Consulting Services & Capabilities

eTec provides professional Consulting Services to a variety of clients including government agencies, major electric utilities, private corporations involved in the areas of Energy and Alternative Fuels and automotive manufacturers.

eTec staff have experience in a broad range of technical and business aspects in energy and alternative fueled topic areas. eTec can provide these services on a Time and Materials basis or where the scope is well defined on a fixed price basis.

Relevant Experience

eTec has performed consulting services for a broad range of clients including:

  • U.S. Department of Energy
  • Roush Industries
  • New York State Energy Research and Development Authority
  • New York Power Authority
  • KeySpan Energy
  • Long Island Power Authority
  • Advanced Lead-Acid Battery Consortium
  • Arizona Public Service Company
  • Salt River Project
  • Southern California Edison Company
  • Sacramento Municipal Utility District
  • Battelle Energy Alliance, LLC
  • Mead Westvaco

A sampling of current consulting contracts is provided below:

Project: Clean Coal Technologies Technology Evaluation
ETEC assisted Arizona Public Service with its evaluation of current technologies suitable for coal gasification. Initial work included a broad evaluation of partial oxidation technologies (US, European and Asian projects) as well as a detailed review of the most recent work performed at the Gas Technology Institute.

Project: Synthetic Natural Gas Project Development
ETEC is assisting Arizona Public Service with development of a project to demonstrate the feasibility of producing synthetic natural gas (SNG) from Four Corners region coal using a hydro gasification process at a target cost of $4.50 MBTU, then transport the SNG Phoenix area combined cycle power plants using existing natural gas pipelines. Hydro gasification differs from tradition partial oxidation processes by not burning or oxidizing coal. It exposes the coal to a hydrogen rich environment, producing more methane than traditional partial oxidation processes. This produces a methane rich product with a heating value similar to natural gas, allowing it to be transported in existing natural gas pipelines. The project includes development of a proof of concept hydro gasification reactor and associated auxiliary systems and controls.

Project: Bio-Solar Reactor Demonstration
ETEC is assisting Arizona Public Service (APS) with the engineering, construction and operation of a demonstration bio-solar reactor for carbon dioxide removal. The reactor is being install at the 2,000 MWe Redhawk combined cycle power plant of APS. A side stream of flue gas is routed through the bio-solar reactor wherein carbon dioxide is absorbed by algae growing in the reactor. The algae is harvested and converted to bio-diesel fuel using a commercial dbio-diesel producer.

Project: Pilot Hydrogen/CNG/ChyNG Station
ETEC provided engineering and Project Management services for the PNW pilot Hydrogen station located in Phoenix Arizona. This activity included design, engineering, construction management, project scheduling. ETEC provided engineering support and guidance during the 18-month effort to obtain certification from City of Phoenix code enforcement officials, the local Fire Marshall and to obtain a certificate as a public motor fuel dispensing station. This station has operated in the downtown Phoenix area for 5 years with zero accidents, zero injuries and zero near-misses.

Project: Hydrogen Facility Monitoring System
Design, engineer, installation and startup of the monitoring system for the APS Pilot Hydrogen/CNG/ChyNG Station. Implemented an automated system to accumulate operating data from the facility systems including hydrogen production, fault monitoring, hydrogen dryer, storage vessel pressure, hydrogen compressor, cooling water temperature, vent stack temperature, conductivity of production supply water, energy consumed by compressor and the hydrogen production unit, IR/UV scanner status, combustible detector status, hydrogen flow control from compressor and feedback from dispenser operation including mass flow per fill. Implemented a remote telemetry system that makes these data available on a graphic process mimic via the Internet ( Includes a system to notify service personnel of trouble via automated text messages to specific mobile phones.

Project: Hydrogen Power Park Development
ETEC provided engineering, construction and testing services to develop and evaluate various hardware configurations for providing added value to a hydrogen production system. Combined power, cooling and heating systems have been evaluated using Hydrogen ICE based engine generator sets. Various hydrogen production, compression and storage system have been evaluated to determine the cost of hydrogen production. Fuel cell and hydrogen ICE generators have been evaluated for distributed generation application as well as back up power.

Project: Heavy Duty CNG/H2 Blending Dispenser
Developed retail packaging for commercial heavy duty CNG-Hydrogen Blending dispenser for transit and vehicle applications based on Hydrogen/CHyNG Dispenser designed and built for APS Pilot Hydrogen/CNG/ChyNG Station. Implemented custom dispensing control algorithms to meet unique needs of the HCNG busses for which this dispenser was built. Also implemented custom software to integrate with the station controller provided at the fueling facility.

