- Call topic: FCH-02-3-2014: Stationary FC system diagnostics: development of online monitoring and diagnostics systems for reliable and durable fuel cell system operation - Project dates: 01/09/15 – 31/12/18 - Total project budget: 2,358,736€ - Coordinator: University of Salerno (I) Single cell models Non-dimensional Parameters (p theorem) Impedance model Single cell impedance data PARAMETERS IDENTIFICATION IMPEDANCE RECONSTRUCTION Stack impedance Stack information Physical knowledge Spectra acquired with EIS board and converter Embedded On-line tool based on Electrochemical Impedance Spectroscopy (EIS) for advanced Fuel Cells Monitoring, Diagnosis and Lifetime Tool (MDLT). The tool performs EIS-based condition monitoring of FC stacks and isolates 5 stack faults. The project HEALTH-CODE (Real operation pem fuel cells HEALTH-state monitoring and diagnosis based on dc-dc COnverter embeddeD Eis) has received funding from the Fuel Cells and Hydrogen 2 Joint Undertaking under grant agreement No 671486. This Joint Undertaking receives support from the European Unions’ Horizon 2020 research & innovation programme and N.ERGHY. www.pemfc.health-code.eu Real operation pem fuel cells HEALTH-state monitoring and diagnosis based on dc-dc COnverter embeddeD Eis PROJECT OVERVIEW EIS SPECTRA MEASUREMENTS DIAGNOSTIC ALGHORITM TOOLS TESTING USEFUL GUIDELINES for companies to implement EIS board on industrial FC systems: • NEW DC/DC converter designed to interact with the EIS board. • ADAPT AVAILABLE converter to allow the communication with the EIS board. 2200+ EIS spectra for stacks (10%) and cells, 25% in nominal and 75% in faulty operations Nominal spectra set the monitoring reference Faulty spectra drive the setting of faults isolation algorithm Air/Reformate O 2 /H 2 Air/Reformate O 2 /H 2 - fuel starvation - air/O 2 starvation - flooding/drying - CO contamination (only air-fed) - sulphur poisoning (only air-fed) Faults IMPACT HEALTH-CODE outcomes will: - increase electrical efficiency and durability of the different fuel cells used for power production; - contribute to reduce degradation by implementing the monitoring and diagnostic tool; - lead to a reduction of total cost ownership (TCO) by increasing the FC system efficiency; - contribute to improve grid stability in the future by applying stationary fuel cells together with energy storage; the EPS backup system has grid interface for H 2 & O 2 production and can support grid balancing. Ballard Europe μ-CHP system DC/DC converter 15 A 25 A 40 A R m R ct,a R ct,c Change detection check with nominal behaviour EIS spectrum acquired on-board Parameters extraction with model fitting R m R ct,a R ct,c 1 0 1 Fault Pattern FAULT ISOLATION: F2 FSM ECM PARAMETERS R m R ct,a R ct,c C a Q φ R d τ FAULTS F1 0 0 1 - - - - - F2 1 0 1 - - - - - F3 - - - - - - - - Equivalent Circuit Modelling III] Classification & Decision making Algorithm Learning : Off-line FDI : Off-line validation & On-board application EIS learning data set New EIS measurement I] Automated features-selection I1: Normalization I2: Variance-Correlative Coef. analysis I3: Space dimension selection Features’ Normalization II] Fuzzy clustering Clusters’ definition 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0 0.5 1 1.5 f1 f2 f3 SOH Assessment Save data file Data file Fuzzy Clustering approach Adaptive Neuro Fuzzy Inference System Active Diagnosis Cell voltage increase >5mV Air Bleed surge routine Yes No CO poisoning No CO poisoning Alarm CO poisoning EIS board cost < 500€ (3% of TCO) Cell à Short stackà Full Stack FC STACK GRID/ LOAD DC/DC CONVERTER SYSTEM CONTROL UNIT BOP EIS BOARD DIAGNOSIS SoH & Lifetime FC SYSTEM SYSTEM MANAGEMENT AND CONTROL UNIT EPS backup/energy system FC Stack EIS board proto 1 DC/DC converter Power 1.3 kW Coolings Water cooled Reactants Air & Reformate Applications Residential μ-CHP power 3 kW Coolings Water cooled Reactants Oxygen & Hydrogen Applications Backup electric power H 2 as energy buffer LOAD LOAD SCALING-UP INFO BITRON EIS Box SHAPE SMOOTHING SIGNIFICANT EIS POINTS ECM FITTING EIS SPECTRA 2 3 4 E0001 #S NOMINAL CONDITION 40A EXPERIMENTAL DATA 2 3 4 E0001 #S NOMINAL CONDITION 40A EXPERIMENTAL DATA SHAPE SMOOTING E0001 #S NOMINAL CONDITION 40A EXPERIMENTAL DATA ECM FITTING 2 3 4 E0001 #S NOMINAL CONDITION 40A EXPERIMENTAL DATA SHAPE SMOOTHING SIGNIFICANT POINTS EIS board (TRL 6) EIS board has been prototyped (proto 2) ready to be engineered for system embedding. Converter (TRL 6) Conventional HW is modified/re-engineered to allow flexibility and multiple market choice for manufacturer strategies. Algorithms (TRL 5) Detection and Isolation of 5 faults in stacks fed with Air+Reformate / O 2 +H 2 .