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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Accelerating Simulation for High-Fidelity PV Inverter System Reliability Assessment with High-Performance Computing

The overall cost of photovoltaic (PV) systems has shown a downward trend during the last decade; however, PV inverter failures account for the highest cost of operation and maintenance. To address this, reliability tools with powerful computation and better accuracy are required for the lifetime prediction and degradation evaluation of PV inverters. This paper proposes an event-driven parallel computing-based simulator. The proposed simulator applies high-performance computing techniques and other accessory optimization techniques-including cluster merging, adaptive model updates, and steady-state identification-to make reliability assessments for PV inverters under given input mission profiles and operating conditions with high efficiency and high fidelity. The main idea of the simulator and its workflow are introduced. Then, a demo PV inverter system simulator is implemented, and the speedup of the total simulations of the switching model reaches 123.03 times.

high-performance computing↗
DOE OSTI2024

PVDeg: Development of a Streamlined Tool for PV Degradation Modeling

The photovoltaic (PV) industry constantly aims for lower costs, higher-efficiency cells, and improved module designs. These trends lead to using new materials, designs, and manufacturing processes, resulting in a continually changing technological landscape. These changes can potentially introduce new, unknown degradation mechanisms and failure modes that are difficult to diagnose, analyze, test, and model. This introduces uncertainty into the expected lifetime of PV modules of 25 to 50 years. research efforts aim to achieve this while keeping performance degradation at a minimum for decades. This puts considerable pressure on improving the accuracy of long-term durability and reliability assessments. There is a need to organize the existing degradation data into an accessible format and to provide industry relevant tools for extrapolation from laboratory to field conditions. Because the core of this type of analysis involves calculations that are complicated but ubiquitous for many degradation processes, an enhanced predictive modeling framework will facilitate the analysis to help researchers keep up with the rapid pace of technological changes. In this work, we present an online tool that can be used to search for and analyze degradation information and extrapolate PV module performance and durability to field exposure. The tool will simplify many of the routine computational operations that are common to many degradation studies. The prediction tool will be built modular and published as open source, enabling users to expand on the existing framework. This repository will contain various degradation models and material parameters suitable for the reliability and durability assessment of materials and components deployed outdoors.

degradation↗
DOE OSTI2022

Correspondence: Bill of Materials Variation and Module Degradation in Utility-Scale PV Systems

We report photovoltaic (PV) modules of the same make and model are often assembled with different bills of materials (BOMs). In this correspondence, we revisit two case studies of utility-scale silicon PV systems in which these differing BOMs were associated with faster-than-expected degradation. In one of the sites, we found that different metallization paste had been used for grid lines in some cells leading to loss of contact to the cell and severe series resistance degradation. We provide details on the observation of this mechanism at two additional sites not described in the original article. In a second case study, we found that two different types of cell had been used, and that they could be distinguished by their back contact. Cells with uniform back contacts suffered from light and elevated temperature induced degradation (LeTID), while those with local back contacts did not. We also briefly describe BOM variations observed at other sites to illustrate the extent of the challenge. Our results from both sites underscore that variations in BOM, even among modules of the same make and model can lead to reliability challenges.

14 SOLAR ENERGY↗
DOE OSTI2023

A study of Cell Cracks Formation During Freight Shipping : Monitoring Shock and Temperature in Real-Time & Assessing Damages With Pre and Post-Transit Characterizations of PV Modules

The solar photovoltaic (PV) industry often experiences module damage during transportation. PV modules stacked horizontally and strapped on wooden pallets may develop failures impacting their efficiency (glass shattering, cracks, frame indentation, etc.), especially when modules are not packed by professionals. The appearance of failures during the shipment from one laboratory to another can be detrimental to research studies. In this study, we tested a reusable plastic pallet designed to ship modules vertically. Five technologies of commercial PV modules were shipped together from Arizona to Florida including: glass/glass bifacial modules (framed and frameless), glass/transparent backsheet bifacial modules and glass/white backsheet modules (framed). Each module technology has a different physical size. Some modules had pre-existing cell-cracks allowing for the study of cell-crack formation and propagation during shipment. Dark current-voltage (I-V), light I-V and electroluminescence characterization were performed before and after shipment. A datalogger was used to monitor shocks and ambient temperature throughout the shipment and identify when the modules were more susceptible to damage. The modules were tilted upon receipt and the pallet were damaged but with no shattered modules. Time series shock data provided by the datalogger were used to determine potential responsible events. Our results reveal a few new post-transportation cracks for some modules. Modules parameters before and after shipment are also compared regarding the module constructions and their position in the pallet.

