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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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49 records · Page 3

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Effects of multiple simultaneous faults on characteristic fault detection features of a heat pump in cooling mode

Faults in air-cooled vapor compression air-conditioning systems are known to reduce performance, including efficiency, capacity, and lifespan. Their effects have been studied, and fault detection and diagnostic (FDD) methods have been developed as tools for field technicians to install or repair systems, or for monitoring to alert operators to the fault’s presence. Most of this work has focused on faults that occur singly. It is likely that in some systems, multiple faults occur simultaneously, but it is uncertain what effects this may have on diagnostics. Here, this paper describes a laboratory study of a split system air source heat pump in which combinations of two, three, and four simultaneous faults occur. The study includes all combinations of: improper evaporator airflow; overcharge or undercharge of refrigerant; liquid line restrictions; and non-condensable gas in the refrigerant, each at multiple fault intensities. Fault features – those characteristics that can be determined from measurements, for use in diagnostics – are analyzed, and the key fault features are presented. A robust existing method for determining refrigerant charge, the virtual refrigerant charge sensor (VRC) is tested using the multiple fault data, in order to understand how its performance is impacted by the combined faults. The VRC performs well, typically able to correctly determine whether a system is undercharged or overcharged, but the magnitude estimates are impacted. The results suggest that simple subcooling-based methods of charging a system are likely to provide unsatisfactory results when other faults are present.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Active multi-mode data analysis to improve fault diagnosis in AHUs

Faults in heating, ventilation and air conditioning systems can lead to increased energy consumption, occupant comfort issues, and reduced equipment lifetime. Commercial fault detection and diagnosis (FDD) tools has been increasingly deployed in U.S. commercial buildings. While they are helping to achieve energy efficiency and operational reliability, there remain gaps in their fault diagnostic capabilities. The diagnostic results often contain multiple distinct candidate root causes (CRCs) or offer no insight into CRCs. This study developed a novel active rule-based multi-mode data analysis method to enhance diagnostic resolution by applying proven rule sets and additional new rules to data from multiple known operational modes. The proposed method was demonstrated using enhanced air handling unit performance assessment rule sets and validated with the simulated data of two air handling units. New metrics, namely, reduced number of CRCs and improvement ratio, were developed to quantify the improvement of fault diagnostic resolution. The validation results showed that the proposed method effectively reduced the number of CRCs in contrast to analyzing data solely for a single mode of operation. It achieved a median improvement ratio of 80% in 19 test cases.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Haxall-based (Axon) fault auto-correction package for building HVAC system (Haxall-based Fault Correction) v1.0

Haxall-based Fault Correction is a set of fault auto-correction algorithms implemented using the Axon language. These algorithms can automatically fix equipment and control problems as they arise and improve the operation of building Heating, Ventilation, and Air Conditioning (HVAC) systems. The coded auto-correction algorithms include mitigation of rogue zones, ASHRAE Guideline 36 static pressure and supply air reset, resolution of control hunting due to improper settings in a proportional-integral-derivative controller, correction of biased temperature sensors, etc. FDD tools with enhanced auto-correction capability can resolve control problems as they are detected, increasing energy savings and emissions reductions while freeing up operational staff expertise for the hardest facility problems.

Vitti, Raphael↗

DOE OSTI2020

Review: Sensor Impact on Building Controls and Automatic Fault Detection and Diagnosis (AFDD)

This report summarizes a literature review as a Q1 deliverable of the “Sensor Impact Evaluation and Verification” project. This project’s overarching goal is to develop a framework for investigating the impact of sensor deployment and configuration for building energy optimization, fault detection and diagnosis (FDD), occupants’ thermal comfort, and potential grid efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Gray-Box Fault Models and Applications for Low-Carbon Emission CO 2 Refrigeration Systems

