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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Next Generation Integrated PV Products Cost and Workflow Analysis (Final Report)

Residential photovoltaic (PV) costs have fallen consistently for over a decade (Ardani et al. 2018). DOE has subsequently developed a new residential PV cost target for 2030 of $0.05/kilowatt hour (SETO 2023). Ardani et al. (2018) conclude that integrated roofing and PV (RIPV) products may be key to achieving the residential target for both new construction and retrofit residential PV. In RIPV, the PV product is incorporated into or replaces the roofing material. RIPV systems can use conventional crystalline or thin-film technologies, may be aesthetically attractive alternatives to traditional racked and mounted PV systems, and may increase building property values (Cook et al. 2023). These products also have the potential to provide customer acquisition, labor, and equipment cost savings over traditional, racked and mounted residential rooftop PV and several companies have recently introduced integrated roofing and PV (RIPV) products (Cook et al. 2023). In 2022, Tesla was the market leader, representing 94% of RIPV capacity installed in 2022 through its Solar Roof offering, while GAF Energy and its Timberline Solar product was second capturing 3% (Feldman et al. 2023). In this project, NREL analyzed three research questions: (1) How do current RIPV products compare to racked and mounted PV in terms of costs, install times and processes? (2) How are RIPV products installed and are there opportunities for cost savings? (3) What are the key barriers to expanding market opportunities for integrating solar and roofing products? In this project, we explored residential RIPV cost reduction opportunities by analyzing installation processes. Our study documented residential RIPV installations at two reroofing sites (20.52 kilowatts) and the equivalent of nine new construction sites (71.75 kW) in California through a methodology known as time and motion study. We also conducted 15 interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration.

14 SOLAR ENERGY↗
DOE OSTI2023

Tracking the Sun: Pricing and Design Trends for Distributed Photovoltaic Systems in the United States (2023 Edition) [Slides]

Berkeley Lab’s annual Tracking the Sun report describes trends among grid-connected, distributed solar photovoltaic (PV) and paired PV+storage systems in the United States. For the purpose of this report, distributed solar includes residential systems, roof-mounted non-residential systems, and ground-mounted systems up to 5 MW-AC. Ground-mounted systems larger than 5 MW-AC are covered in Berkeley Lab’s companion annual report, Utility-Scale Solar. The latest edition of the report is based on 3.2 million systems installed through year-end 2022, representing more than 80% of systems installed to date. The report describes and discusses key trends related to: -Project characteristics, including system size, module efficiencies, prevalence of paired PV with storage, use of module-level power electronics, third-party ownership, mounting configurations, panel orientation, and non-residential customer segmentation ownership -Median installed-price trends, both nationally and by state -Variability in pricing according to system size, state, installer, equipment type, and other factors, relying on both descriptive and econometric analysis The report also includes a multi-variate regression analysis to estimate the effects of key pricing drivers for residential systems installed in 2022.

14 SOLAR ENERGY↗
DOE OSTI2024

Tracking the Sun: Pricing and Design Trends for Distributed Photovoltaic Systems in the United States, 2024 Edition [Slides]

Berkeley Lab’s annual Tracking the Sun report describes trends among grid-connected, distributed solar photovoltaic (PV) and paired PV+storage systems in the United States. For the purpose of this report, distributed solar includes residential systems, roof-mounted non-residential systems, and ground-mounted systems up to 5 MW-AC. Ground-mounted systems larger than 5 MW-AC are covered in Berkeley Lab’s companion annual report, Utility-Scale Solar. The latest edition of the report is based on 3.7 million systems installed through year-end 2023, representing close to 80% of systems installed to date. The report describes and discusses key trends related to: -Project characteristics, including system size, module efficiencies, roof-coverage ratios, prevalence of paired PV with storage, use of module-level power electronics, third-party ownership, mounting configurations, panel orientation, and customer segmentation -Median installed-price trends, both nationally and by state -Variability in pricing according to system size, state, installer, equipment type, and other factors, relying on both descriptive analysis and a multi-variate regression to estimate the effects of key pricing drivers for residential systems installed in 2023.

