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Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2025

A summary of NLR's stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, capability upgrades, and examples of R&D impact. 2025 brought a national focus on energy and ESIF is meeting the moment. All eyes are on data centers and domestic manufacturing and bringing the benefits of artificial intelligence to power system planning and operations. In step with national priorities, ESIF is building out capabilities that advance secure, reliable, and affordable power. ESIF hosted 190 multidisciplinary research projects, 855 high-performance computer users, and collaborated with 81 partners from industry, academia, research, and federal agencies. These research projects resulted in an AI method for detecting high-impedance faults with 90% accuracy, a grid controls demonstration in Connecticut, power quality validation of CorePower's flagship inductor, and a cybersecurity assessment of potential rogue capabilities in digitally connected energy devices. Facility infrastructure improvements enhanced the thermal research network, the SCADA system, the cyber range, power hardware-in-the-loop testing, and more. With support from the U.S Department of Energy (DOE), the ESIF laboratories continue to deliver leading solutions for secure, reliable, and affordable power.

24 POWER TRANSMISSION AND DISTRIBUTION

Artificial Intelligence for Data Center Operations (AIOps): Cooperative Research and Development (Final Report)

High performance computing data centers will increasingly need to rely on automation to keep pace with exascale growth in compute capability and to manage and optimize the data center environment and facility resources. Artificial intelligence and machine learning approaches provide the means to improve HPC data center operational efficiency, by learning historical trends and training models to operate on real-time data collected from both IT and facilities sources. NREL has developed methods of real-time collection, aggregation and streaming of these data in the ESIF HPC Data Center and has collected a significant dataset of relevant metrics across computer systems, racks, environmental, building and utility sources for research into various predictive analytics problems. HPE's Advanced Technology Group (ATG) is doing comprehensive research into exascale monitoring and management for High Performance Computing (HPC) systems (hereinafter HPE's Data Monitoring/ Management Technology). NREL and HPE will collaborate to add Artificial Intelligence (AI) to NREL's real-time data collection/ aggregation/ streaming system and HPE's Data Monitoring/ Management System, with the goal of improving the operational efficiency of NREL's Energy Systems Integration Facility (ESIF) HPC Data Center through data analytics on both historical and real-time data from IT systems and facilities operations. This collaboration will consist of efforts in Data Management, Data Analytics, and AI/ML Optimization for both manual and autonomous intervention in data center operations. This will be a multi-year, multi-staged effort with a goal towards building capabilities for an Advanced Smart Facility, and demonstration of these techniques in the NREL ESIF HPC Data Center.

97 MATHEMATICS AND COMPUTING

Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2024

A summary of NREL's good stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, infrastructure upgrades, and examples of R&D impact. In fiscal year 2024, we developed advanced energy security and resilience capabilities as we built a new test bed for power electronics and completed a 1-megawatt platform for studying energy systems with grid-forming inverters. Researchers collaborated with utilities, manufacturers, and communities to solve their pressing questions, such as a control architecture that heralds a new direction for distributed energy management systems. With support from the U.S Department of Energy (DOE), the work in the ESIF laboratories continues to advance national goals for resilient and affordable energy.

annual report

NLR HPC Facility Power Usage Effectiveness (PUE) Data

Timeseries of Energy Systems Integration Facility (ESIF) Data Center Power Usage Effectiveness (PUE) Data provided in Parquet and compressed CSV formats Power Metrics Timeseries Fields: ts: Timestamp cooling_kw: Cooling (kilowatts) - Captures the power used by fans and pipe trace heaters associated with outdoor cooling equipment. The dedicated tower filter pump power is also captured as cooling load. energy_reuse: Energy Reuse Effectiveness hvac_kw: Heating, ventilation, and air conditioning (kilowatts) - Captures fan walls, fan coils that support the data center electrical rooms, and the make-up air unit. it_power_kw: IT equipment (kilowatts) - Captures power used by the IT equipment on the data center floor. plug_and_light_kw: Lights and utility plugs (kilowatts) - Captures power associated with the data center and dedicated mechanical room. The crank-case heater for the emergency standby generator is also captured as light and plug load. pue: Power Usage Effectiveness pump_kw: Pumps (kilowatts) - Captures power from pumps that move water in the data center Energy Recover Water loop and the Tower Water loops, and also captures power used by the boost pumps that circulate water through the fan walls. Note: The tower filter pump runs constantly to filter water from the data center cooling tower system, so 2.67 kilowatts are attributed to this pump and that is not reflected in this data field. day: Day of month Outside Weather Station Timeseries Fields: ts: Timestamp outside_air_humidity: Outside air humidity - Relative humidity percent outside_air_temp: Outside air temperature - Degrees Fahrenheit day: Day of month More detail: High-Performance Computing Data Center Power Usage Effectiveness

