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DOE OSTI2022

Data Processing Unit Services Module

The Data Processing Services Module (DPUSM) provides the ability to perform pluggable compression, erasure coding, checksuming and other important file system operations within the Linux kernel. The pluggable provider interface allows for the use of hardware acceleration of those services. In-kernel file systems are then able to use these functions to use these accelerators to perform operations that are normally run on the processor, resulting in improved file system performance. Third parties will register "providers" with the DPUSM to communicate with their respective accelerators. Providers will implement functions with DPUSM API signatures so that the DPUSM can translate the data inputted by users of the DPUSM into data that providers recognize.

Lee, Jason↗

DOE OSTI2023

Thermal behaviors of ethylene vinyl acetate encapsulants in fielded silicon photovoltaic modules

Aging of silicon photovoltaic (PV) module packaging is one of the greatest limiters of PV module service lifetimes. Module characterization typically focuses on power degradation metrics, which do not convey the complexities of often simultaneous degradation mechanisms. In this work, PV modules with pristine references and known fielding histories were investigated by non-destructive and destructive methods. Modules from Canadian Solar, Mission Solar, and Hanwha Q-Cells were fielded for up to three years; select modules were removed from fielding each year for coring to allow for characterization of the encapsulant. Modules are commonly encapsulated with two protective layers of partially-crystalline ethylene vinyl acetate (EVA) polymer that must undergo a crosslinking reaction to achieve desired properties. The extent of crystallinity of the encapsulants as studied by differential scanning calorimetry showed differences between manufacturers and over time. Some encapsulants showed different magnitudes of crystal sizes which changed after fielding; encapsulants with the monodisperse crystal sizes did not change with fielding. This is due to differences in thermal history. In conclusion, these results have implications for stress development during module aging, since EVA crystal melting and crosslinking reactions can result in encapsulant density changes.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Thermomechanical and sequential stress performance of photovoltaic backsheets

Photovoltaic backsheet technology is utilized to protect the interior components of solar modules from environmental stress as well as provide electrical insulation to the module. The growing demand for solar energy and longer module service life requirements have brought backsheet performance into focus. Despite being a protective packaging material, many backsheets have exhibited failure in the field, limiting the performance and service life of entire modules. Most backsheets consist of multiple polymeric layers laminated together using adhesives. A new backsheet, with a high performance polyamide structure, has been developed as the solution to module failure. Primarily, it contains a unique polyamide-ionomer alloy targeted at improved weather resistance. In this study, several photovoltaic industry standard backsheets, and the novel polyamide compositions of multilayered backsheets fabricated from the coextrusion process, were examined using thermomechanical analysis (TMA). The coefficient of thermal expansion (CTE) for entire backsheets and their constituent layers was used to model the thermomechanical behavior of various backsheet constructions. Subsequently, thermal cycling was performed in the TMA to examine the intrinsic thermal behavior of the backsheets. Thermal cycling in the TMA indicates the resilience and dimensional stability in the coextruded structures as opposed to the laminated structures. Lastly, results from a Module Accelerated Sequential Testing (MAST), are included to show the mechanical integrity of these backsheets after sequential exposure to stressors including damp heat, ultra-violet (UV) light radiation, and thermal cycling. The laminate backsheets deteriorated extensively after sequential exposure to these stressors, while the novel coextruded structures retained their physical properties.

14 SOLAR ENERGY↗

DOE OSTI2019

Multi-modular power plant with off-grid power source

A multi-modular power plant may include a plurality of on-site nuclear power modules configured to generate a power plant output, wherein one or more of the nuclear power modules may be designated as service module units which are configured to generate a first portion of the power plant output. A remainder of the nuclear power modules may be configured to generate a second portion of the power plant output. A number of power plant systems may be configured to operate using electricity associated with a house load of the power plant, wherein the first portion of the power plant output is equal to or greater than the house load. Additionally, a switchyard may be configured to electrically connect the power plant to a distributed electrical grid. The distributed electrical grid may be configured to service a plurality of geographically distributed consumers, and the switchyard may be configured to apply the second portion of the power plant output to the distributed electrical grid. The switchyard may further be configured to apply at least part of the first portion of the power plant output to the power plant systems during a loss of power from the distributed electrical grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Cohesive and adhesive degradation in PET-based photovoltaic backsheets subjected to ultraviolet accelerated weathering