Project: Hydrogen/CHyNG Dispenser
Engineering support to engineer, design, test, demonstrate and certify a Hydrogen/CHyNG dispenser. This dispenser allows real time blending of CNG and hydrogen for fueling internal combustion engine vehicles. ETEC provided final engineering design drawings, structural and flow analysis and assisted in development of the control programming, integration into the station control system, the integration of a commercial credit card (POS) system and preparation of patent documents.

Project: Generation II Hydrogen Refueling Station
Engineering support for the conceptual design for the H2Gen2 system, including: general equipment arrangement, piping arrangement, structural, electrical, fire/safety, auxiliary systems and HAZOps analysis. Assisted in development of the documentation of the regulatory issues, codes, standards and permitting requirement related to the H2Gen2 siting and operation.

Project: Hydrogen ICE conversion of the GMC Sierra/Chevrolet Silverado 1500HD 4-Door Pickup Truck
ETEC has jointly developed a Hydrogen ICE conversion of the GMC Sierra/Chevrolet Silverado 1500HD 4-Door Pickup Truck with Roush Industries, a major second-stage manufacturing company and Powertech Labs, world-renowned in hydrogen fuel storage design. Of the first 9 vehicle conversions in production, 8 are participating in the British Columbia Hydrogen Highway’s “Integrated Waste Hydrogen Utilization Project” (IWHUP) sponsored by the Canadian Government, Powertech Labs (Subsidiary of BC Hydro), Clean Energy and several other participants. The 9th HICE truck will undergo vehicle durability and performance testing for the DOE’s Advanced Vehicle Testing Activity under the FreedomCAR and Vehicle Technologies Program.

Project Management Services

eTec conducts professional Project Management services for clients involved in technology development projects that require the experienced skill set found in eTec’s staff. eTec manages a broad range of projects related to alternative fuels and renewable energy technologies.

eTec provide complete Project Management responsibility overseeing entire multi-million dollar projects, including overseeing contractors, designers, budget and schedule tracking and producing reports required as part of the project deliverables.

Relevant Experience

eTec has tested dozens of vehicles over the past 10 years including:

Electric Vehicles:

  • General Motors EV1 (Lead-acid and Nickel-Metal-Hydride battery types)
  • Ford Ranger (Lead-acid and Nickel-Metal-Hydride battery types)
  • Chrysler EPIC Electric Mini-van
  • Toyota RAV-4 Electric

Neighborhood Electric Vehicles (NEVs)

  • Global Electric Motorcar (GEM)
  • Club Car
  • Frazer-Nash
  • ZENN Motor Company
  • Roush EV

Hybrid Electric Vehicles (HEVs)

  • Toyota Prius (Both generations)
  • Toyota Highlander
  • Toyota Lexus RX400H
  • Toyota Camry Hybrid
  • Ford Escape
  • Honda Insight
  • Honda Civic Hybrid
  • Honda Accord Hybrid
  • Saturn Vue Hybrid
  • Chevrolet Silverado Hybrid
  • Nissan Altima Hybrid

Plug-in Hybrid Electric Vehicles

  • EnergyCS Prius PHEV
  • Hymotion Prius PHEV
  • Hymotion Escape PHEV
  • Electrovaya Escape PHEV
  • Hybrids-Plus Escape PHEV

For additional information about the work eTec and its sister company, Electric Transportation Applications (ETA), is doing with the U.S. Department of Energy’s Advanced Vehicle Testing Activity (AVTA), please visit

Laboratory Testing Services

Baseline Vehicle Testing

eTec developed a set of highly repeatable test procedures under contract with the U.S. Department of Energy in conjunction with vehicle manufactures and industry stakeholders with the objective of measuring real-world vehicle performance.

This testing is conducted on dynamometers and closed-track environments. Vehicles are evaluated using these Baseline Test Procedures in the following areas:

  • Fuel consumption
  • Acceleration
  • Gradeability
  • Road load coefficients (to support dynamometer testing)
  • Vehicle durability
  • Charger performance

Track testing is conducted at automotive proving grounds near Phoenix, Arizona. Dynamometer testing is conducted at Argonne National Laboratory’s Advanced Powertrain Test Facility outside of Chicago, Illinois.