97 MATHEMATICS AND COMPUTING

EVSE DERMS Controls [SWR-26-010]

An MQTT (Message Queuing Telemetry Transport) and OCPP (Open Charge Point Protocol) based remote smart charging controller framework for AC Electric Vehicle Supply Equipments (EVSEs). The code in this repo allows for the National Laboratory of the Rockies (NLR) controls to interface with the real Distributed Energy Resource Management System (DERMS) and EVSEs in NLR's ESIF Optimization and Control Laboratory (OCL). Different charge management algorithms can be tested to determine which power allocation method is most effective with the overall goal of demonstrating clear and well documented test results as well as providing functional control algorithms which could be utilized to provide effective smart charge management (SCM) at EV charging stations. Different power allocation methods are programmed in lab_demo_controller.py and include allocation based on first come first served, equal sharing, state of charge (SOC), priority factors, and behind the meter control methods.

Panossian, Nadia [National Laboratory of the Rocki

Resilient and Cost-Effective Hybrid Li-Ion Battery Energy Storage System for Sites with Solar Generation and Electric Vehicle (EV) Charging (CRADA Final Report, CRD-19-00799)

The batteries of an energy storage system designed for multiple use-cases are traditionally selected to withstand the highest rate at which a battery is discharged relative to its maximum capacity (C-rate) and cycling requirements of the most intense use-case. However, this is not cost-effective given that the price of the batteries is strongly correlated to C-rate and cyclability. We propose to establish design guidelines for a hybrid energy storage system and test an edge controller that uses high-power and high-energy batteries for high- cyclability use cases such as frequency regulation and electric vehicle (EV) charging and low-cost batteries for low-power and low-cyclability use cases such as summer peak loads. The three main objectives of this proposal are (i) establishing sizing guidelines for such a hybrid storage system, (ii) installing a hybrid storage system in the Energy Systems Integration Facility (ESIF) sized based on those guidelines, and (iii) testing an edge controller specific for the system through hardware tests.

14 SOLAR ENERGY

Renewable Hydrogen to Vehicle (RH2V) – Operation Verification and Risk Mitigation Studies: Original Agreement (Modification 0) (CRADA Final Report)

Toyota has announced plans for commercial fuel cell vehicle deployment in 2015. To fully realize the benefits of fuel cell vehicles (zero emission with no performance loss in terms of vehicle range and capability), hydrogen produced efficiently from renewable sources is necessary. Most of the hydrogen fueling stations today utilize hydrogen reformed from natural gas (produced onsite or delivered). This enables more stations to be deployed cost-effectively within a network. Producing and using cost-effective renewable hydrogen in fuel cell vehicles will enable realization of the full potential. A viable option of green hydrogen that reliably delivers on the full suite of benefits for Toyota fuel cell vehicle drivers is needed. NREL is in a unique position to analyze and optimize renewable hydrogen production scenarios using the Energy Systems Integration Facility (ESIF), a facility that is specifically designed to evaluate renewable energy integration technologies. As the U.S. Department of Energy's (DOE) primary national laboratory for renewable energy and energy efficiency research and development, NREL has extensive knowledge of photovoltaic systems as well as alternative renewable technologies for efficient and reliable production of green hydrogen.

