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DOE OSTI2026

Oversizing and Part-Load Problems

Oversizing, the common engineering practice of specifying devices with capacity exceeding the actual load requirement, is a widespread practice across virtually all building technologies end-use categories, including HVAC, electrical systems, lighting, appliances, and plug loads. This practice, driven by factors like design uncertainty, institutional pressures, and risk aversion, results in wasted capital investment, control difficulties, and excessive energy consumption due to inefficient part-load operation. Part-load operation, where devices run below maximum capacity, is the dominant operating mode in most energy systems and presents a complex design challenge. Solutions to match output to load fall into three broad categories: constraining the output, adjusting the device’s internal behavior, and linking output to energy storage or other waste-heat reuse applications. The energy implications of part-load are critical, as efficiency often drops sharply as load decreases across a wide diversity of devices. To quantify the extent of this problem, we derive a dimensionless Part-Load Metric (PLM) based on device efficiency and its frequency distribution of operating hours at various output levels. The PLM quantifies the deviation of a device's actual efficiency from its maximum design efficiency. This metric also serves as a measure of "capital inefficiency," enabling engineers to compare the impact of different part-load solutions and providing a unified framework for evaluating performance across various devices and systems.

Meier, Alan↗

DOE OSTI2023

A Two-Step Time-Series Data Clustering Method for Building-Level Load Profile

Residential and commercial buildings have huge potential to contribute value to improve grid resilience by participating grid services. To reveal the significant value, it is critical to estimate the grid service capability from these buildings. Unlike the large-scale distributed energy resources such as wind and solar farms, those buildings need to participate grid services in aggregation, not by individual. Therefore, it is important to appropriately group buildings for aggregation. The load profiles in the same group will have similar characteristics at the same time step, so grid operators can send the grid service signal to the customer group with a higher chance to respond at that time step. In this paper, we develop a load profile clustering method to classify the building-level load profiles for grid service capability estimation. In our two-step clustering approach, we first calculate the total load consumption for each building, clustering the load profiles based on energy consumption level. Then, we further cluster the load profiles in each energy cluster based on the load shape. The parameter selection for each clustering step is discussed. The proposed method is applied on actual building-level load profiles, and the results have proved the effectiveness of this method.

advanced metering infrastructure (AMI)↗

DOE OSTI2026

A Physical Model Enhanced Data Driven Method for High-Resolution Residential Load Profile Generation

Residential buildings account for significant energy consumption, creating opportunities to offer grid services. As electric utilities seek to implement effective system operation strategies, understanding residential energy consumption patterns becomes essential; However, the time intervals of load profiles measured by utilities' smart meters are typically from 15 minutes to 60 minutes. The low-resolution data make it hard to extract appliance-level load information, which is critical for providing grid services. This paper presents a load profile generator designed to produce synthetic load profiles for residential buildings that emphasizes the importance of accurate representations of realistic energy consumption patterns. The generator takes realistic low-resolution residential load measurements and weather data as inputs, producing 1-minute interval profiles that match the characteristics of the original profiles. Further, this generator can be used to populate load profiles in areas where actual measurements are limited to improve the ability of utilities to analyze their distribution systems. By providing more high-resolution residential building load profiles, this tool supports electric utilities to enhance their residential building load control strategies and improve overall grid stability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Loads assessment of a fixed-bottom offshore wind farm with wake steering