Baseline testing has been performed under contract with the U.S. Department of Energy for the following types of vehicles:

  • Battery Electric Vehicle
  • Neighborhood Electric Vehicle
  • Hybrid Electric Vehicle
  • Plug-in Hybrid Electric Vehicle
  • Hydrogen ICE Vehicle

Test results are summarized based on each client’s individual requirements. Reports for the US DOE AVTA activity are presented in detailed test reports and summarized for wide dissemination in one-page data sheets. (See the USDOE AVTA webpage at:

On-road Accelerated Testing Services

Accelerated Vehicle Testing provides a way to rapidly collect performance and reliability data for advanced vehicle technologies. Accelerated Vehicle Testing procedures have been developed under contract to the U.S. Department of Energy for the following types of vehicles:

  • Battery Electric Vehicle
  • Neighborhood Electric Vehicle
  • Hybrid Electric Vehicle
  • Plug-in Hybrid Electric Vehicle
  • Hydrogen ICE Vehicle

Accelerated Vehicle Testing typically utilizes dedicated drivers in a carefully controlled environment with the goal of performing repeatable drive cycles and maximizing the number of miles driven in a limited time period. On-board data is collected on the vehicles utilizing either the eTec developed data collection system or data provided through the vehicle manufacturers system. Other data collected includes fuel use, maintenance costs and vehicle reliability.

For additional information about the work eTec and its sister company, Electric Transportation Applications (ETA), is doing with the U.S. Department of Energy’s Advanced Vehicle Testing Activity (AVTA), please visit

Dept. of Energy – HICE Durability Testing Project

U.S. Department of Energy – HICE Durability Testing Project

The U.S. Department of Energy (USDOE), under the Funding Opportunity Announcement No. DE-PS26-06NT42801, entitled “Alternative Hydrogen Production Pathway and Hydrogen Utilization” has awarded eTec $1.247 million for its application entitled “Investigation of Hydrogen-Fueled Internal Combustion Engine Durability.”

The total project, valued at $1.889 million investigates the durability of an internal combustion engine (ICE) running on pure hydrogen gas. The project is divided into four tasks. An abbreviated description of the project is provided below:

Task 1: Laboratory Accelerated Durability Testing
Laboratory testing will center on the long-term durability of the complete engine system. A 6.0-liter V-8 engine will be assembled using the design develop by eTec and Roush Industries, installed on an engine dynamometer test cell operated by Roush prepared specifically for hydrogen and operated for 1000 hours at various performance levels. Engine wear and oil samples will be evaluated at the end of the test period.

Task 2: Field Testing of Diverse Fleets
Field testing will include operation of 8 light-duty HICE pickup trucks converted by eTec and Roush Industries. Vehicles will be operated for a minimum of 12,000 miles per year (each) for two years in typical commuting and transportation service. Records on fuel, maintenance will be collected and analyzed. Tail pipe emissions will be tested on two converted trucks prior to the field testing.

Task 3: Assessment of Durability Risks and Recommendations for Risk Reduction
Upon completion of laboratory and field testing, all operating and engine teardown data will be assembled for review. The data will be analyzed to determine factors impacting engine durability and performance (emissions and power).

Task 4: Reporting
Task reports will be prepared upon completion of each of the tasks. A Final report presenting the results of Task 3 assessments will be prepared which incorporates the final reports for Tasks 1 & 2.

Chevrolet Silverado/GMC Sierra HICE Conversion

eTec-Roush Hydrogen ICE Silverado Truck

Electric Transportation Engineering Corporation (eTec), with technical support from our project partners Roush Industries and Powertech Labs have developed the HICE Chevrolet Silverado/GMC Sierra 1500HD 6 passenger 100% Hydrogen Internal Combustion Engine Truck (“HICE Silverado”).

The HICE Silverado is an OEM-quality conversion of the 1500HD vehicle platform utilizing the Vortec 6.0 Liter V8 engine. For this development effort, ETEC partnered with other experts in the automotive and gas systems field. Roush Industries is a major automotive engineering and low-volume manufacturing company that services automotive OEM’s and Tier One Suppliers in all areas of automotive engineering, development and testing. Powertech Labs is a wholly owned subsidiary of BC Hydro operating 18 Labs at its Surrey BC facility with approximately 80 professional engineers, scientists and technologists and is world-renowned in hydrogen storage component and systems design, testing and certification. With the expertise of ETEC, Roush and Powertech, the HICE Silverado is built to the latest standards (both established CNG standards and those in draft form for hydrogen) and to the highest quality.

Although HICE technology is not considered as technically advanced as fuel cells by some, a significant amount of research and development effort was required to achieve the desired performance and tailpipe emissions goals. Integration with the existing GM platform includes replacement of the original GM Powertrain Control Module (PCM) to provide the flexibility required for proper engine calibration, instrumentation and vehicle systems operation and control for the automatic transmission to properly operate with the power curve of the HICE engine.