14 SOLAR ENERGY↗
DOE OSTI2026

Modeling the PV System Level Economic Impact of PV Connector Failure Modes

Photovoltaic (PV) connectors must maintain mechanical integrity for over 25 years while operating under UV exposure, elevated temperature, and mechanical loading. Connector degradation increases with electrical resistance, leading to energy losses, unplanned downtime, and higher operation and maintenance (O&M) costs and in severe cases, safety risks from overhearing or arcing. Connector related failures remain among the most frequent causes of disruption in utility-scale PV (UPV) systems, yet their lifetime economic impacts are poorly quantified. This work presents a techno-economic analysis (TEA) framework that links identified connector failure modes to system level energy losses and lifetime cost impacts using identified resistance measurements and failure rates from 6,2761 PV connectors inspected. Connector failures increase system level O&M costs, raising LCOE by roughly 5%. Downtime driven availability losses dominate economic impact. Resistance-driven I2R and IV-curve losses are secondary, but remain non-negligible. Thermal damage, bend-radius violations, and loose connections drive the majority of LCOE uplift Improving connector reliability through better installation quality, inspection, and design can meaningfully reduce lost energy, O&M costs, and LCOE.

14 SOLAR ENERGY↗
DOE OSTI2024

AquaPV: Regulatory and Environmental Considerations for Floating Photovoltaic Projects Located on Federally Controlled Reservoirs in the United States

To meet the nation's decarbonization goals, the U.S. Department of Energy's Solar Futures study forecasts that installed solar photovoltaic (PV) capacity must increase nearly tenfold, from 80 gigawatts (GW) in 2020 to approximately 760 GW cumulative installed capacity by 2035. Ground-mounted PV is expected to dominate future solar deployment and will require more than 3.5 million acres of land to meet annual demand projections (of nearly 45 GW) by 2030. However, various competing demands for land (e.g., agricultural production, conservation) and high land acquisition costs in specific locations could be challenges to meeting future PV demand solely with ground-mounted PV deployment. Floating photovoltaics (FPV) may be an alternative in locations where ground-mounted PV is not feasible and aid in reaching the nation's PV deployment and decarbonization goals. FPV is a newer siting approach in which a PV array is affixed to a floating apparatus and sited on a water body like a reservoir behind a dam. FPV systems may be stand-alone or co-located at new or existing hydroelectric facilities or pumped storage hydropower (PSH) facility reservoirs. Co-located FPV systems may or may not be operationally paired and work in tandem with the hydroelectric or PSH facility. This report provides novel analysis to understand the opportunities and challenges associated with developing stand-alone and co-located FPV projects on reservoirs in the United States. Specifically, the report explores potential environmental and energy benefits and environmental impacts associated with the siting, construction, and operation of FPV projects. The report also identifies and analyzes U.S. federal- and state-issued permits and authorizations required by federal laws to understand the licensing pathways and regulatory requirements for FPV projects sited on reservoirs licensed by the Federal Energy Regulatory Commission and on powered and non-powered reservoirs owned by the Bureau of Reclamation or U.S. Army Corps of Engineers.

