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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Practical Insights on Applying Simulation-Based Control Methods in Experimental Studies

Advanced nuclear reactors are crucial to the future of energy both in the United States and around the globe. In contrast to the current operating fleet, they are characterized as being deployable in remote locations and able to operate in semi-autonomous or autonomous fashion. This leap forward necessitates a new reactor control paradigm. Because advanced nuclear reactors are still under development in the United States, the creation of new control methods to achieve autonomous operations has been based on systems modeling and simulation. However, an important factor in successfully deploying these new control methods is the ability to seamlessly transition from simulation environments to real-world settings. Control methods tested in both simulation and experimental settings need to be investigated in the context of advanced reactor applications. This work developed a series of simple controllers for Idaho National Laboratory (INL)’s Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor operating in load-following scenarios. These controllers were tested in both simulation and experimental settings, and a comparative performance analysis was performed. The simulation tests leveraged the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software developed in a previous stage of the current effort, along with the MARVEL Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The experimental tests leveraged the COMMAND software, MARVEL models, and the U.S. Department of Energy Microreactor Program’s Microreactor Automated Control System (MACS). MACS was developed to serve as a control method testbed. It was customized to mirror the MARVEL microreactor, and COMMAND enabled MACS to emulate the physics of MARVEL. The load-following controller was developed using the simulation platform, with efforts to emulate real systems by introducing actuator saturation and noise. These factors were incrementally accounted for in the controller design. After finalizing the controller design, it was implemented with the experimental setup. The experimental conditions tested included an initial test under conditions similar to the final simulation test, and two additional scenarios. The first scenario introduced additional actuator saturation to account for equipment aging over time, which was unknown to the controller. The second scenario introduced sensor delay, a phenomenon anticipated with the use of remote operations or wireless communication in advanced reactors. These tests revealed several notable differences. While the controller performed well in simulation, it exhibited several limitations when transitioning to hardware. The main challenges involved maintaining the steady-state target power, as evidenced by larger error values between the true reactor power and setpoint power, as well as persistent oscillations in controlled reactor power. These issues could lead to unacceptable transient conditions in real reactor testing. Introducing actuator aging and stochastic delays in the experimental setup significantly impacted controller performance, resulting in increased overshoot and undershoot, and exacerbated error and oscillations previously mentioned. These findings underscore the importance of experimental testbeds for testing and validating control methods, as controllers developed using only theory and/or simulation may perform unexpectedly when applied to actual hardware. This research emphasizes the need for an experimental testbed for achieving such validation.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2026

Investigating Temperature Uniformity and Accuracy in PV Module Lamination: A Verification Study

This study investigates the temperature uniformity and accuracy of a photovoltaic (PV) module lamination process by addressing inconsistencies identified in 2017 data where irregular temperature changes were observed across setpoints. The 2017 data showed a notable drop in temperature upon bladder initiation, except for the 145 degrees Celsius profile. This inconsistency indicated potential inaccuracies in manual data recording methods. To address this concern, a verification experiment was conducted to evaluate temperature uniformity across the 2014 Bent River SPL2828 laminator platen and within test samples. Thermocouples, paired with Omega data acquisition software, were deployed to measure temperatures at multiple platen locations and within test samples. The experiment compared lamination temperatures of polyethylene-co-vinyl acetate (EVA) encapsulant when paired with solite glass or TPE backsheets. The methodology included verifying temperature uniformity directly on the platen and by using a large glass/EVA/glass sample using multiple thermocouples. Smaller samples were built with glass/EVA/glass and glass/EVA/backsheet configurations with one centered thermocouple to verify and compare sample temperatures. This verification aims to refine lamination temperature profiles, enhance data accuracy and provide insights into optimal process control for uniform module lamination. Ensuring consistent and uniform lamination may improve the accuracy and reliability of research outcomes.

14 SOLAR ENERGY↗

DOE OSTI2026

AI-Ready Semantic Infrastructure for CEBAF: From CED to PALS Knowledge Graphs

JLab and PNNL are jointly developing an AI-ready data ecosystem that exposes the Continuous Electron Beam Acceleration Facility’s (CEBAF’s) operational configuration, lattice description, and control-system channels to agentic optimization frameworks through a standards-based semantic layer. The effort integrates the existing facility-specific CEBAF Element Database (CED) with extensions of the emerging facility-agnostic Particle Accelerator Lattice Standard (PALS) to produce a knowledge graph (KG) containing coherent, machine-interpretable views of devices, signals, and regions. With this KG, CEBAF’s setpoints, readbacks, and device hierarchies become queryable using a uniform declarative graph query language (e.g., Neo4j Cypher), providing intents and inspectable semantics suitable for agentic control. The resulting graph-backed interfaces will allow autonomous agents to retrieve authoritative machine configurations, reason over device- and signal-level relationships, and execute tuning and diagnostic workflows without bespoke CEBAF-specific logic, thereby delivering a scalable pathway from operational data to trustworthy agentic accelerator tuning frameworks.

