Scott S. Kuszmaul

Photovoltaic DC Arc Fault Detector testing at Sandia National Laboratories

The 2011 National Electrical Code® (NEC®) added Article 690.11 that requires photovoltaic (PV) systems on or penetrating a building to include a listed DC arc fault protection device. To fill this new market, manufacturers are developing new Arc Fault Circuit Interrupters (AFCIs). Comprehensive and challenging testing has been conducted using a wide range of PV technologies, system topologies, loads and noise sources. The Distributed Energy Technologies Laboratory (DETL) at Sandia National Laboratories (SNL) has used multiple reconfigurable arrays with a variety of module technologies, inverters, and balance of system (BOS) components to characterize new Photovoltaic (PV) DC AFCIs and Arc Fault Detectors (AFDs). The devices detection capabilities, characteristics and nuisance tripping avoidance were the primary purpose of the testing. SNL and Eaton Corporation collaborated to test an Eaton AFD prototype and quantify arc noise for a wide range of PV array configurations and the system responses. The tests were conducted by generating controlled, series PV arc faults between PV modules. Arc fault detection studies were performed on systems using aged modules, positive- and negative-grounded arrays, DC/DC converters, 3-phase inverters, and on strings with branch connectors. The tests were conducted to determine if nuisance trips would occur in systems using electrically noisy inverters, with series arc faults on parallel strings, and in systems with inverters performing anti-islanding and maximum power point tracking (MPPT) algorithms. The tests reported herein used the arc fault detection device to indicate when the trip signal was sent to the circuit interrupter. Results show significant noise is injected into the array from the inverter but AFCI functionality of the device was generally stable. The relative locations of the arc fault and detector had little influence on arc fault detection. Lastly, detection of certain frequency bands successfully differentiated normal operational noise from an arc fault signal.

PV array simulator development and validation

The ability to harvest all available energy from a photovoltaic (PV) array is essential if new system developments are to meet levelized cost of energy targets and achieve grid parity with conventional centralized utility power. Therefore, exercising maximum power point tracking (MPPT) algorithms, dynamic irradiance condition operation and startup and shutdown routines and evaluating inverter performance with various PV module fill-factor characteristics must be performed with a repeatable, reliable PV source. Sandia National Laboratories is collaborating with Ametek Programmable Power to develop and demonstrate a multi-port TerraSAS PV array simulator.

Laboratory Simulation of Drill Bit Dynamics Using a Model-Based Servohydraulic Controller

Drilling costs are significantly influenced by bit performance when drilling in offshore formations. Retrieving and replacing damaged downhole tools is an extraordinarily expensive and time-intensive process, easily costing several hundred thousand dollars of offshore rig time plus the cost of damaged components. Dynamic behavior of the drill string can be particularly problematic when drilling high strength rock, where the risk of bit failure increases dramatically. Many of these dysfunctions arise due to the interaction between the forces developed at the bit-rock interface and the modes of vibration of the drill string. Although existing testing facilities are adequate for characterizing bit performance in various formations and operating conditions, they lack the necessary drill string attributes to characterize the interaction between the bit and the bottom hole assembly (BHA). A facility that includes drill string compliance and yet allows real-rock/bit interaction would provide an advanced practical understanding of the influence of drill string dynamics on bit life and performance. Such a facility can be used to develop new bit designs and cutter materials, qualify downhole component reliability, and thus mitigate the harmful effects of vibration. It can also serve as a platform for investigating process-related parameters, which influence drilling performance and bit-induced vibration to develop improved practices for drilling operators. The development of an advanced laboratory simulation capability is being pursued to allow the dynamic properties of a BHA to be reproduced in the laboratory. This simulated BHA is used to support an actual drill bit while conducting drilling tests in representative rocks in the laboratory. The advanced system can be used to model the response of more complex representations of a drill string with multiple modes of vibration. Application of the system to field drilling data is also addressed.

Creating dynamic equivalent PV circuit models with impedance spectroscopy for arc fault modeling

Article 690.11 in the 2011 National Electrical Code® (NEC®) requires new photovoltaic (PV) systems on or penetrating a building to include a listed arc fault protection device. Currently there is little experimental or empirical research into the behavior of the arcing frequencies through PV components despite the potential for modules and other PV components to filter or attenuate arcing signatures that could render the arc detector ineffective. To model AC arcing signal propagation along PV strings, the well-studied DC diode models were found to inadequately capture the behavior of high frequency arcing signals. Instead dynamic equivalent circuit models of PV modules were required to describe the impedance for alternating currents in modules. The nonlinearities present in PV cells resulting from irradiance, temperature, frequency, and bias voltage variations make modeling these systems challenging. Linearized dynamic equivalent circuits were created for multiple PV module manufacturers and module technologies. The equivalent resistances and capacitances for the modules were determined using impedance spectroscopy with no bias voltage and no irradiance. The equivalent circuit model was employed to evaluate modules having irradiance conditions that could not be measured directly with the instrumentation. Although there was a wide range of circuit component values, the complex impedance model does not predict filtering of arc fault frequencies in PV strings for any irradiance level. Experimental results with no irradiance agree with the model and show nearly no attenuation for 1 Hz to 100 kHz input frequencies.