13 HYDRO ENERGY↗
DOE OSTI2024

AquaPV: Regulatory and Environmental Considerations for Floating Photovoltaic Projects Located on Federally Controlled Reservoirs in the United States

To meet the nation's decarbonization goals, the U.S. Department of Energy's Solar Futures study forecasts that installed solar photovoltaic (PV) capacity must increase nearly tenfold, from 80 gigawatts (GW) in 2020 to approximately 760 GW cumulative installed capacity by 2035. Ground-mounted PV is expected to dominate future solar deployment and will require more than 3.5 million acres of land to meet annual demand projections (of nearly 45 GW) by 2030. However, various competing demands for land (e.g., agricultural production, conservation) and high land acquisition costs in specific locations could be challenges to meeting future PV demand solely with ground-mounted PV deployment. Floating photovoltaics (FPV) may be an alternative in locations where ground-mounted PV is not feasible and aid in reaching the nation's PV deployment and decarbonization goals. FPV is a newer siting approach in which a PV array is affixed to a floating apparatus and sited on a water body like a reservoir behind a dam. FPV systems may be stand-alone or co-located at new or existing hydroelectric facilities or pumped storage hydropower (PSH) facility reservoirs. Co-located FPV systems may or may not be operationally paired and work in tandem with the hydroelectric or PSH facility. This report provides novel analysis to understand the opportunities and challenges associated with developing stand-alone and co-located FPV projects on reservoirs in the United States. Specifically, the report explores potential environmental and energy benefits and environmental impacts associated with the siting, construction, and operation of FPV projects. The report also identifies and analyzes U.S. federal- and state-issued permits and authorizations required by federal laws to understand the licensing pathways and regulatory requirements for FPV projects sited on reservoirs licensed by the Federal Energy Regulatory Commission and on powered and non-powered reservoirs owned by the Bureau of Reclamation or U.S. Army Corps of Engineers.

ENERGY PLANNING, POLICY, AND ECONOMY,SOLAR ENERGY↗
DOE OSTI2024

AquaPV: Regulatory and Environmental Considerations for Floating Photovoltaic Projects Located on Federally Controlled Reservoirs in the United States

To meet the nation's decarbonization goals, the U.S. Department of Energy's Solar Futures study forecasts that installed solar photovoltaic (PV) capacity must increase nearly tenfold, from 80 gigawatts (GW) in 2020 to approximately 760 GW cumulative installed capacity by 2035. Ground-mounted PV is expected to dominate future solar deployment and will require more than 3.5 million acres of land to meet annual demand projections (of nearly 45 GW) by 2030. However, various competing demands for land (e.g., agricultural production, conservation) and high land acquisition costs in specific locations could be challenges to meeting future PV demand solely with ground-mounted PV deployment. Floating photovoltaics (FPV) may be an alternative in locations where ground-mounted PV is not feasible and aid in reaching the nation's PV deployment and decarbonization goals. FPV is a newer siting approach in which a PV array is affixed to a floating apparatus and sited on a water body like a reservoir behind a dam. FPV systems may be stand-alone or co-located at new or existing hydroelectric facilities or pumped storage hydropower (PSH) facility reservoirs. Co-located FPV systems may or may not be operationally paired and work in tandem with the hydroelectric or PSH facility. This report provides novel analysis to understand the opportunities and challenges associated with developing stand-alone and co-located FPV projects on reservoirs in the United States. Specifically, the report explores potential environmental and energy benefits and environmental impacts associated with the siting, construction, and operation of FPV projects. The report also identifies and analyzes U.S. federal- and state-issued permits and authorizations required by federal laws to understand the licensing pathways and regulatory requirements for FPV projects sited on reservoirs licensed by the Federal Energy Regulatory Commission and on powered and non-powered reservoirs owned by the Bureau of Reclamation or U.S. Army Corps of Engineers.

ENERGY PLANNING, POLICY, AND ECONOMY,SOLAR ENERGY↗
DOE OSTI2026

Coupled CVD and Float Zone Reactor for Lower Cost, Higher Efficiency Si Boules (Final Technical Report)

This project modeled a new type of photovoltaic (PV) Si production reactor with the promise to reduce the cost, increase the efficiency, and reduce the energy required to manufacture Si wafers. The production of photovoltaic (PV) grade Si is well established, based on the pulling of single crystalline Si boules from polycrystalline Si created from trichlorosilane using the Siemens process. However, these processes are very energy intensive, and manufacturing of PV Si occurs almost entirely in China. To disrupt this paradigm and on-shore production of this critical material and provide benefits to the public, a substantial technological leap is required to move past incumbent technology. This study evaluated a new float zone chemical vapor deposition (Fz-CVD) concept in which trichlorosilane (TCS), the feedstock for polysilicon in the Siemens process, is injected directly into a float zone crystallizer to continuously deposit the feed rod for the boule pulling process through a combination of multiphysics modeling and technoeconomic analysis.