Delamination between layers in photovoltaic (PV) backsheets is often reported in the literature, causing voids that can collect moisture, diminish module backside heat dissipation, and reduce the backsheet’s effectiveness as a physical barrier. While backsheets with weathering-resistant fluoropolymer outer layers have traditionally been used in modules, more recent backsheets using non-fluoropolymer outer layers, such as polyethylene terephthalate (PET), have been developed. These backsheets have shown signs of premature degradation, and their adhesion degradation, in particular, has not been widely studied. In the present work, the single cantilever beam (SCB) adhesion test was used to quantify the adhesion energy in two commercially available PET-based backsheets. To study the effect of minor changes in formulation, the backsheets were obtained from same manufacturer and product line but during different years. To study the effect of environmental variables on adhesion degradation, the backsheets were subjected to artificial weathering at controlled temperature, humidity, and ultraviolet (UV) radiation in an indoor weathering chamber, and the adhesion energy was quantified at several intervals of exposure time. Layering structure, composition, and adhesion failure mode were compared between the backsheets, using Raman and infrared spectroscopy and thermogravimetric analysis. The results show a large difference in initial (unexposed) adhesion energy between the backsheets, despite very similar structures and compositions. Following exposure, adhesion energy dropped significantly, primarily due to thermo-hydrolytic degradation of the polyurethane (PU)-based adhesive layers. Significant UV-induced adhesion degradation of the PET outer layer surface was also observed. The study represents an important step in understanding adhesion degradation in PET-based backsheets, suggesting ways in which adhesion integrity – and, correspondingly, module service life – can be improved.

14 SOLAR ENERGY↗

DOE OSTI2022

Network Models of Active Degradation Mechanisms and Pathways for Service Life Prediction of Indoor and Outdoor PV Modules

ct: PV service lifetime prediction (SLP) enables accurate calculation of levelized cost of energy (LCOE), which is crucial to rationalizing PV investment and installation. However, SLP is challeging since PV reliability in the field is affected by many combined factors, including various environmental stresses and module quality. In order to map out the active degradation mechanisms and pathways that best resemble real world conditions, we introduce the framework of a study protocol and use network models fitted to data, to enable analysis and SLP of complex PV systems with multiple active degradation mechanisms. The study protocol is the experimental design, including module variants and different exposure conditions, selection of evaluation methods, time-series data acquisition and training of network models to these data. We present SLP of minimodules in the lab and PV systems in the field. For lab SLP, minimodules with 8 variants based on manufacturer, architecture, and encapsulation were prepared and aged in modified damp heat with or without full spectrum light exposure. Stepwise I-V and Suns-Voc data acquisition tracks changes in electrical properties including Rs,IV, Isc,IV, Vmp,PIV providing insights into power loss of minimodules. Network structural equation modeling (netSEM) was utilized to construct degradation pathway models that identify active degradation mechanisms and predict power loss over time. For field SLP, datastreams of Pmp values and I-V curve datastreams of two types of modules installed in three distinctly different Köppen-Geiger climate zones for 9 years were acquired. With power loss modes corresponding to uniform current loss (ΔPIsc), recombination (ΔPVoc), series resistance (ΔPRs), and current mismatch (ΔPImis) determined, the performance loss rates (PLR) were determined using PVplr. We show how to establish a study protocol framework to ensure appropriate parametric variations and valid data collection from the variants of your complex systems. Then the data-driven netSEM model fitting provides a comprehensive mapping of multiple active degradation mechanisms, and accurate service life prediction.

network model, degradation, photovoltaic, solar↗

DOE OSTI2020

AGGREGATE: dAta-driven modelinG preservinG contRollable dEr for outaGe mAnagemenT and rEsiliency (Report for Task 13: Functional Specification Report(Deliverable D9))

This report provides functional specification for the AGGREGATE project and associated modules/ tools being developed for outage management and restoration with the Distributed Energy Resources (DERs). This report also provide initial validation of the developed modules and performance metrics. The AGGREGATE team at this stage has been collaborating with General Electric (GE) and Seattle City Light (SCL) to move forward from offline validation to online validation using commercial advanced distribution management system (ADMS). Hence, the functional specifications documents, which outline the requirement of various modules, is provided to address the integration of the modules, including 1) real-time model update and aggregation tools module, 2) observability and controllability metric module, 3) fault location solution service restoration module, 4) transmission-distribution co-simulation module, and 5) advanced distribution management system module. integration of different AGGREGATE modules and functional specification provides the foundation for online multi-scenario testing using SCL system model.