Solar energy grid integration systems : final report of the Florida Solar Energy Center Team.

Initiated in 2008, the Solar Energy Grid Integration Systems (SEGIS) program is a partnership involving the U.S. DOE, Sandia National Laboratories, private sector companies, electric utilities, and universities. Projects supported under the program have focused on the complete-system development of solar technologies, with the dual goal of expanding utility-scale penetration and addressing new challenges of connecting large-scale solar installations in higher penetrations to the electric grid. The Florida Solar Energy Center (FSEC), its partners, and Sandia National Laboratories have successfully collaborated to complete the work under the third and final stage of the SEGIS initiative. The SEGIS program was a three-year, three-stage project that include conceptual design and market analysis in Stage 1, prototype development and testing in Stage 2, and moving toward commercialization in Stage 3. Under this program, the FSEC SEGIS team developed a comprehensive vision that has guided technology development that sets one methodology for merging photovoltaic (PV) and smart-grid technologies. The FSEC teams objective in the SEGIS project is to remove barriers to large-scale general integration of PV and to enhance the value proposition of photovoltaic energy by enabling PV to act as much as possible as if it were at the very least equivalent to a conventional utility power plant. It was immediately apparent that the advanced power electronics of these advanced inverters will go far beyond conventional power plants, making high penetrations of PV not just acceptable, but desirable. This report summarizes a three-year effort to develop, validate and commercialize Grid-Smart Inverters for wider photovoltaic utilization, particularly in the utility sector.

Solar Energy Grid Integration Systems (SEGIS) proactive intelligent advances for photovotaic systems

This paper provides an overview of the activities of and progress made in the US DOE Solar Energy Grid Integration Systems (SEGIS) program. The work has now progressed from the “Conceptual Designs and Market Analysis” Stage 1 through the “Prototype Development” Stage 2. Twelve contractors completed the Stage 1 conceptual designs and market analysis. Best value competition resulted follow on work with control methodologies and hardware prototypes developed and completed by five contractors. The prototypes span system sizes from micro-inverters (200W) to commercial sizes through 100kW. Modularity of the designs enables larger applications. This SEGIS R&D is opening pathways for connecting PV systems to emerging intelligent utility grids and micro-grids. In addition to new grid-interconnection capabilities and “value added” features, the new hardware designs result in smaller, less material-intensive, and higher reliability products. The solutions and “value added” enabled by SEGIS systems will help drive the “advanced integrated system” concepts and “smart grid” evolutionary processes forward in a faster and more focused manner.[1,2,3]

Long-term inverter operation demonstration at Sandia National Laboratories

The performance of a utility interactive photovoltaic (PV) system relies on several key components within the system. The effects of long term operation on utility interactive inverter performance are the topic of this paper. Years of anecdotal evidence indicates that the PV module typically has a 1% per year degradation in performance; this is accepted by industry for how modules are typically rated and warranted. The inverter on the other hand has not undergone such scrutiny to investigate the effects that years of operation may have on the performance of an inverter. The effects of long-term field operation on utility interconnected PV inverters are the focus of the long term inverter evaluation test bed that is dedicated for years of operation. The outcome of this analysis will be factored into the inverter performance model. Sandia National Laboratories Distributed Energy Technology Laboratory (DETL) has recently completed the first re-characterization phase on inverters operating for two years. This paper reports on the effects of long term inverter operation on four residential inverters.

Commanding inverters to establish coordinated μgrid functionality at Sandia National Laboratories

Expanded testing capabilities at Sandia National Laboratories Distributed Energy Technologies Lab (DETL) now include a single phase μGrid research test bed platform. This reconfigurable μGrid topology test bed platform is being utilized to evaluate control strategies and communication algorithms and associated issues applicable to high penetration of distributed resources on the grid. To demonstrate coordinated μGrid functionality, battery based Xantrex inverters were integrated in a μGrid configuration along with custom centralized LabVIEW generated virtual Energy Management System (EMS) software to provide system wide control. Enhanced μGrid cooperation was implemented by invoking control schemes based on existing Xantrex inverter command sets issued over a standard communication interface. Inverter cooperation was achieved without additional modifications to embedded software. This paper outlines test configuration and results for cooperative storage management and voltage support scenarios.

Advanced Energy Industries, Inc. SEGIS developments.

The Solar Energy Grid Integration Systems (SEGIS) initiative is a three-year, three-stage project that includes conceptual design and market analysis (Stage 1), prototype development/testing (Stage 2), and commercialization (Stage 3). Projects focus on system development of solar technologies, expansion of intelligent renewable energy applications, and connecting large-scale photovoltaic (PV) installations into the electric grid. As documented in this report, Advanced Energy Industries, Inc. (AE), its partners, and Sandia National Laboratories (SNL) successfully collaborated to complete the final stage of the SEGIS initiative, which has guided new technology development and development of methodologies for unification of PV and smart-grid technologies. The combined team met all deliverables throughout the three-year program and commercialized a broad set of the developed technologies.