Zhang, He [Thomas Jefferson National Accelerator F↗

DOE OSTI2019

Distributed Barrier Certificates for Safe Operation of Inverter-Based Microgrids

Inverter-interfaced microgrids differ from the traditional power systems due to their lack of inertia. Vanishing timescale separation between voltage and frequency dynamics makes it critical that faster-timescale stabilizing control laws also guarantee by-construction the satisfaction of voltage limits during transients. In this article, we apply a barrier functions method to compute distributed active and reactive power setpoint control laws that certify satisfaction of voltage limits during transients. Using sum-of-squares optimization tools, we propose an algorithmic construction of these control laws. Numerical simulations are provided to illustrate the proposed method.

Kundu, Soumya↗

DOE OSTI2020

Online Control of Process Variance Using Feedback

For many stochastic control problem formulations, design objectives typically include constraining the covariance of the outputs of the system. Recent engineering challenges have demonstrated an interest in controlling system output covariances to a setpoint. However, open-loop control of system output covariance can be exceptionally challenging when the system has significant plant uncertainties. This paper explores closed-loop control of the system’s output covariance using a windowed variance function. The stochastic nature of the windowed variance feedback means that root locus and other classical control design techniques cannot be immediately used. Expected value analysis is used to generate transfer functions for the average response of such systems, and the results are used to design controllers. Stochastic simulations are presented to verify the analytical results and make other observations concerning closed-loop variance control.

Bieniek, Mitchell↗

DOE OSTI2023

A General Purpose Real-Time Optimization Strategy Applied to Minimizing Simultaneous Heating and Cooling in Buildings

Supervisory control strategies in heating, ventilating, and air-conditioning (HVAC) systems hold the potential for significant energy savings but they are difficult to set up and often depend on unreliable sensor measurements. In this paper, we propose a sensor-free approach to minimizing the energy penalties due to simultaneous heating and cooling in variable-air-volume (VAV) systems with reheat. A general-purpose real-time optimizer is described that is easy to set-up and integrate with existing control logic. A cost function is derived that quantifies the simultaneous heating and cooling penalty that does not require any sensor measurements. The optimizer then minimizes this cost function by automatically adjusting the supply temperature setpoint in the air-handling unit. The paper describes the approach and shows results from application from field trials on a 27-zone building.

Salsbury, Timothy↗

DOE OSTI2021

Lawrence Berkley National Laboratory Building 59

The building management system in Building 59 is monitoring and archiving building-level electricity usage, HVAC and lighting system states (e.g., setpoint, temperature, flow rate, pressure), indoor environmental conditions (air temperature, relative humidity, CO2), on-site weather (air temperature, relative humidity), and especially occupant counts as well as other metrics such as Wi-Fi signal. This dataset could support multiple use cases, such as model predictive control and occupant related demand management.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Lawrence Berkley National Laboratory Building 59 (Raw)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Lawrence Berkeley National Lab Building 59

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Linearized Distribution Optimal Power Flow for OEDI SI

This research is to meant to demonstrate the OEDI SI use case for distributed optimal power flow (DOPF). The goal was to formulate the optimal power flow problem in the distribution system for active and reactive power setpoints of PV systems using topology information and voltage measurements. The co-simulation runs every 15 minutes as outlined within the scenario file for the given feeder configuration. The linked GitHub repository includes five federates to achieve DOPF for the small, medium, large, and IEEE 123 feeder scenarios. We are using the OEDI SI framework, as well as the example feeder, sensor, recorder, and estimator federates provided in the example repository for OEDI SI. We also provide a runner script for switching between scenarios.

algorithm↗

DOE OSTI2021

A Case Study on Condenser Water Supply Temperature Optimization with a District Cooling Plant

District cooling (DC) continues to proliferate due to increasing global cooling demands and economies of scale benefits; however, most district-scale modeling has focused on heating, and to the best of our knowledge, researchers have yet to model cooling plants featuring waterside economizers in DC settings. With the popular Modelica Buildings library expanding its capabilities to district scale, this study is one of the first to demonstrate how the open-source models can be used for detailed energy and control analysis of a DC plant. For a real-world case study, we developed and calibrated high-fidelity models for a DC system central plant at a college campus in Colorado, USA, and we optimized the condenser water supply temperature (CWST) setpoint for a DC plant across multiple time horizons using the Optimization library in Dymola. Results indicate that annual CWST optimization saves 4.7% annual plant energy, with less than 1% of additional energy savings gained through daily optimization. This confirms previous studies' findings that high frequency CWST optimizations are not necessary for the studied system.

