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DOE OSTI2021

Glass/glass photovoltaic module reliability and degradation: a review

Glass/glass (G/G) photovoltaic (PV) module construction is quickly rising in popularity due to increased demand for bifacial PV modules, with additional applications for thin-film and building-integrated PV technologies. G/G modules are expected to withstand harsh environmental conditions and extend the installed module lifespan to greater than 30 years compared to conventional glass/backsheet (G/B) modules. With the rapid growth of G/G deployment, understanding the outdoor performance, degradation, and reliability of this PV module construction becomes highly valuable. In this review, we present the history of G/G modules that have existed in the field for the past 20 years, their subsequent reliability issues under different climates, and methods for accelerated testing and characterization of both cells and packaging materials. We highlight some general trends of G/G modules, such as greater degradation when using poly(ethylene-co-vinyl acetate) (EVA) encapsulants, causing the industry to move toward polyolefin-based encapsulants. Transparent backsheets have also been introduced as an alternative to the rear glass for decreasing the module weight and aiding the effusion of trapped gaseous degradation products in the laminate. New amendments to IEC 61215 standard protocols for G/G bifacial modules have also been proposed so that the rear side power generation and UV exposure will be standardized. We further summarize a suite of destructive and non-destructive characterization techniques, such as current-voltage scans, module electro-optical imaging, adhesion tests, nanoscale structural/chemical investigation, and forensic analysis, to provide deeper insights into the fundamental properties of the module materials degradation and how it can be monitored in the G/G construction. This will set the groundwork for future research and product development.

14 SOLAR ENERGY↗

DOE OSTI2021

Glass/Glass Photovoltaic Module Reliability and Degradation: A Review - Figures

transparent backsheet↗

DOE OSTI2026

Autonomous monitoring of algal biomass: Success stories and lessons learned from long-term field deployment

Autonomous, high-frequency monitoring of outdoor algal ponds is needed to quantify biomass productivity and detect culture decline in environments prone to contamination, grazers, and variable operating conditions. We report successes and lessons learned in translating a laboratory spectroradiometric monitoring approach to a multi-year autonomous field deployment at the Arizona Center for Algae Technology and Innovation (AzCATI). The system measures spectrally resolved pond reflectance by ratioing upwelling radiance from each raceway to simultaneous downwelling sky irradiance using fiber-coupled spectrometers. A physics-based reflectance model (ASHARP) is fit to each spectrum pair to estimate optical parameters, including a biomass-proxy coefficient (C a ) which enables near-real-time tracking of biomass accumulation and culture state at 2–5 min intervals. From May 2022 through September 2025 the platform operated continuously while scaling from two to six raceway ponds. Several strains of algae were monitored successfully, including the high productivity Tetraselmis striata and Picochlorum celeri. Transitioning data acquisition from a Windows laptop to a Raspberry Pi improved uptime from 57% (2022) to ~89% (2024–2025) and enabled routine real-time analysis. Further, we converted relative biomass estimates to absolute ash-free dry weight (AFDW) using experimentally-derived calibrations, providing field-relevant biomass predictions with conservative confidence bounds. These results demonstrate the feasibility of long-term, autonomous optical monitoring for well-mixed open-raceway algal cultivation and provide practical guidance for reliable field operation and scaling.

Katinas, Christopher Michael [Sandia National Labo↗

DOE OSTI2024

Performance Modelling and Yearlong Outdoor Degradation Analysis of a GaAs//Si Tandem Module

Silicon-based tandem photovoltaic cells and modules are forecasted to enter mass production around the year 2026. Previous research efforts on tandem photovoltaic technology have focused heavily on increasing cell efficiencies. However, for successful large-scale deployment of tandem modules, reliability and long-term durability will be equally important. Outdoor performance data beyond the one-year mark enable sophisticated degradation analysis and help build confidence in the reliability and durability of this new technology.

degradation rate↗

DOE OSTI2025

Intraday Outdoor Efficiency Changes in Metal-Halide Perovskite Photovoltaic Modules

Here, we present outdoor observations of metal-halide perovskite modules deployed in the Photovoltaic Accelerator for Commercializing Technologies center, which houses one of the world's broadest efforts to test metal-halide perovskite photovoltaic modules outdoors. As of January 2025, outdoor testing has encompassed over 150 modules from 14 different partners. Our findings illustrate how daily changes in efficiency, driven by exposure to light, affect field performance in real-world conditions. These effects cannot be explained by existing outdoor performance models and frustrate the notion of a traditional temperature coefficient.