Wake steering via deliberate yaw offset is an emerging wind farm control technique that has the potential to mitigate wake losses and further increase wind farm energy yield. The loads impact of this technique has been studied, but there is limited insight into wind-farm-wide impacts of wake steering. Understanding such impacts is crucial to determining the feasibility of using wake steering in commercial wind farms. To that end, this work investigates the impacts of wake steering on the loads of all turbine components across all turbines in a wind farm operating under a broad set of inflow conditions, including inflow velocity, shear exponent, turbulence class, and inflow angle. This was done by performing FAST.Farm simulations of a 12-turbine wind farm array, excerpted from a larger hypothetical wind farm. The International Energy Agency Wind 15-MW reference wind turbine was modeled atop a monopile substructure, an open-source model that closely approximates the properties of similar commercial options. Wake steering was included via yaw offsets that were computed using an offline optimization with the National Renewable Energy Laboratory tool FLORIS. For each inflow case, the 12-turbine array was simulated with and without wake steering. Results were compared in terms of time-averaged means, standard deviations, ultimate loads, and damage-equivalent loads. The findings show that because wake steering is generally applied at rated wind speeds and below, it is unlikely to drive ultimate loads. For fatigue loads, wake steering does increase the overall fatigue accumulation for some load channels, such as blade-root and shaft bending. This is to be expected when overall power yield increases but may cause the damage accumulation to be more uniform throughout the array. The significance of the added fatigue loading is dependent on how frequent wake steering is utilized in the overall set of inflow conditions across the wind rose.

17 WIND ENERGY↗

DOE OSTI2024

Solid face sheets enable lattice metamaterials to withstand high-amplitude impulsive loading without yielding

Owing to their ability to provide tunable mechanical responses, lattice materials are frequently studied to elucidate their response to static and dynamic loads. However, these roles are typically in opposition: static loads must be supported sufficiently far away from the onset of buckling or yielding, whereas dynamic loads are typically ameliorated by crushing of the lattice, which provides excellent energy-absorption due to the large plastic deformation accompanying densification. In contrast, this work considers the octet truss as an exemplar topology, in a structural role where it must simultaneously support static loads while enduring high-amplitude impulsive loads. This study focuses on the ability to withstand impulsive loads without yielding, an essential prerequisite to enduring dual loading. Computational studies using the ALE3D hydrocode were performed to examine the response of the octet truss under a short temporal width impulse shape associated with laser-driven shocks. A key finding was that covering the lattice with a solid face sheet and treating this face sheet thickness as a design variable allows the Taylor-like pulse to be attenuated prior to entering the weaker lattice, at the cost of added mass up front. Experimental validation was accomplished by laser-driven shock testing, using octet trusses printed out of Ti-5Al-5V-5Mo-3Cr. The results show that for a given quantity of mass, the attenuation is maximized when as much mass as possible is moved into the face sheet, leaving a more slender lattice structure. The effect of placing mass in the face sheet rather than lattice beams dominates the effect of relative density, to the point where a low-mass structure with most of the mass concentrated in the face sheet can outperform a high-mass structure with most of the mass in the lattice. Finally, by further understanding the propagation of short pulse width waves within under-dense structures, this study expand the domain of applicability of such structures, including lattice materials, to challenging dual-loading regimes spanning decades of strain rates.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Effect of loading orientations on the microstructure and property of Al−Cu single crystal during stress aging

The precipitation behavior and property of Al−Cu alloy during stress aging under various loading orientations were investigated using single crystals. The resulting microstructures and the strength property were examined by transmission electron microscope (TEM) and compression test, respectively, and the effect of the distribution of θ′-plates on strength property were discussed. The results show that the precipitation distribution of θ′ was significantly affected by the loading orientation during stress aging of Al−Cu single crystals. Loading along close to 〈011〉{sub Al} directions provided more uniform precipitation distribution of θ′ as compared to loading along close to 〈001〉{sub Al} directions, and therefore provided higher strengthening stress of the θ′-plates for the stress aging sample. The results suggested that regulating the distribution of θ′ and therefore improving strength property are possible via controlling the loading orientation during stress aging. - Highlights: • We studied the effect of loading directions on stress aging of Al−Cu single crystal. • Precipitation distribution of θ′ was noticeably affected by the loading direction. • Loading along close to 〈011〉{sub Al} directions reduced the stress-orienting effect. • The strength property is closely related to the precipitation distribution of θ′. • It is possible to regulate the distribution of θ′ and improve strength property.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Impact of Porous Transport Layer Morphology on the Performance of Proton Exchange Membrane Water Electrolyzers with Ultra-Low Iridium Loadings