chiller plant↗

DOE OSTI2022

Moisture Stability of Sulfide Solid-State Electrolytes

In this report we detail a comprehensive study on the moisture stability of sulfide solid-state electrolytes in dry room environments. Although sulfide SSEs have many favorable attributes, this class of materials suffers from poor stability with water. Sulfide SSEs react with water to form gaseous H 2 S and a variety of solid byproducts like Li 3 PO 4 and LiOH, which go on to increase the interfacial impedance of solid-state batteries. Lab-scale research typically utilizes gloveboxes with <1 ppm water, however, the large-scale manufacturing of Li-ion batteries occurs in –40°C dewpoint dry rooms with around 126 ppm water. Consequently, the moisture stability of sulfide SSEs must be addressed if the manufacture of solid-state batteries based on sulfide SSEs is to be scaled up. Here, we are the first to characterize the moisture stability of sulfide SSEs according to both H 2 S and the degradation of ionic conductivity at different moisture setpoints ranging from –76°C to –40°C dewpoint. A variety of different SSE compositions are studied; namely, (Li 2 S) 75 (P 2 S 5 ) 25 , (Li 2 S) 70 (P 2 S 5 ) 30 , (Li 2 O) 7 (Li 2 S) 68 (P 2 S 5 ) 25 , (Li 2 O) 7 (Li 2 S) 63 (P 2 S 5 ) 30 , and (Li 2 S) 75 (P 2 S 5 ) 25 + 20 mol% LiI. We find that moisture stability improves with 75 mol% Li2S modifier content and the introduction of a Li 2 O co-modifier. After a 30 min exposure in a –40°C dewpoint dry room environment we found that (Li 2 S) 75 (P 2 S 5 ) 25 + 20 mol% LiI powder generated 0.1 cc/g H 2 S and its ionic conductivity decreased by over 50%. However, when SSE powder was exposed as a slurry in a dodecane carrier the same SSE composition generated 0 cc/g H 2 S and its ionic conductivity only dropped by 14%. Our results show that sulfide SSEs have acceptable moisture stability when appropriately processed in a dry room environment.

25 ENERGY STORAGE↗

DOE OSTI2019

Beyond the Toolpath: Site-Specific Melt Pool Size Control Enables Printing of Extra-Toolpath Geometry in Laser Wire-Based Directed Energy Deposition

A variety of techniques have been utilized in metal additive manufacturing (AM) for melt pool size management, including modeling and feed-forward approaches. In a few cases, closed-loop control has been demonstrated. In this research, closed-loop melt pool size control for large-scale, laser wire-based directed energy deposition is demonstrated with a novel modification, i.e., site-specific changes to the controller setpoint were commanded at trigger points, the locations of which were generated by the projection of a secondary geometry onto the primary three-dimensional (3D) printed component geometry. The present work shows that, through this technique, it is possible to print a specific geometry that occurs beyond the actual toolpath of the print head. This is denoted as extra-toolpath geometry and is fundamentally different from other methods of generating component features in metal AM. A proof-of-principle experiment is presented in which a complex oak leaf geometry was embossed on an otherwise ordinary double-bead wall made from Ti-6Al-4V. The process is introduced and characterized primarily from a controls perspective with reports on the performance of the control system, the melt pool size response, and the resulting geometry. The implications of this capability, which extend beyond localized control of bead geometry to the potential mitigations of defects and functional grading of component properties, are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Infrared-Fused Vision-Based Thermoregulation Performance Estimation for Personal Thermal Comfort-Driven HVAC System Controls

Thermal comfort is one of the primary factors influencing occupant health, well-being, and productivity in buildings. Existing thermal comfort systems require occupants to frequently communicate their comfort vote via a survey which is impractical as a long-term solution. Here, we present a novel thermal infrared-fused computer vision sensing method to capture thermoregulation performance in a non-intrusive and non-invasive manner. In this method, we align thermal and visible images, detect facial segments (i.e., nose, eyes, face boundary), and accordingly read the temperatures from the appropriate coordinates in the thermal image. We focus on the human face since it is often clearly visible to cameras and is not merged into a hot background (unlike hands). We use a regularized Gaussian Mixture model to track the thermoregulation changes over time and apply a heuristic algorithm to extract hot and cold indices. We present a personalized and a generalized comfort modeling method, selected based on the availability of the occupant historical indices measurements in a neutral environment, and use the time-series of the hot and cold indices to define corrections to HVAC system operations in the form of setpoint constraints. To evaluate the efficacy of our proposed approach in responding to thermal stimuli, we designed a series of controlled experiments to simulate exposure to cold and hot environments. While applying personalized modeling showed an acceptable average accuracy of 91.3%, the generalized model’s average accuracy was only 65.2%. This shows the importance of having access to physiological records in modeling and assessing comfort. We also found that individual differences should be considered in selecting the cooling and heating rates when some knowledge of the occupant’s overall thermal preference is available.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Cascaded Control for Building HVAC Systems in Practice