14 SOLAR ENERGY↗

DOE OSTI2025

Evaluating indoor thermal resilience of passive and low-power cooling shelters for outdoor workers in India

India’s 231 million outdoor workers are exposed to deadly heat during heat waves. We report results from a simulation-based study that focuses on passive design of cooling shelters for the hot and dry climate zone of India. The goal is to design a cooler-than-outdoor shelter for outdoor workers’ intermittent rest and recovery from heat stress during their arduous outdoor work, to avoid heat-related morbidities and mortality. Expected indoor thermal conditions in low-cost cooling shelters deploying a range of passive designs and low-power active measures are investigated, consistent with the current Indian standards and practices, located in the city of Jodhpur in western India. Heat resilience of the shelter was measured with the predicted reduction of hazardous hours inside the shelter based on the wet-bulb globe temperature (WBGT) and extended heat index. These measures include improving the building envelope, installing cool roofs, using internal thermal mass, and natural ventilation. Additionally, a low-power active measure of using ventilation fans and ceiling fans is explored. EnergyPlus-based simulation results show that simple, commonly available measures, particularly natural ventilation and ceiling fans, achieve the most significant reductions in overheating danger hours, by 22% and 21%, respectively, while more complex or costly passive strategies yield only marginal additional benefits. Moreover, combined measure packages are identified that can reduce the indoor WBGT by 8 to 10 °C, eliminating overheating danger hours. These findings highlight the critical importance of scalable, low-cost, and easily deployable cooling solutions for developing resilient cooling shelters for vulnerable outdoor workers during heat waves in India.

building performance↗

DOE OSTI2020

Application of Intelligent Load Control to Manage Building Loads to Support Rapid Growth of Distributed Renewable Generation

Electricity utilities are faced with the mounting challenge of providing a stable supply of power to meet the growing demand while also integrating rapid growth in distributed variable renewable generation. Traditional means of balancing short- and long-term supply and demand imbalance will be expensive. Alternative approaches of using flexible loads in buildings are needed to mitigate the imbalance at a lower cost. This paper shows how the intelligent load control (ILC) process can be used to manage loads in buildings by dynamically prioritizing loads for curtailment using both quantitative and qualitative criteria. The ILC process can be deployed on low-cost computing platforms without the need for any additional sensing. ILC was first validated in a simulation environment to provide two grid service use cases: (1) managing monthly peak electricity demand and (2) managing buildings’ electricity consumption during a capacity bidding event. After being successfully tested in a simulation environment, ILC was deployed on real buildings to manage electricity consumption to provide two different use cases under different outdoor operating conditions. Both the simulation tests and the real building experiments were deployed using VOLTTRON™, a distributed sensing and control platform. The results from the tests and experiments showed that ILC was able to manage the controllable loads (heat pumps) in the building to maintain the electricity consumption at the desired level without a significant impact on occupant comfort. Overall, the results demonstrate that the ILC allows coordination of the controllable loads and provides a more intelligent means of load management than the traditional duty-cycling approach.