14 SOLAR ENERGY↗
DOE OSTI2025

Microscopic Measurement: Need for Nuclear Material Sample Specimen Characterization Capability

The Surveillance, Fabrication, and Off-Site Operations team at Lawrence Livermore National Laboratory is beginning an update to the nuclear material machining lab in Superblock. Plutonium and other nuclear materials tend to accelerate the aging process for equipment and machines that would otherwise be maintainable for long lives. They have their lifespans shortened from deteriorated seals, embrittled polymer components, accelerated corrosion, and damage to electronics from exposure to radioactive materials. The cost of installation of equipment into a glove box (GB) tends to outstrip the cost of the equipment itself. Due to the magnification of cost, the historical approach to equipment installs has been to purchase and install the highest-quality and most robust equipment available to maximize time between failures and updates. To make room for the installation of a new lathe, the inspection GB is being moved to a different location within the machining lab. As part of the overall effort, the equipment within the inspection GB is being revisited. Current measurement capabilities are antiquated and starting to become problematic due to age. Advances in metrology are sought for more comprehensive characterization of scientific samples. This document aims to identify several options for the replacement of current measurement equipment and identify a system for purchase and eventual installation. The intention is not to select the cheapest system, but rather to identify a system that best meets the needs of both the operators and principal investigators (PI). Following the convention of the SYSM-5620 Design Thinking and System Engineering, it was determined that a laser confocal measurement system from Keyence is the most suitable option for our programmatic need. Form factor, capability, and maintainability were considered. Along with stakeholder input, to ensure the best decision for the Nuclear Material Technology Program.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024

In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Component pose reconstruction using a single robotic total station for panelized building envelopes

The construction industry can benefit greatly from increased automation in construction processes in terms of precision, time, and labor costs. This is especially true for prefabricated construction for either new buildings or envelope retrofits. Here, prefabricated components are manufactured offsite according to design specifications and installed onsite. Accurate information on the component’s position and orientation (pose) is needed to achieve this. A tool named “Real-Time Evaluator” (RTE), designed to autonomously track prefabricated components as they are being installed and provide real-time installation instructions, is currently under development using a single robotic total station. This is challenging since at least three points are needed to determine the pose of an object in space. To achieve this goal with a single robotic total station, two key algorithms were developed: the “resection” algorithm aligns the digital twin with the physical twin regardless of the location of the total station, and the “transformation” algorithm gives instructions of translations and rotations to installers to achieve the desired installation pose. The algorithms were evaluated experimentally on a lab-scale demonstration. Results show that the resection algorithm achieved an average error of < 3.1 mm, while the transformation algorithm predicted the rotation angle along a single axis with an error of < 0.5◦.

Tang, Mengjia↗
DOE OSTI2023

Observations and Lessons Learned in Residential Roofing Integrated Photovoltaics

The data file includes field observations of residential roofing integrated photovoltaics installation that happened between July 2021 and June 2022 in California. There are 21 observations - 2 in the re-roofing category and 19 in the new construction category. The file includes two time and motion forms (Re-Roofing & New Construction) we used to capture the time it takes for each activity in the rooftop solar and electrical installation process. You will see the duration for detailed steps along with activities that are included for total installation time for the paper. There are three parts to the time and motion form - Part 1 has project and crew characteristics, product information, and inspection and permitting data and can be filled before the installation. Part 2 has the actual installation time stamps and related notes. Part 3 has the crew information and can be filled on-site or off-site, but this section is optional. The re-roofing form has pre-solar activities and gutters and vents section in Part 2 of the form, whereas new construction form includes a section for capturing the time it took for rough wiring. The re-roofing form does not include rough wiring but instead includes the final electrical wiring process. These are the key differences in both the forms. Each day/step/installation activity needs to include the crew break time as they happen and there is space available to capture the crew breaks duration. In Table 1 below, the different terms used in the time and motion form are defined and their corresponding unit of measurement stated. We also highlight the optional sections. The data is captured in total mins, total hours, person mins, person hours. You can use this form or make edits to the form to recreate the study or make your own observations. The data herein was reviewed but may not be comprehensive. NREL invites questions and inputs to improve the data, including to: Correct erroneous information Fill in missing/updated information Clarifications on data and variables Updated information may be submitted to Sushmita Jena at sushmita.jena@nlr.gov.

