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MAX Team Member Orientation R.K. Rogers Assistant Vice President, Technical Services Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition Mike Hubbell Vice President, Maintenance NGV Bridge Fleet Framework Summit 2013 April 2, 2014

Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

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MAX Team Member Orientation. Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition. Mike Hubbell Vice President, Maintenance NGV Bridge Fleet Framework Summit 2013 April 2, 2014. R.K. Rogers Assistant Vice President, Technical Services. Agenda. DART Overview - PowerPoint PPT Presentation

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Page 1: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

MAX Team Member

Orientation

R.K. Rogers Assistant Vice President,

Technical Services

Dallas Area Rapid TransitCNG Bus Fleet Fuel Transition

Mike HubbellVice President, MaintenanceNGV Bridge Fleet Framework Summit 2013April 2, 2014

Page 2: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Agenda• DART Overview• Fuel Transition Program Overview

– Fuel Supply Elements– Vehicle Elements– Facility Elements

• Quick Math• Design & Construction Elements

– Approach– Budget – Schedule

• Lessons Learned / Conclusions

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Page 3: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

The Multimodal DART System• Dallas & 12 cities• 120+ bus routes

• 85 miles light rail

• 35 miles commuter rail

• Paratransit, vanpool & rideshare

• Nearly 250,000 passenger trips per weekday

Page 4: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

192 miles and 61 stations

163 SLRVs

39,031,000 miles/year

654 buses

Page 5: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Fuel Transition Program

• Board Resolution 090148 - October 27, 2009– Compressed natural gas (CNG) for all replacement buses

within the FY 2010 Twenty-Year Financial Plan

• Six program elements:– Predictable future pricing and supply of natural gas– CNG fueled fixed route buses– CNG fueled Innovative Services buses– CNG fueled Mobility Management Services buses– Design & construction of infrastructure– Potential continuation of Federal tax rebates

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Page 6: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Fuel Transition ProgramProgram Element Board Action

CNG Long Term Supply December 2009

CNG Federal Tax Rebates in Legislative Agenda December 2010

CNG Fixed Route Buses January 2011

CNG Infrastructure Design / Build April 2011

CNG Innovative Services Buses September 2011

CNG Mobility Management Services November 2011

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Page 7: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

CNG ContractLong Term Supply of CNG• FY 2013-2020• ~9.235M MMBtu• Texas General Land Office

(GLO) - ~$70M• ~$7.19/MMBtu• ~$0.99 / DGE

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Page 8: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Incremental Cost Breakdown

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Direct Gas; 6.9517411789937; 69%

Utility Tariffs; 0.347575584648093; 3%

Franchise Fees; 0.253757900510984; 3%

GLO Contract Fees; 0.0311178040636959;

0%

Compression; 0.751508727029241; 7%

Station Maintenance; 1.48; 15%

Tax Decal; 0.24449; 2%

Natural Gas in MMBTU Cost Distribution

Period: April - July 2013 $1.40$ Per DGE Diesel Gallon $

$3.42

Page 9: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Fleet Overview

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New faces of DART are rolling

Page 10: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Fixed Route Buses• 4-year contract - 459

CNG low floor buses• North American Bus

Industries, Inc. (NABI) ~$217M

• Delivery 12/2012 thru 12/2014

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Page 11: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Innovative Services Buses• ARBOC Specialty Vehicles -

$26M• 11 14-passenger buses

– On-Call region service– Operated by contractor

• 112 17-passenger buses– FLEX route service– Operated by DART

• Delivered 2/2012 – 5/2012

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Page 12: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Mobility Management Services• Contract Awarded 2/2012• Start up 10/2012• MV Transportation

– Amount - ~$186M– Term – 7 years

• Unique fleet blend– Traditional vans – 92– Certified Taxi Cabs – 168

• DART provides facility & CNG fuel for vans

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Page 13: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

CNG InfrastructureInfrastructure Design / Build• 4 facilities

– Compressors/Dispensers– Methane Detection/Alarms

• Transtar Energy Company, LP - ~$40.4M

• Design & construction of CNG fuel stations & facility modifications

• Startup – 10/2012

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Page 14: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Federal Excise TaxFederal Tax Rebate - EXPIRED• Rebate recently expired 12/2013• Fuel $0.556/gallon

• ~$5.3M credit annually at full deployment

• FY2014 Financial Plan assumed no rebates

• Continues as part of Board legislative agenda

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Page 15: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Quick MathDiesel Bus Natural Gas Bus Delta