14 SOLAR ENERGY↗
DOE OSTI2020

Impact of High PV Penetration on Voltage Stability

Photovoltaics (PV) are becoming increasingly relevant in modern power systems. With this increase also comes reliability concerns as photovoltaics behave differently than conventional generators. One reliability concern is voltage stability. In this paper, voltage stability of the Austin area in the Electric Reliability Council of Texas (ERCOT) system is studied using dynamic models with varying levels of photovoltaic penetration. The base case is set at 0% renewable penetration. Additional cases include 15% wind penetration and up to 65% photovoltaic penetration. The study results show that voltage/var control capacity is critical to voltage stability, which PV lacks. Voltage regulation of photovoltaics may cause over-voltage and voltage collapse may be more abrupt under high regional photovoltaic penetration.

Till, Jeremy↗
DOE OSTI2020

Evaluation of Curtailment Associated with PV System Design Considerations

Distributed photovoltaic (PV) systems equipped with advanced inverters can control real and reactive power output based on grid and atmospheric conditions. The Volt-Var control method allows inverters to regulate local grid voltages by producing or consuming reactive power. Based on their power ratings, the inverters may need to curtail real power to meet the reactive power requirements, which decreases their total energy production. To evaluate the expected curtailment associated with Volt-Var control, yearlong quasi-static time-series (QSTS) simulations were conducted on a realistic distribution feeder under a variety of PV system design considerations. Overall, this paper found that the amount of curtailed energy is low (<; 0.55%) compared to the total PV energy production in a year but is affected by several PV system design considerations.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2022

Multimode Characterization Approach for Understanding Cell-Level PV Performance and Degradation

Cell-level degradation processes impact the economic viability and large-scale deployment prospects for both established and emerging photovoltaic (PV) technologies. This project addresses the need to develop experimental and device-modeling approaches for studying cell-level degradation processes in photovoltaic (PV) devices using a variety of characterization techniques that provide access to complementary material and device properties. Our results demonstrate that by coupling characterization results with device modeling it is possible to develop comprehensive understanding of processes leading to performance limitations and degradation. This project developed a suite of novel measurement techniques including pulsed-light-bias operando X-ray and photoelectron spectroscopy (popXPS), light-biased scanning microwave impedance microscopy (sMIM), and near-field transport imaging (TI). In addition, operando characterization methodologies and in situ stressing capabilities have been developed and applied for techniques including electron-beam-induced current (EBIC), cathodoluminescence (CL), and Kelvin probe force microscopy (KPFM). Device-physics models were developed and applied to simulate correlative, multi-mode measurements to extract material and device parameters that control performance degradation. These characterization and modeling techniques were applied in a multi-mode approach to probe cell-level degradation mechanisms in Cd(Se,Te) and hybrid perovskite PV devices. Together these efforts contribute to foundational PV degradation science by establishing a framework for understanding PV performance degradation at the cell level and benefit the U.S. PV industry by providing resources in the form of novel experimental capabilities, knowledge gained, and available expertise that can accelerate research and development of improved PV device materials and architectures. The project provided a comprehensive understanding of degradation in baseline Cd(Se,Te) solar cells provided by our collaborators at Colorado State University (CSU). EBIC and CL-based measurements and revealed unusual collection and recombination profiles in these devices, which underwent significant changes with during stressing. KPFM and operando XPS measurements showed that device stressing permanently alters energy-band alignments at the (Mg,Zn)O/Cd(Se,Te) interface, which in turn account for an observed loss in fill factor. Studies on hybrid perovskite devices were hampered to a significant extent by delays related to the pandemic. Nevertheless, a set of hybrid perovskite devices (supplied through an NREL-industry partnership) were stress tested and characterized with techniques including EBIC, sMIM, popXPS/popUPS and optically excited TI. Available results from these measurements informed the device modeling effort and suggest that defects and related band offsets at the C60/LiF/hybrid perovskite interface are the primary source of degradation in these devices.