Reducing Ir loadings in proton exchange membrane water electrolyzer anodes is critical for lowering capital expenses. Loading reduction could be achieved by improving the Ir activity via doping/alloying and/or the development of advanced microstructures. However, the anode porous transport layer (PTL) is a comparatively simple component whose properties also impact Ir utilization. Therefore, well-designed PTLs may also enable reduced Ir loadings. In this work, we survey eight PTLs from various manufacturers to observe their impact on cell performance at low (0.4 mg Ir cm -2 ) and ultralow (0.1 mg Ir cm -2 ) Ir loadings. The PTLs were characterized by their microstructural properties, including porosity, particle size distribution, and pore size distribution. Electrochemical cell performance was correlated to PTL morphology, and it was found that PTLs with lower porosities and smaller particle and pore radii enabled good performance even at ultralow Ir loadings. 1000-h durability testing indicated that using lower porosity PTLs can significantly improve durability behavior. A runaway voltage phenomenon was observed during durability testing of cells with ultralow Ir loadings, which was caused by increases in both anode and cathode overpotentials. Furthermore, we observed that the beginning of test performance of 0.1 mg Ir cm -2 cells correlates to the 1000-h degradation rates of 0.4 mg Ir cm -2 cells, suggesting that for the Ir catalyst used in this work, short-term testing at ultralow loadings can be used as an indicator of long-term degradation at higher loadings.

08 HYDROGEN↗

DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2022

Harmonic Modeling, Data Generation and Analysis of Power Electronics-Interfaced Residential Loads

The share of electronics-based residential load is expected to rise as devices such as variable frequency drives (VFDs), electric vehicle chargers, and inverter-based distributed energy resources (DERs), e.g., photovoltaic (PV) systems become more common. These loads may introduce significant harmonics into power networks that need to be closely studied in order to perform accurate load modeling and forecasting. However, it can be difficult to obtain harmonic-rich voltage and current data - necessary for identifying accurate load models - for residential electrical loads. Recognizing this need, we identify and model a set of electronics-based end-use loads and DERs in an electromagnetic transients program (EMTP) tool for a residence with a single- phase split-phase supply. Further, a procedure is developed to model harmonic interactions between end-use loads connected to the same non-ideal supply voltage in a residential setting. Finally, a harmonic-rich dataset produced via the proposed procedure is utilized to identify frequency coupling matrix (FCM) based load model. Numerical results demonstrate the accuracy of the model, and explore model identifiability with limited data points.

harmonics, power quality, load modeling↗

DOE OSTI2017

Estimating the Impacts of Direct Load Control Programs Using GridPIQ, a Web-Based Screening Tool

In direct load control (DLC) programs, utilities can curtail the demand of participating loads to contractually agreed-upon levels during periods of critical peak load, thereby reducing stress on the system, generation cost, and required transmission and generation capacity. Participating customers receive financial incentives. The impacts of implementing DLC programs extend well beyond peak shaving. There may be a shift of load proportional to the interrupted load to the times before or after a DLC event, and different load shifts have different consequences. Tools that can quantify the impacts of such programs on load curves, peak demand, emissions, and fossil fuel costs are currently lacking. The Grid Project Impact Quantification (GridPIQ) screening tool includes a Direct Load Control module, which takes into account project-specific inputs as well as the larger system context in order to quantify the impacts of a given DLC program. This allows users (utilities, researchers, etc.) to test and compare different program specifications and their impacts.

Demand Reponse↗

DOE OSTI2018

Load Aggregation Methods for Quasi-Static Power Flow Analysis on High PV Penetration Feeders

This paper focuses on developing load aggregation methodologies for analyzing quasi-static power flows on high photovoltaic penetrated distribution feeders so statistics of the transformer loading levels, voltage ramping events, and voltage violation events can be properly quantified. A load profile aggregation algorithm is presented to construct 24-hour, minute-by-minute load profiles at each load node on the test feeder so the aggregation of those load profiles matches the load profile measured at the feeder head. A quasi-static power flow analyses are conducted to obtain minute-by-minute power flow results that can be used to quantify transformer overloads and voltage issues in distribution systems. To demonstrate the effectiveness of the developed methodology, the IEEE-123 test feeder model and residential load profiles collected from the PECAN street project are used in the case studies. Simulation results show that the method is effective in producing the required operation statistics.