Annual Miles 29,516,740 29,516,740MPG/MPDGE 3.84 3.68

Annual Gallons 7,686,651 8,020,853~$ / Gallon $3.42 $1.40

Lifetime Fuel $ $315,460,159 $134,750,3352 x DPFs $ 4,640,000 $ 0

Total Life Fleet $ $320,100,159 $134,750,335 $(185,349,824)

CapEx Bus Inc $ $ 0 $ 17,400,000CapEx Fuel Stations $ 0 $ 40,400,000

Total Cap Ex $ 0 $ 57,800,000 $ 57,800,000Lifetime Delta $(127,549,824)

CapEx ROI 3.74 years

15580 Bus Fleet w/12 Year Life

Page 16: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Facilities Infrastructure

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SOC Time Lapse

Page 17: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Facility Design / BuildCons’t Timeline

– Board Resolution October, 2009

– Request for Qualifications (Start) April, 2010– Request for Proposals (Start) August, 2010– Board Approval

April, 2011– Final Design (End)

December, 2011– Construction (Start)

• Gas LinesNovember, 2011

• Sub GradeMarch, 2012

• Above GradeApril, 2012

– Revenue Service Fueling October 1, 2012

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Page 18: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Facility Design Considerations• Utility Gas Pressure• Methane and Fire Alarm Integration• Underground Utilities• Modify / Eliminate Facility Heating• Facility / Dispensers Footprint• Compressor Controls for Fuel Lane Priority• Daily Service & Facility Maintenance Plan• Redundancy

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Page 19: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Refueling Performance Standard• Original-

– Less than Seven Minutes– All Lanes Concurrent– Empty Bus Fuel Tanks

• Revised – 80% of Maximum Domicile Capacity– Defined Fueling Window (7PM to 3AM)– Prioritized by Dispenser

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Page 20: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

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Natural Gas Compressor

3-250HP Twin Compressor Skids 3,800 SCFM Nom

Facility Major Components

Station Generator Generator - 1250 KW Engine - 1675 HP

Natural Gas Dryer Twin Tower/Auto Regen 3,200 SCFM Nom

Page 21: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Facility Construction Costs

• High Pressure Gas Line $1 Million/Mile

• Station (3 Lanes)$4.25 Million

• Facility Modifications* $1.85 Million

* Includes Alarms, Ventilation, Methane Detectors, Integrated Fire/Methane Reporting Panels for Running Repair, Paint, Brake and Overhaul Shop

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Page 22: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

BEFORE AFTERFixed Route Bus Garages

Supply Pressure 12-15 PSIG (Actual) 100-200 PSIG (Actual) Pipe Material Polyethylene (8” to

10” Dia.)Steel (6” to 8” Dia.)

Compressor Stages 5 Stage 4 Stages

Mobility Management Garage Supply Pressure 12 PSIG (Actual) 12 PSIG (Actual) Pipe Material Polyethylene (8” Dia.) Polyethylene (8” Dia.) Compressor Stages 5 Stage 5 Stages

Facility Supply Pressure

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Page 23: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Lessons Learned

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Page 24: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Facility Design / Construction• Preliminary Design Consultants• Methane and Fire Alarm Integration• Coordination w/ local regulatory agencies• Underground Utilities• Modify / Eliminate Facility Heating• Weatherizing Equipment

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Page 25: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Agency Communications• Engage and educate Safety personnel early• Engage and educate labor unions early• Training• Revision of Standard Operating Procedures• Communication

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Page 26: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Ancillary Support• Engage engine and NG fuel equipment suppliers• Vehicle methane detection & fire suppression

systems• Revise maintenance processes and procedures• Revise financial plans• Establish material supply chain & service

contracts

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Page 27: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Cummins Engine Failures• January 2014• Delaminated piston• 4 out of 459 engines• Cummins determined:

– Cold weather over fuel potential

– Re-flashed ECM w/new program

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Page 28: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

ARBOC Engine Failures• Multiple unit failures

– 38k – 45k miles• July to October

– 47 engine failures– 924 lost days

• National Bus Sales / General Motors worked with DART to indentify oil sources

• Not from CNG stations• GM inspection concludes:

– Valve seat recession– CNG conversion / higher temps– Non-hardened cylinder head

materials

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Page 29: Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

Conclusions

• Substantial fuel cost savings – ~60%• Organization commitment at the highest level• Know your performance requirements

– On street operations– Refueling

• Select suppliers carefully• Develop & communicate transition plan

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