14 SOLAR ENERGY↗
NASA NTRS1977

Effect of forward motion on engine noise

Methods used to determine a procedure for correcting static engine data for the effects of forward motion are described. Data were analyzed from airplane flyover and static-engine tests with a JT8D-109 low-bypass-ratio turbofan engine installed on a DC-9-30, with a CF6-6D high-bypass-ratio turbofan engine installed on a DC-10-10, and with a JT9D-59A high-bypass-ratio turbofan engine installed on a DC-10-40. The observed differences between the static and the flyover data bases are discussed in terms of noise generation, convective amplification, atmospheric propagation, and engine installation. The results indicate that each noise source must be adjusted separately for forward-motion and installation effects and then projected to flight conditions as a function of source-path angle, directivity angle, and acoustic range relative to the microphones on the ground.

Blankenship, G. L.↗
NASA NTRS1981

Integrated residential photovoltaic array development

Three basic module design concepts were analyzed with respect to both production and installation costs. The results of this evaluation were used to synthesize a fourth design which incorporates the best features of these initial concepts to produce a module/array design approach which offers the promise of a substantial reduction in the installed cost of a residential array. A unique waterproofing and mounting scheme was used to reduce the cost of installing an integral array while still maintaining a high probability that the installed array will be watertight for the design lifetime of the system. This recommended concept will also permit the array to be mounted as a direct or stand-off installation with no changes to the module design.

Shepard, N. F., Jr.↗
NASA NTRS1989

A supersonic through-flow fan engine airframe integration study

A study is undertaken to investigate the engine airframe integration effects for supersonic through-flow fan engines installed on a Mach 3.20 supersonic cruise vehicle. Six different supersonic through-flow fan engine installations covering the effects of engine size, nacelle contour, nacelle placement, and approximate bypass plume effects are presented. The different supersonic through-flow fan installations are compared with a conventional turbine bypass engine configuration on the same basic airframe. The supersonic through-flow fan engine integrations are shown to be comparable to the turbine bypass engine configuration on the basis of installed nacelle wave drag. The supersonic through-flow fan engine airframe integrated vehicles have superior aerodynamic performance on the basis of maximum lift-to-drag ratio than the turbine bypass engine installation over the entire operating Mach number range from 1.10 to 3.20. When approximate bypass plume modeling is included, the supersonic through-flow fan engine configuration shows even larger improvements over the turbine bypass engine configuration.

Barnhart, Paul J.↗
NASA NTRS1989

A supersonic through-flow fan engine airframe integration study

Engine airframe integration effects are investigated for supersonic through-flow fan engines installed on a Mach 3.20 supersonic cruise vehicle. Six different supersonic through-flow fan engine installations covering the effects of engine size, nacelle contour, nacelle placement, and approximate bypass plume effects are presented. The different supersonic through-flow fan installations are compared with a conventional turbine bypass engine configuration on the same basic airframe. The supersonic through-flow fan engine integrations are shown to be comparable to the turbine bypass engine configuration on the basis of installed nacelle wave drag. The supersonic through-flow fan engine airframe integrated vehicles have superior aerodynamic performance on the basis of maximum lift-to-drag ratio than the turbine bypass engine installation over the entire operating Mach number range from 1.10 to 3.20. When approximate bypass plume modeling is included, the supersonic through-flow fan engine configuration shows even larger improvements over the turbine bypass engine configuration.

Barnhart, Paul J.↗
NASA NTRS1993

Implementation of interconnect simulation tools in spice

Accurate computer simulation of high speed digital computer circuits and communication circuits requires a multimode approach to simulate both the devices and the interconnects between devices. Classical circuit analysis algorithms (lumped parameter) are needed for circuit devices and the network formed by the interconnected devices. The interconnects, however, have to be modeled as transmission lines which incorporate electromagnetic field analysis. An approach to writing a multimode simulator is to take an existing software package which performs either lumped parameter analysis or field analysis and add the missing type of analysis routines to the package. In this work a traditionally lumped parameter simulator, SPICE, is modified so that it will perform lossy transmission line analysis using a different model approach. Modifying SPICE3E2 or any other large software package is not a trivial task. An understanding of the programming conventions used, simulation software, and simulation algorithms is required. This thesis was written to clarify the procedure for installing a device into SPICE3E2. The installation of three devices is documented and the installations of the first two provide a foundation for installation of the lossy line which is the third device. The details of discussions are specific to SPICE, but the concepts will be helpful when performing installations into other circuit analysis packages.

