Dallas Area Rapid Transit CNG Bus Fleet Fuel Transition

1. MAX Team Member Orientation Dallas Area Rapid TransitCNG 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

2. 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

3. 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

4. 163 SLRVs 192 miles and 61 stations 39,031,000 miles/year 654 buses

5. 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

6. Fuel Transition Program

7. CNG Contract Long Term Supply of CNG • FY 2013-2020 • ~9.235M MMBtu • Texas General Land Office (GLO) - ~$70M • ~$7.19/MMBtu • ~$0.99 / DGE

8. Incremental Cost Breakdown

9. Fleet Overview New faces of DART are rolling

10. Fixed Route Buses • 4-year contract - 459 CNG low floor buses • North American Bus Industries, Inc. (NABI) ~$217M • Delivery 12/2012 thru 12/2014

11. 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

12. 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

13. CNG Infrastructure Infrastructure 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

14. Federal Excise Tax Federal 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

15. Quick Math 580 Bus Fleet w/12 Year Life

16. Facilities Infrastructure SOC Time Lapse

17. 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 Lines November, 2011 • Sub Grade March, 2012 • Above Grade April, 2012 • Revenue Service Fueling October 1, 2012

18. 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

19. 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

20. Facility Major Components • Natural Gas Compressor • 3-250HP Twin Compressor Skids • 3,800 SCFM Nom • Natural Gas Dryer • Twin Tower/Auto Regen • 3,200 SCFM Nom • Station Generator • Generator - 1250 KW • Engine - 1675 HP

21. 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

22. Facility Supply Pressure

23. Lessons Learned

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

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

26. 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

27. 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

28. 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

29. 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