
 Acronyms and Abbreviations
CNG compressed natural gas kW kilowatt
dge diesel gallon equivalent kWh kilowatt-hour
DOE U.S. Department of Energy lb. pound
FC fuel cell MBRC miles between roadcalls
FCEB fuel cell electric bus mi mile
ft feet mpdge miles per diesel gallon equivalent
FTA Federal Transit Administration mpgge miles per gasoline gallon equivalent
gge gasoline gallon equivalent mph miles per hour
GVWR gross vehicle weight rating NREL National Renewable Energy
hp horsepower Laboratory
HVAC heating, ventilation, and air PM preventive maintenance
conditioning PMI preventive maintenance inspection
in. inch psi pounds per square inch
kg kilogram
NREL | 35
 Acknowledgments

This work was supported by the U.S. Department of Energy under Contract No.
DE-AC36-08GO28308 with Alliance for Sustainable Energy, LLC, the Manager and
Operator of the National Renewable Energy Laboratory. Funding was provided by the
U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Fuel Cell
Technologies Office.

The views and opinions of the authors expressed herein do not necessarily state or
reflect those of the United States Government or any agency thereof. Neither the
United States Government nor any agency thereof, nor any of their employees, makes
any warranty, expressed 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.

NREL | 36
 Appendix:
Fleet Summary Statistics
 Fleet Summary Statistics
FCEB CNG
Number of vehicles 10 10
Period used for fuel and oil analysis Feb 2020 -Jul 2021 Feb 2020 -Jul 2021
Total number of months in period 18 18
Fuel and oil analysis base fleet mileage 427,162 808,781
Period used for maintenance analysis Feb 2020 -Jul 2021 Feb 2020 -Jul 2021
Total number of months in period 18 18
Maintenance analysis base fleet mileage 439,224 817,321
Average monthly mileage per vehicle 2,579 4,541
Availability 62.5 ≥85
Fleet fuel usage in kg hydrogen or gge CNG 51,026.7 214,258.0
Roadcalls 70 30
Total MBRC 6,275 27,244
Propulsion roadcalls 49 21
Propulsion MBRC 8,964 38,920
Fleet mi/kg hydrogen (FCEB), mi/gge (CNG) 8.37 3.77
Representative fleet mpg (energy equiv.) 9.46 4.22
Fuel cost per kg hydrogen or gge CNG 8.48 1.15
Fuel cost per mile 1.013 0.361
Total scheduled repair cost per mile 0.142 0.177
Total unscheduled repair cost per mile 0.321 0.487
Total maintenance cost per mile 0.463 0.664
Total operating cost per mile 1.476 1.025 NREL | 38
 Maintenance Cost Summary
Maintenance Cost Summary
FCEB CNG
Fleet mileage 439,224 817,321
Total parts cost 39,733.32 228,369.41
Total labor hours 3265.3 6293.1
Average labor cost (@ $50.00 per hour) 163,262.50 314,654.17
Total maintenance cost 202,995.82 543,023.58
Total maintenance cost per bus 20,299.58 54,302.36
Total maintenance cost per mile 0.46 0.66