Kim, Woohyun↗

DOE OSTI2023

Development of a field-deployable qPCR assay for real-time pest monitoring in algal cultivation systems

Outdoor cultivation is commonly used to produce algal biomass for a variety of bioproducts including food, feed, fuel, pharmaceuticals, and nutraceuticals. Outdoor cultivation ponds are highly susceptible to pest pressures that may lead to periods of low productivity or even entire loss of the algal crop. Consequently, there is a need for rapid, real-time tracking of pests for early intervention to mitigate crop loss. In this work, we describe the development of a field deployable, low-cost qPCR assay for detecting both known and novel pests of a farmed eukaryotic alga species, Nannochloropsis sp. We performed a proximity guided metagenome deconvolution approach (ProxiMeta™) to discover novel pests that temporally correspond to periods of reduced pond productivity. This approach provided high-quality metagenome assemblies that were used to design qPCR probes to detect specific pests of interest. The portable qPCR assay, designed to be deployed at remote field locations, enables low-cost surveillance with a rapid (2 h) turn-around time. Frequent sampling allows for early detection and prompts intervention strategies to remedy infected ponds to minimize crop loss. The qPCR assay was used to successfully detect a known predatory bacterium within the order Bdellovibrionales both in the lab and at a remote field location. Furthermore, we assembled the genome of two novel, site-specific pests in the Saprospiraceae family and successfully designed qPCR probes that differentially detected their presence in two different pond locations. Ultimately, this assay has the potential to monitor multiple pests simultaneously and tailor targets to match likely pest infections that differ across geographical locations, helping to mitigate crop loss on a large scale.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Detecting Low-level Radiation Sources Using Border Monitoring Gamma Sensors

We consider a problem of detecting a low-level radiation source using a network of Gamma spectral sensors placed on the periphery of a monitored region. We propose a computationally light-weight, correlation-based method which is primarily intended for systems with limited computing capacity. Sensor measurements are combined at the fusion by first generating decisions at each time step and then taking their majority vote within a time widow. At each time step, decisions are generated using two strategies: (i) SUM method based on a threshold decision on a correlation statistic derived from measurements from all sensors, and (ii) OR method based on logical-OR of threshold decisions based on correlations statistics of individual sensor measurements. We derive analytical performance bounds for false alarm rates of SUM and OR methods, and show that their performance is enhanced by the temporal smoothing of majority vote within a time window. Using measurements from a test campaign, we generate a border monitoring scenario with twelve 2"x2" NaI Gamma sensors deployed on the periphery of 42m x 42m outdoor region. A Cs-137 source is moved in a straight-line across this region, starting several meters outside and finally moving away from it. We illustrate the performance of both correlation-based detection methods, and compare their performances with each other and with a particle filter method. Overall, under small false-alarm conditions, the OR fusion is found to produce better detection performance.

Sen, Satyabrata↗

DOE OSTI2021

Development of Risk Mitigation Guidance for Hydrogen Sensor Placement Indoors and Outdoors

Guidance on Sensor Placement remains one of the top priorities for the safe deployment of hydrogen and fuel cell equipment in the commercial marketplace. Building on the success of Phase 1 work reported at ICHS2019 and published in IJHE, this paper discusses the consecutive steps to further develop and validate such guidance for mechanically ventilated enclosures. The key step included a more in-depth analysis of sensitivity to variation of physical parameters in a small enclosure, and finally, expansion of the developed approach to confined spaces in an outdoor environment.