Of the first 9 HICE Silverados in production, eight will participate in the “Integrated Wasted Hydrogen Utilization Project (IWHUP)” a 3-year, 18 million dollar (Cdn) initiative sponsored by several departments of the provincial and Canadian federal government. The ninth truck will participate in the DOE Advanced Vehicle Testing Activity (AVTA) under the FreedomCAR and Vehicle Technologies Program which will perform vehicle durability and performance tests and publish the results on the AVTA website.

The HICE Silverado has excellent performance and versatility with 195 Hp / 265ft.lbs of torque, 6-passenger capability and a range of 210 miles (EPA Highway driving schedule).

Although more advancements and refinements are always desired, the performance and emission results of the current HICE Silverado are very encouraging. Delivery of the first few HICE Silverados has begun and customer feedback has been extremely positive.

HICE Silverado Development Background

Development of the HICE Silverado can be broken down into the following major development categories:

  • Mechanical engine modifications
  • Engine control hardware and software integration efforts
  • HICE Silverado Fuel System Integration
  • HICE Silverado Final Engine and Transmission Calibration

Mechanical Engine Modifications

The Vortec 6.0L V8 engine selected (shown in the accompanying pictures) provided some unique advantages including:

  • Available with desired truck platform
  • Alt Fuel Engine option (CNG & Propane) available that provides internal components designed for traditional alternative gaseous fuels that is also beneficial for use with Hydrogen
  • High horsepower rating of 300 hp @ 4400 rpm (gasoline fuel)
  • High torque rating of 360 lb-ft @ 4000 rpm (gasoline fuel)

Performance goals were established early on in the development program that focused on a “lean-burn” strategy to achieve very low NOx emissions while trying to maintain acceptable horsepower and torque performance for the Silverado HD1500 truck platform. Integration of a Lysholm supercharger to the intake manifold and large liquid- to-air intercooler provide the added air-boost to meet this requirement. Gaseous fuel injectors designed for use with Hydrogen are installed on the engine using custom fuel rails with fuel temperature and pressure sensors. Additional engine modifications include the integration of an OEM electronic throttle and replacement of the standard spark plugs with custom plugs designed to operate in the Hydrogen fuel environment.

Summarizing the engine modifications:

  • Integration of Lysholm supercharger to intake manifold
  • Integration of large liquid to air intercooler
  • Integration of OEM electronic throttle
  • Integration of fuel-specific fuel injectors, fuel rails and sensors
  • Selection of spark plugs for operation in hydrogen combustion environment

Project Management Services

eTec has qualified staff to perform complete project management services from the overall design of the hydrogen station to project managing the construction, start-up and system operation and maintenance services. eTec’s experience includes:

  • Project Management, design and construction of the Arizona Public Service Company Hydrogen Park refueling station
  • Ongoing Operation and Maintenance of the Arizona Public Service Company Hydrogen Park refueling station
  • eTec was awarded the California Fuel Cell Partnership (CaFCP) contract in August 2007 to own, operate and maintain the Hydrogen Station Testing Apparatus (STA). eTec performs Hydrogen testing using the STA for the CaFCP at selected H2 stations throughout the State of California.

H2 GEN 2 Storage System

The Generation 2 Hydrogen Energy Storage System addresses the challenges of siting a Hydrogen Fueling Station in close proximity to other commercial buildings and reduces the typically long time periods required for obtaining a station operating permit.

GEN 2 Station Features:

  • Modular Systems
  • Compression and Storage
  • 100/5/1 Vehicle/Day Capacities
  • Compatible with all Product Systems
  • Interfaces with any Dispenser System
  • Designed for Severe Environmental Conditions (Seismic Zone 4 & 100mph wind load)
  • Designed for Commercial Application
    • Exhaustive Safety Analysis Supports Permitting
    • Design Features Provide Inherent Safety
    • Zero Setback Requirement Allows Convenient Siting

GEN 2 Station Design

  • Storage
    • Vertical Tubes
    • Modular Options (Diameter and Length)
  • Compression
    • Oil Free
    • 5,000 psi or 10,000 psi
    • Direct Fill Option
  • Designs to Minimize Magnitude of Hazards
    • Compartmentalize Storage
    • Elevate Piping
    • Minimize Pipe Diameter
    • Double Wall Piping System
    • Valve Manifold Vessels
  • Facilitates Gas Zone Separation
  • Redirects Detonation through Coaxial Pipe to Benign Location
  • Allows Valve Maintenance

Shop Assembled – Skid Design

Valve Manifold Vessels