Field Evaluation of Medium-Duty Plug-in Electric Delivery Trucks Robert Prohaska, Mike Simpson, Adam Ragatz, Kenneth Kelly, Kandler Smith and Kevin Walkowicz NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy Operated by the Alliance for Sustainable Energy, LLC This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications. Technical Report NREL/TP-5400-66382 December 2016 Contract No. DE-AC36-08GO28308 Field Evaluation of Medium-Duty Plug-in Electric Delivery Trucks Robert Prohaska, Mike Simpson, Adam Ragatz, Kenneth Kelly, Kandler Smith and Kevin Walkowicz Prepared under Task Nos. VTP2.3102 and VTP2.3103 NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy Operated by the Alliance for Sustainable Energy, LLC This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications. National Renewable Energy Laboratory Technical Report 15013 Denver West Parkway NREL/TP-5400-66382 Golden, CO 80401 December 2016 303-275-3000 • www.nrel.gov Contract No. DE-AC36-08GO28308 NOTICE This 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. This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications. Available electronically at SciTech Connect http:/www.osti.gov/scitech Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 OSTI http://www.osti.gov Phone: 865.576.8401 Fax: 865.576.5728 Email: [email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5301 Shawnee Road Alexandria, VA 22312 NTIS http://www.ntis.gov Phone: 800.553.6847 or 703.605.6000 Fax: 703.605.6900 Email: [email protected] Cover Photos by Dennis Schroeder: (left to right) NREL 26173, NREL 18302, NREL 19758, NREL 29642, NREL 19795. NREL prints on paper that contains recycled content. Acknowledgments This evaluation is funded through the Advanced Vehicle Testing Activity, which is managed by Lee Slezak and David Anderson within the U.S. Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy. All publications regarding the Frito-Lay North America (FLNA) electric delivery vehicle evaluation will be posted on DOE’s Energy Efficiency and Renewable Energy Web site. See the Medium- and Heavy-Duty Vehicles section at the following link: http://www1.eere.energy.gov/vehiclesandfuels/avta/index.html. This evaluation, which was conducted at FLNA’s Federal Way, Washington, distribution center, would not have been possible without the support and cooperation of many people. The authors wish to thank each of the following: U.S. Department of Energy Lee Slezak David Andersen Frito-Lay North America Steve Hanson Ron Sorenson Matt Myers Smith Electric Austin Hausmann iii This report is available at no cost from the National Renewable Energy Laboratory at www.nrel.gov/publications. List of Acronyms and Abbreviations AC alternating current ARRA American Recovery and Reinvestment Act AVTA Advanced Vehicle Testing Activity CARB California Air Resources Board CO2 carbon dioxide CO2e carbon dioxide equivalent DC direct current DOE U.S. Department of Energy EV electric vehicle EVSE electric vehicle supply equipment FLNA Frito-Lay North America ft-lb foot-pounds GPS global positioning system HHDDT Heavy Heavy-Duty Diesel Truck kW kilowatt kWh kilowatt-hour lb. pound LiFePO4 lithium iron phosphate mpg miles per gallon mpgde miles per gallon diesel equivalent mph miles per hour NREL National Renewable Energy Laboratory PSE Puget Sound Energy Smith Smith Electric Vehicles Corp. SOC state of charge iv This report is available at no cost from the National Renewable Energy Laboratory at www.nrel.gov/publications. Executive Summary This report focuses on medium-duty electric delivery vehicles operated by Frito-Lay North America (FLNA) at its Federal Way, Washington, distribution center. The 100% electric drive system is an alternative to conventional diesel delivery trucks and reduces both energy consumption and carbon dioxide (CO2) emissions. Evaluation Design This in-use evaluation studied Smith Electric Vehicles’ (Smith’s) Newton electric vehicles (EVs) configured as delivery trucks operating at FLNA’s Federal Way distribution center. The EVs were compared to conventional diesel delivery trucks operating at the same location and driving on similar routes. In-use vehicle data were collected for both vehicle types over several weeks. In addition to characterizing the in-use performance of the EVs compared to the conventional diesels, detailed facility load data were collected at the main building power feed as well as from each of the 10 EV chargers to better understand the broader implications associated with commercial EV deployment. Evaluation Results The results and related discussions included here are specific to in-field data collected from the Smith EVs deployed at the Federal Way facility and the comparable conventional diesels. Vehicle Use and Duty Cycle Route and drive cycle analysis showed that the Smith EVs were operated on the same routes, performed the same type of work, and were operated in a similar manner as the conventional diesels in and around the Tacoma, Washington, area. The vehicles spend a small proportion of their total day actually driving as the drivers are responsible for stocking their customers’ accounts on route as well as delivering product, averaging just over 1.5 hours of driving per day with an average daily distance of less than 40 miles for both the diesel vehicles and the EVs. Vehicle Performance and Emissions In-use operation of the EVs demonstrated a 216% (3.15x) improvement in equivalent fuel economy (24.09 MPGe vs 7.63 MPG) over the data reporting period compared to the conventional diesel vehicles as well as a 46% reduction in CO2 equivalent emissions based on the local energy generation source. Charging and Infrastructure FLNA installed 10 chargers at the Federal Way facility, which has the ability to remotely monitor use of each charger. NREL researchers installed a power meter on the main facility power supply line. Together, these data streams allowed researchers to characterize energy use and power requirements. The researchers found a significant increase in the overall facility peak power load (approximately 70kW to 110 kW) and energy requirements with the introduction of the EVs. This additional charging load also increased the peak demand charges of the facility as charging time corresponded with peak facility loads; however, the peak demand charges are comparatively low in the Pacific Northwest and were not found to be high enough to justify the integration of onsite solar and managed EV charging at this location. v This report is available at no cost from the National Renewable Energy Laboratory at www.nrel.gov/publications. Table of Contents List of Acronyms and Abbreviations ....................................................................................................... iv Executive Summary .................................................................................................................................... v List of Figures ........................................................................................................................................... vii List of Tables .............................................................................................................................................. ix Overview ...................................................................................................................................................... 1 Advanced Vehicle Testing Activity ....................................................................................................... 1 Project Background ................................................................................................................................ 1 Project Objective .................................................................................................................................... 1 Frito-Lay North America Advanced Fleet ................................................................................................. 2 Smith Electric Vehicles – Smith Newton ............................................................................................... 3 Data Collection ...........................................................................................................................................