14 SOLAR ENERGY↗
DOE OSTI2021

Techno-economic Analysis of Novel PV Plant Designs for Extreme Cost Reductions

A techno-economic analysis is underway examining the cost and performance of future large-scale photovoltaic (PV) plant components, including bifacial modules, tandem modules, increased plant voltage architectures, and module-level power electronics. Integration of these components into PV plant designs is compared with current PV technologies based on levelized cost of electricity (LCOE). Baseline models are developed and validated against recorded PV plant performance data. Expected cost and performance data of future PV technologies are incorporated into the baseline models. An evolutionary algorithm is utilized to optimize PV plant configuration, technology combination, and LCOE. Furthermore, this paper focuses on the bifacial module analysis.

14 SOLAR ENERGY↗
DOE OSTI2023

Task 12 PV Sustainability - Life Cycle Assessment of Crystalline Silicon Photovoltaic Module Delamination with Hot Knife Technology

The objective of this study is to complete a life cycle assessment (LCA) of a novel technology that separates the crystalline silicon (c-Si) photovoltaic (PV) module front glass from the backsheet using hot knife technology. This is known to be the most challenging step in module recycling, where the choice of delamination approach can determine the process selection for the next steps of the recycling process, the economic value of the recovered materials, and environmental performance. The life cycle inventory (LCI) reported here is based on primary data from the technology manufacturer. Different LCIs are established following the cut-off approach and the end-of-life (EOL) approach. The environmental impacts of the hot knife delamination process are analysed based on six indicators, and the main contributors to delamination efforts are identified. For the EOL approach, the potential environmental benefits from the recovered materials are compared to the environmental impacts caused by the delamination process. The functional unit of this analysis is the delamination of 1 kg of used framed c-Si PV modules at the place of installation.

14 SOLAR ENERGY↗
DOE OSTI2024

Frequency Stability Enhancement in a Fully Solar Power Grid: A Case Study on the Saudi Model

Recently, renewable energy sources (RES) such as solar photovoltaic (PV) have been recognized for their significant potential. Several studies have explored the issue of frequency stability with high RES penetration. A significant observation related to this issue is the decline in the weighted short circuit ratio (WSCR), which has the potential to adversely affect system stability. This research uniquely focuses on the gradual transition of the Saudi Electricity Company (SEC) system to a fully integrated solar PV grid, offering insight and methodology that can be adapted for other power systems. While a variety of mitigation methods are available, synchronous condensers (SC) were used in this study to stabilize grid frequency, and their implementation has been shown to improve the overall performance of the system. In response to the observed decline in WSCR, a comprehensive short circuit analysis was applied across all regions in the Saudi power grid model to evaluate the reduction in short circuit power and highlight areas requiring enhancement. Finally, scenarios illustrating frequency response with a gradual increase in SCR were analyzed, with the objective of establishing a stable, fully solar PV power system that is resilient to sudden power grid disturbances.

14 SOLAR ENERGY↗
DOE OSTI2022

Evaluation of Adaptive Volt-VAR to Mitigate PV Impacts [Slides]

Distributed generation (DG) sources like photovoltaic (PV) systems with advanced inverters are able to perform grid-support functions, like autonomous Volt-VAR that attempts to mitigate voltage issues by injecting or consuming reactive power. However, the Volt-VAR function operates with VAR priority, meaning real power may be curtailed to provide additional reactive power support. Since some locations on the grid may be more prone to higher voltages than others, PV systems installed at those locations may be forced to curtail more power, adversely impacting the value of that PV system. Adaptive Volt-VAR (AVV) could be implemented as an alternative, whereby the Volt-VAR reference voltage changes over time, but this functionality has not been well-explored in the literature. In this work, the potential benefits and grid impacts of AVV were investigated using yearlong quasi-static time-series (QSTS) simulations. After testing a variety of allowable AVV settings, we found that even with aggressive settings AVV resulted in <0.01% real power curtailment and significantly reduced the reactive power support required from the PV inverter compared to conventional Volt-VAR but did not provide much mitigation for extreme voltage conditions. The reactive power support provided by AVV was injected to oppose large deviations in voltage (in either direction), indicating that it could be useful for other applications like reducing voltage flicker or minimizing interactions with other voltage regulating devices.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