Propulsion System Maintenance Cost Summary

FCEB CNG
Total Engine/Fuel-Related Systems (ATA VMRS 27, 30, 31, 32, 33, 41, 42, 43, 44, 45, 46, 65)
Parts cost 15,868.70 136,716.19
Labor hours 731.5 1974.3
Average labor cost 36,575.00 98,712.50
Total cost (for system) 52,443.70 235,428.69
Total cost (for system) per bus 5,244.37 23,542.87
Total cost (for system) per mile 0.12 0.29
NREL | 39
 Maintenance Cost by Vehicle System
FCEB CNG
Exhaust System (ATA VMRS 43)
Parts cost 0.00 5,753.34
Labor hours 0.0 55.5
Average labor cost 0.00 2,775.00
Total cost (for system) 0.00 8,528.34
Total cost (for system) per bus 0.00 852.83
Total cost (for system) per mile 0.000 0.01
Fuel System (ATA VMRS 44)
Parts cost 116.50 18,737.30
Labor hours 120 720.5
Average labor cost 6,000.00 36,025.00
Total cost (for system) 6,116.50 54,762.30
Total cost (for system) per bus 611.65 5,476.23
Total cost (for system) per mile 0.01 0.07
Power Plant (Engine) (ATA VMRS 45)
Parts cost 12,999.46 19,058.42
Labor hours 259 615.5
Average labor cost 12,950.00 30,775.00
Total cost (for system) 25,949.46 49,833.42
Total cost (for system) per bus 2,594.95 4,983.34
Total cost (for system) per mile 0.06 0.06
NREL | 40
 Maintenance Cost by Vehicle System
FCEB CNG
Electric Propulsion (ATA VMRS 46)
Parts cost 1,013.42 0.00
Labor hours 187.5 0.0
Average labor cost 9,375.00 0.00
Total cost (for system) 10,388.42 0.00
Total cost (for system) per bus 1,038.84 0.00
Total cost (for system) per mile 0.02 0.000
Electrical System (ATA VMRS 30-Electrical General, 31-Charging, 32-Cranking, 33-Ignition)
Parts cost 315.50 34,256.73
Labor hours 131 185
Average labor cost 6,550.00 9,250.00
Total cost (for system) 6,865.50 43,506.73
Total cost (for system) per bus 686.55 4,350.67
Total cost (for system) per mile 0.02 0.05
Air Intake System (ATA VMRS 41)
Parts cost 1,079.23 3,323.65
Labor hours 0 31
Average labor cost 0.00 1,550.00
Total cost (for system) 1,079.23 4,873.65
Total cost (for system) per bus 107.92 487.37
Total cost (for system) per mile 0.00 0.01
NREL | 41
 Maintenance Cost by Vehicle System
FCEB CNG
Cooling System (ATA VMRS 42)
Parts cost 344.59 4,064.72
Labor hours 33 246.75
Average labor cost 1,650.00 12,337.50
Total cost (for system) 1,994.59 16,402.22
Total cost (for system) per bus 199.46 1,640.22
Total cost (for system) per mile 0.00 0.02
Hydraulic System (ATA VMRS 65)
Parts cost 0.00 11.57
Labor hours 0.0 2
Average labor cost 0.00 100.00
Total cost (for system) 0.00 111.57
Total cost (for system) per bus 0.00 11.16
Total cost (for system) per mile 0.000 0.00
General Air System (ATA VMRS 10)
Parts cost 7,268.30 12,731.38
Labor hours 174 222.5
Average labor cost 8,700.00 11,125.00
Total cost (for system) 15,968.30 23,856.38
Total cost (for system) per bus 1,596.83 2,385.64
Total cost (for system) per mile 0.04 0.03
NREL | 42
 Maintenance Cost by Vehicle System
FCEB CNG
Brake System (ATA VMRS 13)
Parts cost 806.93 23,499.24
Labor hours 56.5 608.5
Average labor cost 2,825.00 30,425.00
Total cost (for system) 3,631.93 53,924.24
Total cost (for system) per bus 363.19 5,392.42
Total cost (for system) per mile 0.01 0.07
Transmission (ATA VMRS 27)
Parts cost 0.00 51,510.46
Labor hours 1 118
Average labor cost 50.00 5,900.00
Total cost (for system) 50.00 57,410.46
Total cost (for system) per bus 5.00 5,741.05
Total cost (for system) per mile 0.00 0.07
Inspections Only - No Parts Replacements (101)
Parts cost 0.00 0.00
Labor hours 839.75 1142
Average labor cost 41,987.50 57,100.00
Total cost (for system) 41,987.50 57,100.00
Total cost (for system) per bus 4,198.75 5,710.00
Total cost (for system) per mile 0.10 0.07
NREL | 43
 Maintenance Cost by Vehicle System
FCEB CNG
Cab, Body, and Accessories Systems (ATA VMRS 02-Cab and Sheet Metal, 50-Accessories, 71-Body)
Parts cost 15,071.20 44,347.28
Labor hours 1216.25 1892.8333
Average labor cost 60,812.50 94,641.67
Total cost (for system) 75,883.70 138,988.94
Total cost (for system) per bus 7,588.37 13,898.89
Total cost (for system) per mile 0.17 0.17
HVAC System (ATA VMRS 01)
Parts cost 232.62 3,728.85
Labor hours 57 106
Average labor cost 2,850.00 5,300.00
Total cost (for system) 3,082.62 9,028.85
Total cost (for system) per bus 308.26 902.88
Total cost (for system) per mile 0.01 0.01
Lighting System (ATA VMRS 34)
Parts cost 4.16 1,824.18
Labor hours 31.5 65.5
Average labor cost 1,575.00 3,275.00
Total cost (for system) 1,579.16 5,099.18
Total cost (for system) per bus 157.92 509.92
Total cost (for system) per mile 0.00 0.01
NREL | 44
 Maintenance Cost by Vehicle System
FCEB CNG
Frame, Steering, and Suspension (ATA VMRS 14-Frame, 15-Steering, 16-Suspension)
Parts cost 291.39 3,753.07
Labor hours 86.75 116.25
Average labor cost 4,337.50 5,812.50
Total cost (for system) 4,628.89 9,565.57
Total cost (for system) per bus 462.89 956.56
Total cost (for system) per mile 0.01 0.01
Axle, Wheel, and Drive Shaft (ATA VMRS 11-Front Axle, 18-Wheels, 22-Rear Axle, 24-Drive Shaft)
Parts cost 190.02 1,769.22
Labor hours 48.5 150.25
Average labor cost 2,425.00 7,512.50
Total cost (for system) 2,615.02 9,281.72
Total cost (for system) per bus 261.50 928.17
Total cost (for system) per mile 0.01 0.01
Tire (ATA VMRS 17)
Parts cost 0.00 0.00
Labor hours 23.5 15
Average labor cost 1,175.00 750.00
Total cost (for system) 1,175.00 750.00
Total cost (for system) per bus 117.50 75.00
Total cost (for system) per mile 0.00 0.00
NREL | 45
 Fleet Summary Statistics: SI Units
FCEB CNG
Number of vehicles 10 10
Period used for fuel and oil analysis Feb 2020 -Jul 2021 Feb 2020 -Jul 2021
Total number of months in period 18 18
Fuel and oil analysis base fleet kilometers 233,587 1,315,315
Period used for maintenance analysis Feb 2020 -Jul 2021 Feb 2020 -Jul 2021
Total number of months in period 18 18
Maintenance analysis base fleet kilometers 706,843 1,315,315
Average monthly kilometers per vehicle 4,151 7,307
Availability 62.5 ≥85
Fleet fuel in FCEB kg/CNG L 16,745.5 280,854.3
Roadcalls 130 51
Total KBRC 5,437 25,790
Propulsion roadcalls 49 21
Propulsion KBRC 14,425 62,634
Representative fleet fuel consumption (L/100 km) 7.17
H2 cost per kg/ CNG cost per liter 24.01 21.35
Fuel cost per km 8.10 0.32
Total scheduled repair cost per km 0.58 0.07
Total unscheduled repair cost per km 0.09 0.11
Total maintenance cost per km 0.20 0.30
Total operating cost per km 0.29 0.41
NREL | 46
 Maintenance Cost Summary: SI Units
Maintenance Cost Summary
FCEB CNG
Fleet mileage 706,843 1,315,315
Total parts cost 39,733.32 228,369.41
Total labor hours 3,265.3 6,293.1
Average labor cost (@ $50.00 per hour) 163,262.50 314,654.17
Total maintenance cost 202,995.82 543,023.58
Total maintenance cost per bus 20,299.58 54,302.36
Total maintenance cost per kilometer 0.09 0.04