codes and standards↗

DOE OSTI2023

FY23 Update: Aerosol Sampling for the Canister Deposition Field Demonstration

This report describes the results of preliminary testing of aerosol monitoring equipment that will be used to continuously monitor the aerosol source term for the multi-year Canister Deposition Field Demonstration (CDFD). These data are required inputs for the development and validation of models for the deposition of dust and potentially corrosive salts on the surface of spent nuclear fuel (SNF) dry storage canisters. Surface salt loads correlate with the extent of corrosion damage on a metal surface, and potentially to the likelihood and timing of initiation of stress corrosion cracks. Aerosols will be monitored at the CDFD site using three instruments. A Dekati ® ELPI+ cascade impactor will be used for real-time monitoring of aerosol particle sizes. It will also collect dust in 14 size bins on impactor targets that can be chemically analyzed to determine the soluble salts present as a function of particle size. However, this instrument can only measure dried aerosols, with a diameter of <10 µm. The second instrument is a Topas laser particle size spectrometer, which provides real-time monitoring of aerosol particle sizes up to ~40 µm in size. It monitors both the ambient (potentially deliquesced) aerosol particle size distributions required for the dust deposition models and the distributions of the equivalent dried particles, allowing correlation with the Dekati ® data. However, it does not discriminate between inert dust particles and salt aerosols, and it does not retain samples of the different particle sizes for later analysis. The third instrument that will monitor aerosols at the CDFD site is a Clean Air Status and Trends Network (CASTNET) tower, which uses a multiple canister system to collect weekly samples for analysis to total suspended aerosol particle compositions and atmospheric gas concentrations. This status report describes work in FY23 to develop the capabilities for using these tools. In two training exercises, the cascade impactor and laser particle sizer were deployed in two different testing environments, one indoor and one outdoor. For the cascade impactor, the tests provided opportunities for the operators to familiarize themselves with impactor substrate preparation, and post-test sample removal and analysis. For the laser particle sizer, the tests were used to evaluate different instrument parameters, to determine the most appropriate settings for capturing transient events. Data and samples were collected for weeks to months for each test, and the results are presented here. In addition to the preliminary testing, contracts were developed with WSP Analytical Labs for sample preparation and analysis of the cascade impactor samples. The impactor tower from outdoor test was delivered to WSP and used to train the staff there in disassembly, sample extraction, sample analysis, and tower reassembly with new target substrates. These are tasks that WSP will be performing routinely for the CDFD project. The CASTNET system cannot be purchased or tested until an actual site has been selected for the CDFD test. Work for this FY has been restricted to preparation of contracts for purchasing the CASTNET tower, and for sample analysis, once the tower is in operation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

60 GHz Outdoor Propagation Measurements and Analysis Using Facebook Terragraph Radios

The high attenuation of millimeter-wave (mmWave) would significantly reduce the coverage areas, and hence it is critical to study the propagation characteristics of mmWave in multiple deployment scenarios. In this work, we investigated the propagation and scattering behavior of 60 GHz mmWave signals in outdoor environments at a travel distance of 98 m for an aerial link (rooftop to rooftop), and 147 m for a ground link (light-pole to light-pole). Measurements were carried out using Facebook Terragraph (TG) radios. Results include received power, path loss, signal-to-noise ratio (SNR), and root mean square (RMS) delay spread for all beamforming directions supported by the antenna array. Strong line-of-sight (LOS) propagation exists in both links. We also observed rich multipath components (MPCs) due to edge scatterings in the aerial link, while only LOS and ground reflection MPCs in the other link.

60 GHz↗

DOE OSTI2022

Package Development for Reliability Testing of Perovskites

Metal halide perovskite solar cells have reached a critical point in their development. At a current certified record efficiency of 25.7% for a single-junction, research-scale cell, they now garner serious attention from the solar cell industry as a promising route to widespread, low-cost photovoltaics in single- or tandem-junction configurations. However, more work to demonstrate their durability under real-world outdoor test conditions is necessary to ensure the long-term success and deployment of the technology. Differences in chemistry, processes, and their combination result in unique performance limiters for both efficiency and stability. Further, as many active formulations and layer/cell stack combinations are sensitive to temperature, air, and moisture, it is important to separate intrinsic limitations to stability relative to these extrinsic sources. This presents a particular need for the development of an appropriate and reliable package for environmental (i.e., accelerated and outdoor) testing that will permit these different factors to be evaluated and understood.

14 SOLAR ENERGY↗

DOE OSTI2022

Quantifying Impacts of Renewable Electricity Deployment on Air Quality and Human Health in Southeast Asia Based on Aims III Scenarios