Load aggregaton, PV integration, quasi-static powe↗

DOE OSTI2024

Heliostat Consortium: Gap Analysis on State of the Art in Wind Load Design

Wind loads are a major driver of heliostat cost. Standardized methods and tools are needed for a more detailed understanding of the static and dynamic loads of a heliostat design. This will enable cost reduction of wind-dependent heliostats to avoid unnecessarily conservative heliostat designs and increase field efficiency and reliability to reduce the risk of component failures due to high-wind events. Gaps related to wind load include lack of site characterization for wind measurements, insufficient critical load cases for heliostat design, insufficient understanding of turbulence impacts on heliostat tracking error, lack of knowledge on wind load under various heliostat array configurations, and underexplored heliostat field wind-load reduction and operating strategies. Recommended pathway forward is to develop wind load and site characterization guidelines for heliostat design and develop heliostat field wind-load models with optical performance impacts.

aerodynamics↗

DOE OSTI2024

Validation of Local Structural Loads Computed by OpenFAST Against Measurements From the FOCAL Experimental Campaign

This work presents the validation of the local structural load modeling capability in OpenFAST for floating substructures based on data from the FOCAL experimental campaign. Previously, OpenFAST could only represent the floating substructure as a rigid body, and though this approach can model the global response of the floater in most cases, it is not able to capture the structural loads within the floater's individual members. Consideration of local substructure loads is important for some floating designs, because the pursuit of cost reduction often results in lighter and more flexible structures. To address this limitation, the HydroDyn (hydrodynamics) and SubDyn (substructure dynamics) modules of OpenFAST have been recently extended to account for the flexibility of floating substructures. To validate this new capability, we compare the results obtained by OpenFAST with data measured during the FOCAL experimental campaign, which analyzed a 1:70 scale performance-matched model of the IEA 15-MW reference turbine atop a modified University of Maine VolturnUS-S semisubmersible in a wave basin under the action of both wind and waves. For the purposes of the present work, the most important feature of the experiment is the presence of load cells at the root of each pontoon, and our objective is to assess how well those loads are reproduced by OpenFAST. To model the distributed hydrodynamic and hydrostatic loads along the floating substructure, we adopt a strip-theory approach based on the Morison equation, and we discuss the impact of different hydrodynamic modeling options (wave stretching, MacCamy-Fuchs correction, and second-order wave kinematics) on both motions and loads. For simplicity, we focus on wave-only conditions, both regular and irregular. The results demonstrate good overall agreement for the loads at the root of the pontoons for the waves analyzed in this work, especially given the assumptions and simplifications inherent to a simple strip-theory model.

floating offshore wind turbine↗

DOE OSTI2024

Commercialization of Distribution System Load Modeling Tool for Improved DER Interconnection Studies

14 SOLAR ENERGY↗

DOE OSTI2020

Data-Driven Linear Parameter-Varying Modeling and Control of Flexible Loads for Grid Services

Flexible loads have great potential to improve the electric grid's flexibility and stability. To effectively control large ensembles of heterogeneous loads, reliable models thereof are required. This paper presents a data-driven modeling and control approach to manage flexible loads for providing grid services. We leverage a linear parameter-varying autoregressive moving average (LPV-ARMA) model to describe the aggregate load response, where the parameters in the model are used to capture external environmental impacts (e.g., weather). A gain-scheduling feedback controller is then developed to adapt to environmental variations. This data-driven approach can be easily applied to different types of loads in various environmental conditions. In addition to the ensemble controller, distributed load controllers are designed to deliver grid services, while maintaining the quality of service of inherent load tasks. We demonstrate the work on the IEEE 37-node distribution system for real-time power regulation services through control of thermostatically controlled loads.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2017