Propulsion System Maintenance Cost Summary

FCEB CNG
Total Engine/Fuel-Related Systems (ATA VMRS 27, 30, 31, 32, 33, 41, 42, 43, 44, 45, 46, 65)
Parts cost 15,868.70 136,716.19
Labor hours 731.5 1974.3
Average labor cost 36,575.00 98,712.50
Total cost (for system) 52,443.70 235,428.69
Total cost (for system) per bus 5,244.37 23,542.87
Total cost (for system) per kilometer 0.07 0.18
NREL | 47
 Part Replacement Occurrences

This analysis indicates the number of work orders that requires a part to be replaced.
The entire system, indicated by the VMRS code, is not replaced. Instead, it is a part
within the system that has been replaced. This does not include work orders where
only labor is needed.

NREL | 48
 Part Replacement Occurrences
FCEB CNG
All data All data
Part Replacement Number of Occurrences
Exhaust System (ATA VMRS 43) 0 38
Fuel System (ATA VMRS 44) 12 499
Power Plant (Engine) (ATA VMRS 45) 151 583
Electric Propulsion (ATA VMRS 46) 5 0 FCEB Total Miles =
Electrical System (ATA VMRS 30, 31, 32, 33) 13 179 439,224
Air Intake System (ATA VMRS 41) 41 80 CNG Total Miles =
Cooling System (ATA VMRS 42) 6 159 817,321
Hydraulic System (ATA VMRS 65) 0 5
General Air System (ATA VMRS 10) 114 115
Brake System (ATA VMRS 13) 83 337
Transmission (ATA VMRS 27) 0 55
Cab, Body, and Accessories (ATA VMRS 02, 50, 71) 387 804
HVAC System (ATA VMRS 01) 8 31
Lighting System (ATA VMRS 34) 8 49
Frame, Steering, and Suspension (VRMS 14, 15, 16) 26 44
Axle, Wheel, and Drive Shaft (ATA VMRS 11, 18, 22, 24) 12 33
Tire (ATA VMRS 17) 0 27 NREL | 49
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