42 ENGINEERING↗

DOE OSTI2021

A two-stage service restoration method for electric power distribution systems

Improving the reliability of power distribution systems is critically important for both utilities and customers. This calls for an efficient service restoration module within a distribution management system to support the implementation of self-healing smart grid networks. Although the emerging smart grid technologies, including distributed generators (DGs) and remote-controlled switches, enhance the self-healing capability and allow faster recovery, they still pose additional complexity to the service restoration problem, especially under cold load pickup (CLPU) conditions. Herein, a novel two-stage restoration framework is proposed to generate a restoration solutions with a sequence of control actions. The first stage generates a restoration plan that supports both the traditional service restoration using feeder reconfiguration and the grid-forming DG-assisted intentional islanding methods. The second stage generates an optimal sequence of switching operations to bring the outaged system quickly to the final restored configuration. The problem is formulated as a mixed-integer linear program that incorporates system connectivity, operating constraints, and the CLPU models. It is demonstrated that on using a multi-feeder test case, the proposed framework is effective in utilizing all available resources to quickly restore the service and generate an optimal sequence of switching actions to be used by the operator to reach the desired optimal configuration.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2017

PPPL ST-FNSF Engineering Design Details

One of the goals of the PPPL Spherical Tokamak (ST) Fusion Nuclear Science Facility (FNSF) study was to generate a self-consistent conceptual design of an STFNSF device with sufficient physics and engineering details to evaluate the advantages and disadvantages of different designs and to assess various ST-FNSF missions. This included striving to achieve tritium self-sufficiency; the ability to provide shielding protection of vital components and to develop maintenance strategies that could be used to maintain the in-vessel components (divertors, breeding blankets, shield modules and services) and characterize design upgrade potentials to expanded mission evolutions. With the conceptual design of a 2.2 m ST pilot plant design already completed emphasis was placed on evaluating a range of ST machine sizes looking at a major radius of 1m and a mid-range device size between 1 m and 2.2 m. This paper will present an engineering summary of the design details developed from this study, expanding on earlier progress reports presented at earlier conferences that focused on a mid-size 1.7 m device. Further development has been made by physics in defining a Super-X divertor arrangement that provides an expanded divertor surface area and places all PF coils outside the TF coil inner bore, in regions that improve the device maintenance characteristics. Physics, engineering design and neutronics analysis for both the 1.7 m and 1 m device have been enhanced. In conclusion, the engineering results of the PPPL ST-FNSF study will be presented along with comments on possible future directions.

42 ENGINEERING↗

DOE OSTI2017

Reliable SOFC Systems

The goal of this U.S. Department of Energy (DOE) sponsored project was to advance the reliability, robustness and endurance of low-cost SOFC technology suitable for ultimate deployment in ≥100 MWe Integrated Gasification Fuel Cell (IGFC) or Natural Gas Fuel Cell (NGFC) systems capable of ≥97% CO2 capture. The ultimate SOFC program goals are ≤ 0.2% per 1000 hours power degradation over a 5-plus year stack life, high-volume (≥ 250 MW/year) stack production cost of ≤$225/kWsystem net AC, and “power block” (exclusive of fuel supply, contaminant removal, and CO2 capture subsystems) capital cost of ≤ 900/kWsystem net AC (in year 2011). To progress towards the ultimate program goals, the specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours in a 100 kW (125 kW Peak) Modular Power Block (MPB) stand-alone power system under thermally self-sustained normal operating conditions and to verify the prospects for high volume SOFC stack production cost below the DOE target of ≤ 225/kW. This final technical report summarizes the progress made during the project period of 36 months. Significant progress was made in the areas of cell and stack technology development, Modular Power Block (MPB) development, sub-MW MPB system development, and MW-class SOFC System Development and Costing. The work focused on areas necessary for comprehensive development of an SOFC fuel cell system, including, active cell improvement, contaminant resistance, process engineering, and development of non-repeat module components. Additionally, several custom built balance-of-plant components were designed and fabricated to support the fuel cell system. SOFC cell and stack development focused on improving cell performance and durability. Enhancements were achieved in areas of electrode stability and impurity tolerance. Additionally, several quality control techniques and tools were developed to ensure predictable and repeatable fabrication of SOFC stacks. Module development continued previous development efforts to achieve footprint reduction and higher efficiency by incorporating balance-of-plant functional equipment into the fuel cell containment module. Several improvements were made to prior design. Control and instrumentation hardware was integrated within the module for serviceability and size reduction. The design efforts culminated in a complete SOFC power plant system. The designed plant was constructed and tested at FCE. Stack and system costs were updated, reflecting advances made in this program.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