Exposure to outdoor air pollution is the largest environmental risk factor for death and disease worldwide, associated with millions of cases of excess deaths (mortality) each year. Although there are many pollutants in the air that affect our health, the most important class of pollutants is fine particulate matter, PM 2.5 , which are airborne particles of diameter ≤2.5 micrometers (µm). These particles are small enough to deposit deep in the respiratory system where they can then enter the bloodstream, traveling and causing damage to other bodily systems. Exposure to outdoor (ambient) PM 2.5 has been found to be the most important environmental risk factor for mortality in Southeast Asia, associated with 130,000 - 320,000 excess deaths in Association of Southeast Asian Nations (ASEAN) member countries in 2019. Southeast Asia, especially its mega-cities, but also other areas, has some of the worst air quality in the world. Almost all human activity emits air pollutants. Fine particulate matter is both directly emitted and formed in the atmosphere through chemical reactions, the latter of which requires modeling to predict. Power generation is one of the major sources of air pollutants that lead to elevated concentrations of fine particulate matter, including in Southeast Asia. Fossil fuel combustion for power generation, especially coal but also diesel, is the main source of air pollutant emissions from power generation. While natural gas burns cleaner than coal or diesel, in the quantities combusted for power generation in Southeast Asia, it is also a significant emitter. This study augments the ASEAN Interconnection Masterplan Study III (AIMS III) by quantifying changes to air quality and human health that result from its renewable integration and transmission interconnection scenarios. Performing this analysis requires translation of the changes in projected generation from different power sector fuel sources in the AIMS III scenarios to changes in air pollutant emissions, developing what's known as an emissions inventory for each scenario and year evaluated. We then use for the first time a new global, reduced-complexity air quality model to transform the changes in emissions to changes in air pollutant concentration of the deadliest air pollutant for human health, fine particulate matter (or PM 2.5 ). The air quality model, Global InMAP, then utilizes the location of human population in ASEAN countries to calculate exposure to PM 2.5 concentration changes and translates that to estimates of excess mortality attributable to the AIMS III scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Organisation of Diverse Mechanisms of Secondary Ice Production among Basic Convective and Stratiform Cloud-types

This 3-year DoE-funded joint project had the over-arching aim of understanding how ice is initiated in clouds of various types. Focus was given to processes of fragmentation of pre-existing ice, which can occur in positive feedback loops (‘ice multiplication’). A basic question to address was which fragmentation processes prevail in which basic cloud-types. The approach was to use cloud models and field observations, while pioneering our own lab observations of ice initiation to break the deadlock from the past lack of lab observations. Historically, the tendency of the cloud physics community to avoid doing lab observations has allowed a vast gap in knowledge about ice initiation to persist for decades. During the first part of the project, new formulations were created to treat two overlooked types of fragmentation of ice. First, sublimational breakup of ice was treated based on a theoretical formula that we fitted to a pooled dataset of lab observations published previously in the literature. Second, a new mode of fragmentation of freezing raindrops was treated, which involves a supercooled drop being hit by a more massive ice particle. Some of the secondary droplets from the impact freeze. This work was done at Manchester University by Co-I Connolly. Then during the second part, both formulations were implemented in our ‘aerosol-cloud model’ (AC). AC has a hybrid bin/bulk microphysics scheme, and now represents four processes of SIP. The accuracy of AC was evaluated for four cases typifying four basic cloud-types: slightly cold-based stratiform cloud and cold-, warm- and very warm-based convective clouds. We discovered that the warmth of cloud-base, especially in the tropics, promotes SIP processes of raindrop-freezing fragmentation and rime-splintering, and surprisingly, sublimational breakup too. It was found that breakup in ice-ice collisions is ubiquitous. Finally, a portable laboratory chamber was constructed at Lund and deployed in northern Sweden to observe breakup in graupel-snow collisions outdoors. This was seen to be even more prolific than treated in our 2018 formulation. Papers describing results are either published or soon to be published.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Design and evaluation of a low-cost sensor node for near-background methane measurement

Abstract. We developed a low-cost methane sensing node incorporating two metal oxide (MOx) sensors (Figaro Engineering TGS2611-E00 and TGS2600), humidity and temperature sensing, data storage, and telemetry. We deployed the prototype sensor alongside a reference methane analyzer at two sites: one outdoors and one indoors. We collected data at each site for several months across a range of environmental conditions (particularly temperature and humidity) and methane levels. We explored calibration models to investigate the performance of our system and its suitability for methane background monitoring and enhancement detection, first selecting a linear regression to fit a sensor baseline response and then fitting methane response by the sensor deviation from baseline. We achieved moderate accuracy in a 2 to 10 ppm methane range compared to data from the reference analyzer (RMSE < 0.6 ppm), but we found that the sensor response varied over time, possibly as a result of changes in non-targeted gas concentrations. We suggest that this cross sensitivity may be responsible for mixed results in previous studies. We discuss the implications of our results for the use of these and similar inexpensive MOx sensors for methane monitoring in the 2 to 10 ppm range.

