cafcp bus team dec 15 201515, 2015. ballard cafcp bus team... · bahamas – sheldon usa – chris...

CaFCP Bus Team Dec 15 201515, 2015

Ballard’s Market LeadershipBallard s Market Leadership

OVER 7 GENERATIONS OF HD DEVELOPMENT, BALLARD HAS:• Partnered with over 10 bus manufacturers

• Integrated 4 different drive systems• Integrated 4 different drive systems

• Powered more than 100 fuel cell buses in 20 cities

• Driven over 8 million km across 12 countries with challenging climates and road conditions

• Created 6 global service centers to ensure fleet availabilityavailability

• Achieved 20,000 of operation in London on fuel cell stacks

Extending Ballard’s Market LeadershipExtending Ballard s Market Leadership

45 buses in operation today +350 new fuel cell buses in the next 18 months

Europe: 45+

India: 1

China: 300+

Europe: 45+

USA: 20+

India: 1

Brazil: 3

Ballard’s Competitive AdvantageBallard s Competitive Advantage

Ballard’s Technology LeadershipBallard s Technology Leadership

>80% Availability P5 94% Availability HD6* HD7

High volume manufacturing equipment & processes; common componentsImproved component

robustness & reduced warranty accrual costs

Leveraging automotive technology and volumes

>20,000 hrsEnhanced MEA; 25 000 h

4,000 hrsDemonstrated in service (TFL)

>10,000 hrs~ 4 Million km’s demonstrated in service (BC Transit)

Enhanced MEA; Demonstrated in service (TFL)

>25,000 hrs projected

service (TFL)

* AFCBP 2nd Evaluation, http://www.nrel.gov/docs/fy15osti/64344.pdf, page 16

Ballard FCvelocity® Motive Moduley

• Modular Design

o separate air and coolant sub‐systems enable flexible integration of components into the bus design and easy access for enhanced serviceability.

• High Temperature Operation

o permits a smaller cooling package for integration flexibility and heat can be used in the cabin, significantly improving overall vehicle fuel economy.

• Humidification• Humidification

o Integrated humidification system to maximize system performances and durability

• Climate Protection

o IP‐rated enclosure and freeze protection system guard against premature deterioration of key module components in extreme climates.

• High Pressure SystemHigh Pressure System

o offers better performance, fuel efficiency and durability by preventing degradation of the fuel cell power module.

• Remote Diagnostics

o direct or wireless connection allows customer to remotely monitor performance data and anticipate preventative maintenance.

Preventive MaintenancePreventive Maintenance

REDUCING THE PREVENTIVE MAINTENANCE BURDEN WITH EACH HD GENERATION

P5 HD6 HD7

Service Interval 320hr 1000hr 1000hr

Key Service Activities 9 8 5

Interval Task Time Requirement

250 Hours / 5000 Miles • Check ventilation filter and fan 10 min• Check hydrogen sensor calibration

1000 Hours / 20,000 Miles

• Check hydrogen sensor calibration, replace sensor filter

• Test smoke detector

• Replace air compressor oil and filter

120 min

• Replace air compressor oil and filter

Annual • Test ground fault monitor 5 min

All Preventive Maintenance activities are accomplished outside of the module

Corrective MaintenanceCorrective Maintenance

EASE OF MAINTENACNE WAS A DESIGN PRIORITY IN THE HD7 MODULE• Cooling and air systems are remotely mounted for easy access and repair

• Two main access points designed into the module for access and repair 1 Slid El i P l id1. Slide‐out Electric Panel provides access to:

o Contactors Harnesses

o Controllers Power Distribution

2. Front Panel provides access to:o Fuel recirculation blower and controls

o Fuel pressure control and purge valve

o No need to drain coolant for access through Front panel

• Removal of the module is only required for:o Stack > 15,000 hr lifetime

o Humidifier > 20,000 hr lifetime,

o Aftercooler > 30,000 hr lifetime

Ballard’s Service & SupportBallard s Service & Support

Systems Integration Support

• World Class Engineering supporto 30 years of experience with fuel cell buses

o Integration kits, hardware and software interfaces

o On‐site commissioning support

• Strong Customer Base

Fuel Cell Bus Maintenance ExperienceFuel Cell Bus Maintenance Experience

Chicago (1996 -1999) CUTE (2002 -2009) BC Transit (2009 -2014)C g ( 996 999)• First field trials• A dedicated technician on

each bus

( )• Site technicians at each

deployment• Managing parts logistics

for 13 locations across 5

( )• Coordinated technician training

(with New Flyer) for Whistler Transit

• No Ballard on-site techniciano 3 oca o s ac oss 5continents

No Ballard on site technician required

• Parts logistics managed from the Burnaby office

Transportation for London (2010 – to date)• Trained Tower Transit site techs• Telephonic support from• Telephonic support from

Burnaby• Parts stored at London site

Lessons Learned –Keys to SuccessLessons Learned Keys to Success

OEM Engagement• OEM’s willing and able to perform troubleshooting and repairs of all glider and hybrid drive system (including

FCM) as they currently do for other technologies.