The git based ATLAS data acquisition configuration service in LHC Run 3

The ATLAS experiment at the LHC at CERN uses a large, distributed trigger and data acquisition system composed of many computing nodes, networks, and hardware modules. Its configuration service is used to provide descriptions of control, monitoring, diagnostic, recovery, dataflow and data quality configurations, interconnections, and parameters for modules, chips, and channels of various online systems, detectors, and the whole ATLAS experiment. Those descriptions have historically been stored in more than one thousand interconnected XML files, which are updated by various experts many times per day. Maintaining error-free and consistent sets of such files and providing reliable and fast access to current and historical configurations is a major challenge. This paper gives details of the configuration service upgrade on the modern Git version control system backend for LHC Run 3 and its exploitation experience. It may be interesting for developers using human-readable file formats, where consistency of the files, performance, access control, traceability of modifications, and effective archiving are key requirements.

Soloviev, Igor [Univ. of California, Irvine, CA (U↗

DOE OSTI2017

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

42 ENGINEERING↗

DOE OSTI2016

VOLTTRON-Based System for Providing Ancillary Services with Residential Building Loads

Ancillary services entail controlled modulation of building equipment to maintain a stable balance of generation and load in the power system. Ancillary services include frequency regulation and contingency reserves, whose acting time ranges from several seconds to several minutes. Many pilot studies have been implemented to use industrial loads to provide ancillary services, and some have explored services from commercial building loads or electric vehicle charging loads. Residential loads, such as space conditioning and water heating, represent a largely untapped resource for providing ancillary services. The residential building sector accounts for a significant fraction of the total electricity use in the United States. Many loads in residential buildings are flexible and could potentially be curtailed or shifted at the request of the grid. However, there are many barriers that prevent residential loads being widely used for ancillary services. One of the major technical barriers is the lack of communication capabilities between end-use devices and the grid. End-use devices need to be able to receive the automatic generation control (AGC) signal from the grid operator and supply certain types of telemetry to verify response. With the advance of consumer electronics, communication-enabled, or 'connected,' residential equipment has emerged to overcome the communication barrier. However, these end-use devices have introduced a new interoperability challenge due to the existence of numerous standards and communication protocols among different end devices. In this paper, we present a VOLTTRON-based system that overcomes these technical challenges and provides ancillary services with residential loads. VOLTTRON is an open-source control and sensing platform for building energy management, facilitating interoperability solutions for end devices. We have developed drivers to communicate and control different types of end devices through standard-based interfaces, manufacturer-provided application programming interfaces, and proprietary communication interfaces. We document the ability to manage nine appliances, using four different standards or proprietary communication methods. A hardware-in-the-loop test was performed in a laboratory environment where the loads of a laboratory home and a large number of simulated homes are controlled by an aggregator. Upon receipt of an AGC signal, the VOLTTRON home energy management system (HEMS) of the laboratory home adjusts the end-device controls based on the comfort criteria set by the end users and sends telemetry to the aggregator to verify response. The aggregator then sends the AGC signal to other simulated homes in attempts to match the utility request as closely as possible. Frequency regulation is generally considered a higher value service than other ancillary services but it is also more challenging due to the constraint of short response time. A frequency regulation use case has been implemented with the regulation signals sent every 10 seconds. Experimental results indicate that the VOLTTRON-controlled residential loads are able to be controlled with sufficient fidelity to enable an aggregator to meet frequency regulation requirements. Future work is warranted, such as understanding the impact of this type of control on equipment life, and market requirements needed to open up residential loads to ancillary service aggregators.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Use and Testing of a Wind Turbine for the Supply of Balancing Reserves and Wide-Area Grid Stability

This report documents the use of wind turbine inertial energy for the supply of two specific electric power grid services; system balancing and real power modulation to improve grid stability. Each service is developed to require zero net energy consumption. Grid stability was accomplished by modulating the real power output of the wind turbine at a frequency and phase associated with wide-area modes. System balancing was conducted using a grid frequency signal that was high-pass filtered to ensure zero net energy. Both services used Phasor Measurement Units (PMUs) as their primary source of system data in a feedforward control (for system balancing) and feedback control (for system stability).