Furuta, Daniel↗

DOE OSTI2021

PV Reference Cells for Outdoor Use: An Investigation of Calibration Factors

Reference cells are widely used in the photovoltaic (PV) industry to measure irradiance. For field applications and outdoor use, a variety of products are on the market, and they are often perceived as a low-cost alternative to thermopile radiometers. But reference cell characteristics differ substantially from the latter, therefore measurements made by one category of instrument cannot be substituted for or directly compared with the other. The National Renewable Energy Laboratory's (NREL's) Solar Radiation Research Laboratory is currently in a multiyear effort to develop guidance and recommendations for the design and use of outdoor reference cells, with a view to reducing inconsistencies and measurement uncertainty. The core of this effort is the long-term deployment of 39 units of 10 distinct types made by 6 manufacturers. This report compares the calibration factors provided by manufacturers - which most users rely upon - to those measured at a high level of accuracy by NREL's Cell Lab. It also reports on the application of the Broadband Outdoor Radiometer Calibration (BORCAL) method to reference cells. As a group, the factory calibrations for the crystalline silicon cells showed a small positive bias of +0.7%, with a tight distribution around this value. This is a very good result for the manufacturers. The two World Photovoltaic Scale cells constituted outliers, with a mean deviation of -0.8%, which is still within the reported uncertainty ranges. The data collected during the BORCAL procedures show a strong and systematic fluctuation of the apparent responsivity of the reference cells over the course of a day, which was anticipated. Consequently, the standard BORCAL R@45 calibration factors underestimated the reference cell responsivities by 1%-4%. An alternate responsivity indicator was developed, R'@30, incorporating adjustments for temperature response, spectral response, and directional response. This reduced the mean deviation to -0.4% compared to the Cell Lab. Further, two independent BORCAL sessions were able to produce the same values to within ±0.2%. This could be a viable approach for verifying reference cells using existing BORCAL infrastructure, for example, to evaluate their long-term stability. The daily profiles of responsivity obtained during the BORCAL sessions (provided in Appendix A) show clear patterns of differences between models, which provides evidence that their directional responses differ from each other; thus, two sensors that are calibrated correctly might give the same reading at 30° zenith angle but systematically different readings at 60°. The impact of these inconsistencies in field operation will be quantified using the long-term observations started in 2020.

14 SOLAR ENERGY↗

DOE OSTI2023

Medium-Voltage Testbed for Comparing Advanced Power Line Sensors vs. Measurement Transformers with Electrical Grid Events

Electrical utilities have relied upon potential transformers (PTs) and current transformers (CTs) for very accurate metering and to provide reliable signals for protective relays. Less expensive alternative sensing technologies offer the possibility of wider deployment, particularly in grids that employ distributed energy resources. In this work, the performance of an advanced medi-um-voltage sensor is compared with a reference PT and CT and experimentally evaluated for different power grid scenarios on an advanced outdoor power line sensor testbed at the US De-partment of Energy’s Oak Ridge National Laboratory. The sensor is based on a capacitive divider for voltage monitoring and a Rogowski coil with integrator for current monitoring. The advanced outdoor power line sensor testbed has a real-time simulator that was used to generate transient scenarios (e.g., electrical faults, capacitor bank operation, service restoration), while the analog signals were recorded by the same high resolution power meter. The behavior of analog signals, harmonic components, total harmonic distortion, and crest factors were assessed for this power line sensor compared with the reference PT/CT, because of the absence for testing standards for advanced outdoor power line sensors.

Piesciorovsky, Emilio↗