Short-Term Forecasting of Electric Loads Using Nonlinear Autoregressive Artificial Neural Networks with Exogenous Vector Inputs

Short-term load forecasting is crucial for the operations planning of an electrical grid. Forecasting the next 24 h of electrical load in a grid allows operators to plan and optimize their resources. The purpose of this study is to develop a more accurate short-term load forecasting method utilizing non-linear autoregressive artificial neural networks (ANN) with exogenous multi-variable input (NARX). The proposed implementation of the network is new: the neural network is trained in open-loop using actual load and weather data, and then, the network is placed in closed-loop to generate a forecast using the predicted load as the feedback input. Unlike the existing short-term load forecasting methods using ANNs, the proposed method uses its own output as the input in order to improve the accuracy, thus effectively implementing a feedback loop for the load, making it less dependent on external data. Using the proposed framework, mean absolute percent errors in the forecast in the order of 1% have been achieved, which is a 30% improvement on the average error using feedforward ANNs, ARMAX and state space methods, which can result in large savings by avoiding commissioning of unnecessary power plants. The New England electrical load data are used to train and validate the forecast prediction.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2018

Load Estimation of Offshore Wind Turbines

The influence of 3 MW Hywind-II wind turbine wakes from an upstream offshore floating wind turbine on a downstream turbine with a separation distance of seven rotor diameters was studied for a site in the Gulf of Maine. The turbines and the platforms were subjected to atmospheric boundary layer flows. Various sensitivity studies on fatigue loads with respect to the positions of the downstream turbine were performed and validated with a large-eddy simulation tool. In particular, the effect of various lateral positions of the downstream turbine relative to the upstream turbine were considered using time-series turbine wake data generated from the large-eddy simulation tool which served as an input to an aero-elastic wind turbine model to assess the loads. The load response from the rotor, tower, and the floating platform for the downstream turbine were sensitive to the lateral offset positions where turbines that were partially exposed to upstream turbine wakes yielded significant increases in the cyclic load range. For the given set of lateral positions for the downstream turbine, the largest damage equivalent load occurred when the turbine was one rotor diameter to the left of the centerline, when looking upstream, which is the position of the turbine fully exposed to upstream turbine wake. On the other hand, the fatigue load on the downstream turbine placed on the right side of the position fully exposed to the upstream turbine wake, yielded lower stress due to the non-symmetric shape of the turbine wake. The configuration associated with the largest damage equivalent loads was further investigated in a large-eddy simulation, modeling both the upstream and downstream turbines. It was found that the energy spectra at the blade rotational frequency were a magnitude order higher for the downstream turbine, especially for surge, heave, pitch, and yaw motion of the platform. In conclusion, the increase of the damage equivalent load for the flapwise blade root moment was 45% compared to the upstream turbine, which can potentially reduce the turbine service life time.

17 WIND ENERGY↗

DOE OSTI2022

Wind Turbine Gust Load Alleviation with Active Flow Control

Large wind turbine rotors are becoming more common in utility-scale wind power, especially for offshore wind plants. However, the trend toward large rotors can be limited by their ability to manage dynamic and extreme loads. To provide a safety margin for the rotor design and avoid catastrophic events such as tower strikes, extreme loads need to be controlled. The objective of this study is to develop and evaluate a feedback control system to alleviate extreme loads and reduce blade deflections under gust events using active flow control devices. We also propose a modification in the turbine controller to achieve further reduction in extreme loads. The extreme load reductions are evaluated under gust wind conditions with direction changes according to the IEC standard. The effects of the gust alleviation controller on turbine performance and fatigue loads are investigated as well. With the deployment of the gust alleviation controller and modified turbine baseline controller, the extreme loads and deflections reduce by up to 23%. The energy captured by the turbine is not affected by the proposed gust alleviation controller. The fatigue loads of various wind turbine components are either reduced or remain unchanged.

17 WIND ENERGY↗