17 WIND ENERGY↗

DOE OSTI2023

In-situ determination of moisture- and temperature-driven deflection of an encapsulated Si photovoltaic cell

Module reliability and service lifetime are critical factors in improving photovoltaic system performance and reducing the levelized cost of electricity (LCOE). Soldering and lamination of the cell impart residual stresses that persist over time and superimpose additional loads during operation. This paper demonstrates the use of X-ray Topography (XRT) to image in-situ the dynamic response of a glass/backsheet mini-module upon drying at elevated temperature after saturation at humidity levels compatible with accelerated testing. The local water content in the encapsulant is also determined in-situ over time via Water Reflectometric Detection (WaRD), with diffusion of water in the front (glass side) and rear (backsheet side) resolved. As water diffuses out from the back of the glass/backsheet module, the cell curves towards the backsheet concomitantly. Here we find that the cell edges deflect 40μm out-of-plane with respect to its center while the encapsulant dries, compared to ~100 μm deflection when heating from 25°C to 85°C. The local cell deflections (changes in cell orientation) are correlated with the dynamic loss of water in the backside encapsulant. We conclude that the observed cell deflections are the result of hygroscopic stress induced by the encapsulant upon moisture outdiffusion. Therefore, the cell experiences a continually changing stress state and curvature dependent on local humidity and temperature. Depending on cell architecture and interconnection, this “breathing” mode of the cell may induce wear out and fatigue of the interconnects, affect the electrical connection of cracked pieces or cause failure near the interconnected edges of two cells.

14 SOLAR ENERGY↗

DOE OSTI2019

Degradation in PV Encapsulant Transmittance: Results of the First PVQAT TG5 Study

Reduced optical transmittance of encapsulants resulting from ultraviolet (UV) degradation has frequently been identified as a cause of decreased PV module performance through the life of service in the field. The present module safety and qualification standards, however, apply short UV doses only capable of examining design robustness or 'infant mortality' failures. The latest versions of the safety and qualification apply ~40 - ~160 days cumulative dose of the AM1.5G total UV radiation. Essential information that might be used to screen encapsulation through product lifetime also remains unknown. For example, the relative efficacy of xenon-arc and UVA-340 fluorescent sources or the typical range of activation energy for degradation is not quantified. We have conducted an interlaboratory experiment to provide the understanding that will be used towards developing a higher fidelity, more rigorous UV weathering test. Five representative, known formulations of EVA were studied in addition to one TPU material. Replicate laminated silica/polymer/silica specimens were examined at 10 institutions using a variety of indoor chambers (including Xenon, UVA-340, and high pressure mercury light sources). Specimens were artificially weathered for 180 cumulative days at pre-designated accelerated test conditions. The solar-weighted transmittance, yellowness index, and the UV cut-off wavelength, determined from the measured hemispherical transmittance, are examined to provide understanding and guidance for the UV light source (lamp type) and temperature used in accelerated UV aging tests.

14 SOLAR ENERGY↗

DOE OSTI2021

The Role of Water on the Interfacial Adhesion in Si Solar Modules

Delamination of solar module interfaces often occurs in field-tested solar modules after decades of service due to environmental stressors such as humidity. As water diffuses into the module, failure mechanisms like corrosion and delamination are significantly affected. In the presence of water, the interfaces between EVA and the cell, glass, and backsheet all experience losses of adhesion exposing the module to accelerated degradation. Understanding the relation between interfacial adhesion and water content inside PV modules can help mitigate detrimental power losses. Water content measurements via short wave infrared reflectometry combined with 180 degrees peel tests were used to study and quantify the effect of water ingress and egress on adhesion. Changes in adhesion strength for different module interfaces are quantified, correlating spatial distribution of water content to adhesion for damp heat and dry heat exposed samples. After 1000 hours of damp heat exposure, decreases in adhesion strength of approximately 1 N/mm were noted for all interfaces.

adhesion↗