Satsangi, H.↗
NASA NTRS1988

STS-26: Preparations for Launch

Preparations for launch of STS-26 are shown. They include: (1) VAB to OPF high bay rollover; (2) Main engine unpacking and installation; (3) OMS pod installation; (4) Crew hatch removal; (5) Modified crew hatch installation; (6) Nose cap installation; (7) 17 inch disconnect work; (8) Ku-band antenna stow and deploy; (9) Tile work; (10) Oasis payload installation; (11) Solid rocket boosters arrival, preps and stacking; (13) Modified SRB segments: Arrival via train at KSC RPSF; (14) AFT segment rotation to vertical in RPSF; (15) AFT skirt to AFT segment mating; (16) SRB grain inspection; (17) Lift AFT segment; and (18) Lift and mate external tank.

Source record↗
NASA NTRS2003

Design-of-experiments to Reduce Life-cycle Costs in Combat Aircraft Inlets

It is the purpose of this study to demonstrate the viability and economy of Design- of-Experiments (DOE), to arrive at micro-secondary flow control installation designs that achieve optimal inlet performance for different mission strategies. These statistical design concepts were used to investigate the properties of "low unit strength" micro-effector installation. "Low unit strength" micro-effectors are micro-vanes, set a very low angle-of incidence, with very long chord lengths. They are designed to influence the neat wall inlet flow over an extended streamwise distance. In this study, however, the long chord lengths were replicated by a series of short chord length effectors arranged in series over multiple bands of effectors. In order to properly evaluate the performance differences between the single band extended chord length installation designs and the segmented multiband short chord length designs, both sets of installations must be optimal. Critical to achieving optimal micro-secondary flow control installation designs is the understanding of the factor interactions that occur between the multiple bands of micro-scale vane effectors. These factor interactions are best understood and brought together in an optimal manner through a structured DOE process, or more specifically Response Surface Methods (RSM).

Anderson, Bernhard H.↗
NASA NTRS2006

STS-121: Discovery Space Shuttle Safety Improvements Briefing

Steve Poulos, Space Shuttle Orbiter Projects Office Manager, and John Chapman, Space Shuttle External Tank Project Manager is shown in this STS-121 Space Shuttle Discovery safety improvements briefing. A graphic presentation of the gap filler installation is shown. The graphics include: 1) Protruding gap fillers during STS-114 mission; 2) STS-114 gap fillers removed on orbiter; 3) Gap filler installation prior to STS-114; 4) Post-STS-114 installation techniques; 5) Gap filler installation post STS-114; 6) Gap filler priority areas; 7) Discovery gap filler installation table and status for STS-121; 8) Damaged blanket on STS-114; 9) On-orbit photography and post-landing photography on STS-114; and 10) STS-114 insulation tiles. Poulos presents imagery that was obtained on STS-114. The imagery includes: 1) The Enhanced Launch Vehicle Imaging System (ELVIS); 2) Liquid oxygen external tank view; 3) Hand-held imagery of the external tank falling into the ocean; 4) ELVIS on STS-121, short, medium and long range camera configurations; 5) Radar capability on the ground at Kennedy Space Center, and 6) STS-121 aft external tank door tiles. Poulos says that STS-121 will have even more imagery than STS-114. John Chapman presents video animation of the external tank where modifications were made along with the ice frost ramps with extensions. Chapman explains these areas using an external tank model. Questions are then answered from the media.

Source record↗
NASA NTRS2009

Testing and Performance Verification of a High Bypass Ratio Turbofan Rotor in an Internal Flow Component Test Facility

A 1/5 scale model rotor representative of a current technology, high bypass ratio, turbofan engine was installed and tested in the W8 single-stage, high-speed, compressor test facility at NASA Glenn Research Center (GRC). The same fan rotor was tested previously in the GRC 9x15 Low Speed Wind Tunnel as a fan module consisting of the rotor and outlet guide vanes mounted in a flight-like nacelle. The W8 test verified that the aerodynamic performance and detailed flow field of the rotor as installed in W8 were representative of the wind tunnel fan module installation. Modifications to W8 were necessary to ensure that this internal flow facility would have a flow field at the test package that is representative of flow conditions in the wind tunnel installation. Inlet flow conditioning was designed and installed in W8 to lower the fan face turbulence intensity to less than 1.0 percent in order to better match the wind tunnel operating environment. Also, inlet bleed was added to thin the casing boundary layer to be more representative of a flight nacelle boundary layer. On the 100 percent speed operating line the fan pressure rise and mass flow rate agreed with the wind tunnel data to within 1 percent. Detailed hot film surveys of the inlet flow, inlet boundary layer and fan exit flow were compared to results from the wind tunnel. The effect of inlet casing boundary layer thickness on fan performance was quantified. Challenges and lessons learned from testing this high flow, low static pressure rise fan in an internal flow facility are discussed.