CO 2 refrigeration systems have attracted more attentions in recent years because of their zero-carbon emission advantages compared with traditional refrigerants. These systems are widely used in certain commercial buildings such as supermarkets. However, very limited energy studies have been done for such refrigeration systems under faults. This study investigated five common faults for supermarket transcritical CO 2 refrigeration systems with display cases. The following major tasks were implemented for this study. (1) Five fault models (gray-box format) regarding the power consumption and supply air temperature were proposed for low- and high-temperature display cases, respectively. The models cover: ice accumulation on evaporator coil, evaporator fan partial failure, expansion valve failure, display door open, and condenser blockage. (2) These fault models were calibrated with field tests, and the modeling accuracies were in good agreement with measurement datasets. (3) The proposed fault models demonstrated more than 90% of fault detection for Fault Detection and Diagnostics (FDD) purposes for both field measurement and simulated data.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Development and Validation of Home Comfort System for Total Performance Deficiency/Fault Detection and Optimal Comfort Control

In this project, we developed and tested a learning-based home thermal model that facilitates the operation of a model predictive control (MPC)-based optimization agent and an automated fault detection and diagnosis (AFDD) agent. The home thermal model was constructed using a two-node resistor-capacitor model. Moreover, two accompanying parameter identification methods were introduced, least-squares and optimization. Based on the home thermal model, the MPC-based optimization agent was developed to optimize residential HVAC operation. Using two FDD methods, the AFDD agent was constructed to detect and diagnose two prevalent residential AC faults, airflow reduction and refrigerant undercharge. The home thermal model, along with the MPC-based optimization agent and AFDD agent, were tested at the Norman Test House, Miami Test House, Pacific Northwest National Laboratory (PNNL) Test House A, and PNNL Test House B. Finally, they were also field tested in nine demonstration homes with real occupants.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

5G-TSN Architecture Capable of Providing Real-time Situational Awareness to Fossil-Energy (FE) Generation Systems (Final Technical Report)

This final report highlights the comprehensive achievements of the project focused on developing and validating a 5G-Time Sensitive Networking (TSN) architecture tailored for real-time operational awareness in fossil energy systems. The initiative successfully advanced through a series of technical milestones, including the integration of EMI-aware network models, deployment of advanced simulation frameworks, and real-world performance characterization at key sites such as UTEP and Fabens. Through the strategic use of NetSim® software, the team created and validated network configurations for wired and wireless environments, tested under varying congestion conditions, and verified network slicing implementations for URLLC-specific applications. Major accomplishments include the migration of simulation tools to the latest NetSim® version to support accurate modeling of TSN and network slicing, extensive EMI measurement campaigns, and the development of a robust simulation model for end-to-end SCADA system integration. Simulations compared both TDD and FDD duplexing modes, revealing insights into their performance under congested conditions. The wireless network was benchmarked for throughput, jitter, and delay metrics, aligning with 3GPP Release 15/16 and IEEE 802.1-TSN standards. A peer-reviewed conference paper was accepted and published, contributing to the broader academic and industrial discourse on 5G-TSN integration in energy systems, in addition to a journal article. Despite minor delays due to software limitations, the project achieved its objectives and delivered validated architecture ready for deployment in advanced energy network environments.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Compressor is A Sensor (Final Report)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

LBNL Fault Detection and Diagnostics Datasets

These datasets can be used to evaluate and benchmark the performance accuracy of Fault Detection and Diagnostics (FDD) algorithms or tools. It contains operational data from simulation, laboratory experiments, and field measurements from real buildings for seven HVAC systems/equipment (rooftop unit, single-duct air handler unit, dual-duct air handler unit, variable air volume box, fan coil unit, chiller plant, and boiler plant). Each dataset includes a .pdf file to document key information necessary to understand the content and scope, multiple csv files containing all the time-series data for faults at different severity levels and one fault-free case, and a ttl file to visualize the data according to BRICK schema. The dataset was created by LBNL, PNNL, NREL, ORNL and Drexel University.