R&D to Ensure a Scientific Basis for Qualification Tests and Standards (Final Report)

Project return on investment in a photovoltaic (PV) system depends increasingly on maintaining high energy yields, and the system lifetime is a major factor in levelized cost of electricity (LCOE). Thus, the rate of PV deployment and the success of these assets depends upon reliable long-term power generation. The overarching objective of this program is to improve photovoltaic (PV) module reliability via development of tests and standards. Where reliability problems or risk are discovered, we can design tests to ensure that these liabilities don't affect future generations of products. Customers can use these tests to understand which products are susceptible to certain degradation mechanisms, and manufacturers can use the tests to design unwanted characteristics out of their products. The work under this program identifies PV reliability needs, performs characterization that provides scientific understanding of targeted degradation mechanisms, and translates those data into practical and predictive test protocols and standards. Major accomplishments include: A model for polarization-type potential induced degradation (PID-p) was developed and validated against experimental data. NREL is currently leading a new edition of IEC 62804-1 for PID detection. PID-p can cause large losses in current and voltage for some module designs on cloudy days. Finite element modeling (FEM) and experiment was used to determine when cells crack in a module. It was shown that cells in landscape orientation are much more likely to crack than those on portrait orientation. Shortly thereafter, the first products with portrait-oriented cells were introduced. Studies of how to test for light and elevated temperature degradation (LeTID) culminated with the publication of IEC TS 63342. Software to predict the progression of LeTID was developed, validated, and made publicly available. Field validated tests and international standards for durability of PV module coatings abrasion, backsheets, and encapsulants were developed. Examples are IEC 62788-1-1, IEC 62788-2 ED2, IEC TS 62788-7-2, IEC 62788-7-3 ED1, IEC 63209-2. NREL led the development a high-temperature testing technical specification, and published guidelines that enable installers to determine whether higher-temperature testing is needed, simply based on location and mounting configuration. In a number of our case studies, variations in the bills of materials or workmanship have been associated with variations in reliability. These observations emphasize the importance of quality assurance to reliability. A framework for criticality (i.e. Pareto) analysis was developed and published. The framework helps us and other researchers determine what problems should be addressed for reliability research to have the biggest industry impact. NREL continues to participate actively in international standards development and stakeholder engagement activities, including organizing an annual PV Reliability Workshop. These activities are important for ensuring we address issues that are relevant and timely, and that we convey our results to those who may benefit.

14 SOLAR ENERGY↗
DOE OSTI2025

Rapid characterization and failure analysis of 6276 rooftop-harvested photovoltaic connectors

Photovoltaic (PV) connectors, which link modules in series and connect PV strings in parallel, have increasingly been recognized as a primary contributor to PV system failures and a source of numerous fire incidents. However, publicly available data on the rates and types of connector failures are scarce, primarily due to the proprietary nature of the information and the need for comprehensive analysis. This study represents the first large-scale investigation of harvested PV connectors, drawing from a dataset of 6276 connectors from residential rooftop solar systems across the United States. The outcome of this work is twofold: 1) we have established a rapid characterization method for large populations of harvested connectors, incorporating visual inspection, resistance measurements, and X-ray imaging; and 2) the analysis made possible by our rapid-processing method has revealed, for a population of connector models provided by a single rooftop installer, failure statistics and insights for various connector makes and models, installation practices, operating currents, and internal component displacements. This research identifies common failure modes that could be considered in future connector designs standards, and operations and maintenance practices, to ultimately improve the reliability of this vital component of PV infrastructure.

MC4↗