Actuator hunting is a widespread and often neglected problem in the HVAC field. Hunting is typically characterized by sustained or intermittent oscillations, and can result in decreased efficiency, increased actuator wear, and poor setpoint tracking. Cascaded control loops have been shown to effectively linearize system dynamics and reduce the prevalence of hunting. This paper details the implementation of cascaded control architectures for Air Handling Unit chilled water valves at three university campus buildings. A framework for implementation the control in existing Building Automation software is developed that requires only a single line of additional code. Results gathered for more than a year show that cascaded control not only eliminates hunting in control loops with documented hunting issues, but provides better tracking and more consistent performance during all seasons. A discussion of efficiency losses due to hunting behavior is presented and illustrated with comparative data. Furthermore, an analysis of cost savings from implementing cascaded chilled water valve control is presented. Field tests show 2.2–4.4% energy savings, with additional potential savings from reduced operational costs (i.e., maintenance and controller retuning).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Leveraging Energy Storage in a Solar-Tower and Combined Cycle Hybrid Power Plant

A method is presented to enhance solar penetration of a hybrid solar-combined cycle power plant integrated with a packed-bed thermal energy storage system. The hybrid plant is modeled using Simulink and employs systems-level automation. Feedback control regulates net power, collector temperature, and turbine firing temperature. A base-case plant is presented, and plant design is systematically modified to improve solar energy utilization. A novel recycling configuration enables robust control of collector temperature and net power during times of high solar activity. Recycling allows for improved solar energy utilization and a yearly solar fraction over 30%, while maintaining power control. During significant solar activity, excessive collector temperature and power setpoint mismatch are still observed with the proposed recycling configuration. A storage bypass is integrated with recycling, to lower storage charging rate. This operation results in diverting only a fraction of air flow to storage, which lowers the storage charging rate and improves solar energy utilization. Recycling with a storage bypass can handle larger solar inputs and a solar fraction over 70% occurs when following a drastic peaking power load. The novel plant configuration is estimated to reduce levelized cost of the plant by over 4% compared to the base-case plant.

14 SOLAR ENERGY↗

DOE OSTI2020

Development and Implementation of Fault-Correction Algorithms in Fault Detection and Diagnostics Tools

A fault detection and diagnostics (FDD) tool is a type of energy management and information system that continuously identifies the presence of faults and efficiency improvement opportunities through a one-way interface to the building automation system and the application of automated analytics. Building operators on the leading edge of technology adoption use FDD tools to enable median whole-building portfolio savings of 8%. Although FDD tools can inform operators of operational faults, currently an action is always required to correct the faults to generate energy savings. A subset of faults, however, such as biased sensors, can be addressed automatically, eliminating the need for staff intervention. Automating this fault “correction” can significantly increase the savings generated by FDD tools and reduce the reliance on human intervention. Doing so is expected to advance the usability and technical and economic performance of FDD technologies. This paper presents the development of nine innovative fault auto-correction algorithms for Heating, Ventilation, and Air Conditioning pi(HVAC) systems. When the auto-correction routine is triggered, it overwrites control setpoints or other variables to implement the intended changes. It also discusses the implementation of the auto-correction algorithms in commercial FDD software products, the integration of these strategies with building automation systems and their preliminary testing.

field testing↗

DOE OSTI2020

A Comparison of DER Voltage Regulation Technologies Using Real-Time Simulations

Grid operators are now considering using distributed energy resources (DERs) to provide distribution voltage regulation rather than installing costly voltage regulation hardware. DER devices include multiple adjustable reactive power control functions, so grid operators have the difficult decision of selecting the best operating mode and settings for the DER. In this work, we develop a novel state estimation-based particle swarm optimization (PSO) for distribution voltage regulation using DER-reactive power setpoints and establish a methodology to validate and compare it against alternative DER control technologies (volt–VAR (VV), extremum seeking control (ESC)) in increasingly higher fidelity environments. Distribution system real-time simulations with virtualized and power hardware-in-the-loop (PHIL)-interfaced DER equipment were run to evaluate the implementations and select the best voltage regulation technique. Each method improved the distribution system voltage profile; VV did not reach the global optimum but the PSO and ESC methods optimized the reactive power contributions of multiple DER devices to approach the optimal solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