VanZante, Dale E.↗
NASA NTRS2007

Electrostatic Evaluation of the SRB Velostat(Trademark) Pads

During RSRM Grain inspection, pads constructed of Velostat are grounded and installed in the RSRM bore enabling inspectors to move throughout the bore during the inspection. Velostat pads are installed by grounding the first pad installed and subsequent pads are installed overlapping the previously installed pad maintaining a conductive path to facility ground. Pads are removed upon completion of the inspection in a reverse fashion. As the pads are removed scanning of propellant surfaces is performed per OMRS. During PPICI Audit of B5308.006 (Forward Segment Grain Inspection) in October 07 one audit finding noted that electrostatic scanning of propellant surfaces was being performed during removal of conductive pads following grain inspection. ATK does not perform electrostatic scanning of propellant surfaces during pad removal following final inspection at the plant. The integrated team consisting of NASA SE, USA SE, USA QE, ATK LSS, ATK Systems Safety and ATK DE concurred that electrostatic scanning of propellant surfaces was unnecessary as the conductive pads are grounded. Additional time spent in bore performing scanning presents itself as additional risk. Technicians reported that they have never seen any voltage readings while scanning propellant surfaces during pad removal. USA Systems engineering has written KB 17530 in response to the finding which will delete the requirement (item 2 B47GEN.ll0) to scan propellant surfaces during pad removal. As a result of an E3 panel discussion on December 13, 2007, it was decided that verification of the electrical grounding of the Velostat pads be verified.

Buhler, Charles R.↗
NASA NTRS2004

Modifying Ship Air-Wake Vortices for Aircraft Operations

Columnar-vortex generators (CVG) have been proposed as means to increase the safety of takeoffs and landings of aircraft on aircraft or helicopter carriers and other ships at sea. According to the proposal, CVGs would be installed at critical edge locations on ships to modify the vortices in the air wakes of the ships. The desired effects of modifications are to smooth airflows over takeoff and landing deck areas and divert vortices from takeoff and landing flight paths. With respect to aircraft operations, the wake flows of primary interest are those associated with the bow and side edges of aircraft-carrier decks and with superstructures of ships in general (see Figure 1). The bow and deck-edge vortices can adversely affect airplane and helicopter operations on carriers, while the superstructure wakes can primarily affect operations of helicopters. The concept of the CVG is not new; what is new is the proposed addition of CVGs to ship structures to effect favorable modifications of air wakes. Figure 2 depicts a basic CVG, vertical and horizontal CVGs installed on a simple superstructure, and horizontal CVGs installed on the bow and deck edges. The vertical CVGs would be closed at the deck but open at the top. Each horizontal CVG would be open at both ends. The dimensions of the CVGs installed on the aft edges of the superstructure would be chosen so that the portion of the flow modified by the vertical CVGs would interact synergistically with the portion of the flow modified by the horizontal CVG to move the air wake away from the takeoff-and-landing zone behind the superstructure. The deck-edge CVGs would be mounted flush with, and would extend slightly ahead of the bow of, the flight deck. The overall length of each tube would exceed that of the flight deck. Each deck-edge CVG would capture that portion of the airflow that generates a deck-edge vortex and would generate a columnar vortex of opposite sense to that of the unmodified vortex. The vortex generated by the CVG could be dispersed at its base, thereby removing unwanted turbulence in the path of an approaching airplane. The deck-edge CVGs would promote smooth flow over the entire flight deck. In the case of a Nimitz-class aircraft carrier like that of Figure 1, there would be a CVG on each of the outer edges of the two left portions of the flight deck and a single CVG on the right side of the flight deck. The forward-most CVG on the left side would take the generated vortex underneath the angled flight deck. A CVG could also be installed on the bow of the flight deck to smooth the flow of air onto the flight deck. In the case of wind incident on the deck from an azimuth other than straight ahead, the vortex generated by the bow CVG could, perhaps, be used to feed the CVG(s) of the leeward side edge of the flight deck.

Lamar, John E.↗