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

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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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

192 miles and 61 stations

163 SLRVs

39,031,000 miles/year

654 buses

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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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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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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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

Fleet Overview

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New faces of DART are rolling

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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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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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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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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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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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

Facilities Infrastructure

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SOC Time Lapse

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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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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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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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

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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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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Lessons Learned

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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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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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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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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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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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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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