AC↗

DOE OSTI2020

Virtual Pressure Sensor for Electronic Expansion Valve Control in a Vapor Compression Refrigeration System

Virtual sensor technology, which uses simulation models/algorithms to calculate a value to represent an unmeasured variable or replace a directly measured reading, has attracted many studies in the heating, ventilation, air conditioning and refrigeration (HVAC&R) industry. However, most virtual sensor technologies are developed for fault detection and diagnostics (FDD) purposes, which generally compare the virtual sensor values with actual measured values to detect if any fault occurred and identify the causes that led to the fault. It is rare to see studies focus on control performance of virtual sensors after substituting an actual sensor. This is particularly important for the system with no redundant sensor since a virtual sensor is the most effective way to operate the system in the desirable region when any sensor failure occurs. To address this gap, this paper develops a new virtual pressure sensor technology to substitute the actual pressure measurement for electronic expansion valve (EXV) control in a vapor compression refrigeration system by integrating compressor and valve characteristics. The control performance of this proposed virtual pressure sensor technology under various operating conditions is validated with experimental data. Closed loop EXV control simulations with the proposed virtual pressure sensor are conducted, and the results are analyzed.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Air Conditioning Systems Fault Detection and Diagnosis-Based Sensing and Data-Driven Approaches

The air conditioning (AC) system is the primary building end-use contributor to the peak demand for energy. The energy consumed by this system has grown as fast as it has in the last few decades, not only in the residential section but also in the industry and transport sectors. Therefore, to combat energy crises, urgent actions on energy efficiency should be taken to support energy security. Consequently, the faults in AC system components increase energy consumption due to the degradation of the system’s performance and the losses in the energy conversion procedure. In this work, AC system fault detection and diagnosis (FDD) methods are investigated to propose analytic tools to identify faults and provide solutions to those problems. The analysis of existing work shows that data-driven approaches are more accurate for both soft and hard fault detection and diagnosis in AC systems. Therefore, the proposed methods are not accurate for simultaneous fault detection, while in some works, authors tested the method with several faults separately without investigating scenarios that combine more than one fault. Moreover, this study shows that integrating data-driven approaches requires deploying an optimal sensing and measurement architecture that can detect a maximum number of faults with minimally deployed sensors. The new sensing, information, and communication technologies are discussed for their integration in AC system monitoring in order to optimize system operation and detect faults.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Empirical Modeling of Direct Expansion (DX) Cooling System for Multiple Research Use Cases

This study provides a general procedure to generate a direct expansion (DX) cooling coil system for a roof top unit (RTU), which is a typical heating ventilation and air-conditioning (HVAC) system for commercial buildings in the United States. Experimental data from a full-scale unoccupied 2-story commercial building is used for the HVAC modeling. The regression for identifying the model coefficients was carried out with multiple stages, and the results were validated with measured data. The model’s applicability was evaluated with multiple case studies, including a building energy simulation (BES) program validation, model-based predictive control (MPC), and fault diagnostics and detection (FDD).

42 ENGINEERING↗

DOE OSTI2022

A Universal Refrigerant Charge Fault Detection and Diagnostics Method Based on Pump Down Operation

The performance of the heat pump system varies greatly depending on the refrigerant charge amount. Improving the refrigerant charge fault detection and diagnostics (FDD) method of vapor compression systems have the potential for increasing energy efficiency and reducing service cost. Previous studies to predict refrigerant charge amount are mostly empirical methods which require significant amount of experimental data for high accuracy. The primary goal of this research is to develop a universal charge fault detection method which requires only a few experimental data with high prediction accuracy.Currently, pump down operations are typical practices by HVAC technicians when they need to open the refrigerant circuit to make a repairment. In addition, compressors have a built-in low-pressure cut-off protection function, and the compressor performance maps are commonly available from manufacturers. The proposed method innovatively utilizes the typical pump down operation, the compressor low-pressure cut-off protection, and the compressor performance map. It does not require any geometry information of heat exchangers, refrigerant lines, or charge buffers.The new charge prediction method is firstly formulated through theoretical analysis, then verified and calibrated by a quasi-steady-state simulation of the pump down process for a residential heat pump system. The quasi steady-state simulation uses an HVAC system simulation framework driven by DOE/ORNL Heat Pump Design Model (HPDM). Preliminary experiment validations with heat pump refrigerant leakage tests demonstrate the deviation of the proposed charge prediction method compared with measurement is within 8%. This technology makes refrigerant charge amount available at the technician’s fingertips and leads to shorter maintenance time and fewer site visits.

Li, Zhenning↗