• Proper training and a integrated diagnostic tool will be key factors for success (Tier 2 Support)

l i id ll d ifi d iLocal Service Provider –Ballard Certified Service Partner• Will have to be able and willing to perform troubleshooting and minor repairs for the FC system. Proper

training and a diagnostic tool will be a key factors for success (Tier 3 Support)

T h lTechnology:• Each sub‐system needs to have a MTBF of 2,500h minimum to allow a module availability of 98% plus,

required for a bus availability of 95%

Parts:Parts:• Allocation of Satellite inventories in coordination with service facilities Locations

• For OCTA –this will be Service Centre with parts inventory located in Thousand Palms, CA

Ballard’s Service Model a a d s Se ce ode

Level 1• End‐user’s technicians trained • First POC for product support• Includes: preventive maintenance, fuelingp , f g

• OEM or system integrator’s service teams trained

Level 2• OEM or system integrator s service teams trained• Second POC for product support• Includes: commissioning, standard troubleshooting, spare parts support

• Ballard service technicians• Third POC for product support

Level 3

Third POC for product support• Includes: failure analysis, design evaluation, advanced troubleshooting

Develop and deliver programs to meet customer‐specific requirements

Our Team:Our Team:Steve Karaffa – CCO

Silvano Pozzi Director After Sales DepartmentSilvano Pozzi – Director After Sales Department

Byron Somerville – Manager Technical Support

Guenther Rapp – Services Support and Logistics Coordinator

Personal Touch Answering Services - Call Centre

Our Support Specialists Team

BUP BUS DG MH Repairs

Tier 3 Support teams:APAC – Kelly, Yee, Fahmi

India – Ravindra, Syed, Bhupinder,

NH2

Tier 3 Support teams:EU – Gordon, Baback, EMCell Team, NH1

USA – Steve, NH1

Burnaby – Manny, NH1, NH2

Tier 3 Support team:USA – Steve

Tier 3 Support team:Burnaby – Martin

Tier 3 Support team:Burnaby – Emilio

Burnaby – Kevin

Bahamas – Sheldon

USA – Chris

BLD Denmark Team

u aby a y, ,

BLD Denmark Team

HD7 Training CurriculumHD7 Training Curriculum• Bus Introduction• Fuel Cell Basics

• HD7 Trainingo Special Tools

C bl• HD7 Training

o P&IDo Safety o Performance

o Consumableso Preventative Maintenanceo Facility Requirementso Alarm & Document Portalo Field Replaceable Unit (FRU)

o Fuel Cell Failure Modeso Module Interface Control Drawings (ICD)o Air System ICDo Cooling System ICDo Software

• After Sales Support• Servicing (refer to next slide p3)• Freeze Protection

Ai Ki• Controls• Alarms• State Diagrams• Control Logic• CAN Matrix

• Air Kit

• Start‐up Diagramo Electrical Interface Schematico High Voltage Connectionso Customer Harnesseso Ground Faultso Ground Faultso Troubleshooting Guideo Bus Hybridizationo TC3 Demonstration

• Setup• Alarm History• Alarm History• Flashing Software• P&ID• Enable / Disable pumps, valves, motors, etc…

Global Service & Support InfrastructureGlobal Service & Support Infrastructure

Preventative and Corrective Maintenance Training Provided at each Deployment Site

Service Provider Certification Program available (currently one in EU)

24 x 7 Call Centre Response

ESPACE Lier Belgium Burnaby Canada Aberdeen UK

24 x 7 Call Centre Response

China California andESPACE Lier, BelgiumEuropean Service Centre Co‐located with Van HoolService TechniciansFull Parts Inventory

Burnaby, CanadaGlobal and North AmericaService CenterTelephone supportService Technicians

Aberdeen, UK UK Service Center Telephone supportService TechnicianParts Inventory

China, California and Cologne Service Center Telephone supportService TechnicianFull Parts Inventory

(Implemented)Service TechniciansFull Parts InventoryFlying DoctorsEngineering

Parts Inventory(implemented)

Service TechnicianFull Parts Inventory(In implementation)

SummarySummary

• Fuel cell technology has proven itself out in deployments• Fuel cell technology has proven itself out in deployments throughout the world

• The only zero‐emission technology that provides the benefits of air quality improvement, GHG savings and energy conservation, while maintaining route flexibility

• Ballard has the experience of supplying, servicing & maintainingBallard has the experience of supplying, servicing & maintaining heavy‐duty fuel cell technology for over 15 years

• Having worked with multiple transit agencies, OEMs & integrators, b t t f f l d l twe are your best partner for a successful deployment

Thank YouThank You

cafcp bus team dec 15 201515, 2015. ballard cafcp bus team... · bahamas – sheldon usa – chris...

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