08 HYDROGEN

Electrical Validation Testing for ORPC MHK Generator, Modification 6: ORPC SBV for MHK Generator System (CRADA Final Report)

For the U.S. Department of Energy’s (DOE) 2016 Small Business Voucher for Marine and Hydrokinetic (MHK) System, Second Round 2016, ORPC intends to work with the National Renewable Energy Laboratory (NREL) to perform dynamometer testing of the MHK generator systems and its associated controls and inverters. ORPC will provide the generator, variable frequency drives (VFD), controls, and inverter for this testing. NREL will utilize the NREL Energy Systems Integration Facility (ESIF) and dynamometer facilities at the National Wind Technology Center (NWTC) for this work. Modification 6: Additionally, NREL will conduct a feasibility study for implementing passive DC rectification at the turbine.

17 WIND ENERGY

Toyota Highlander FCHV (CRADA CRD-12-00469 Final Report)

This project relates to the loan of four Toyota Mirai FCEV-adv vehicles to NLR to provide a load (vehicles to fill with hydrogen) to our fueling station research facility to study hydrogen fueling infrastructure performance using 700 bar precooled hydrogen at ESIF’s Hydrogen Infrastructure Testing and Research Facility (HITRF) facility.

33 ADVANCED PROPULSION SYSTEMS

Production of Renewable Natural Gas from Waste Carbon Dioxide Sources (CRADA Final Report)

This CRADA provides new funding from SoCalGas and DOE's BETO and FCTO Offices focused hydrogen mass transfer limitations in H2@Scale processes. The project leverages the existing hydrogen production capabilities at the Energy Systems Integration Facility (ESIF) and SoCalGas' 700 L bioreactor system designed, built, and delivered to NLR under the first phase of this CRADA. This Joint Work Statement will cover new hardware modifications between NLR's electorlyzer stack and the SoCalGas bioreactor located outdoors. The new hardware and controls will provide researchers with the tools needed to obtain preliminary experimental data for a non-provisional application due in July 2019. The IP being developed is expected to improve the productivity of the bioreactor and would have wider impacts on other end-use processes using pressurized hydrogen (H2). In addition, this new funding enhances an existing BETO Biopower award by developing a 10-15 kW electrolyzer that is scalable to the MW-class with reduced capital cost and higher efficiency aimed at improving H2 mass transfer to downstream processes, like biomethanation. Finally due to the close-coupling between the electrolyzer stack and bioreactor, R&D will focus on cell retention, nutrient maintenance, optimal water management and process controls.

08 HYDROGEN

Enabling Evaluation of a Southern Company Distribution Feeder on NREL ADMS Test Bed: Cooperative Research and Development (Final Report)

The objective of this project is to enable evaluation of a Southern Company distribution feeder on the Advanced Distribution Management System (ADMS) test bed. The long-term goal is to evaluate a federated distributed energy resource (DER) management solution that aggregates DERs through either direct control, transactive control or an aggregator to provide bulk services while observing distribution system voltage and power constraints. The DER aggregation needs to be coordinated with an ADMS that is responsible for reliable power delivery across the distribution systems. This project takes the first step towards enabling such evaluation by deploying an ADMS from Oracle (Southern Company's ADMS supplier) with a Southern Company feeder at NREL.

24 POWER TRANSMISSION AND DISTRIBUTION

NLR HPC Eagle GPU Node Metrics

Ganglia node metrics and iLO (Integrated Lights Out) power data captured from six representative Eagle GPU nodes The Eagle HPC operated at NLR from 2019 through 2024. Eagle was a 2,000-node, 8-petaflop system. This dataset is a representative sample of metrics for 6 of the GPU nodes. Each GPU node contained 2 CPUs and 2 GPUs. Data provided in compressed CSV format. Ganglia and iLO Power Time Series Fields ts: Timestamp dv: Device / Node - Rack and Unit - r103u17 == r(ack)103u(nit)17 mt: Metric (only present for Ganglia) vl: Value - Value in watts for iLO power (instantaneous value at sampling time) or specified Ganglia metric below Ganglia Metrics Metric name -- Metric description -- Unit cpu_aidle -- Percent of time since boot idle CPU -- Percent cpu_idle -- Percent CPU idle -- Percent cpu_nice -- Percent CPU nice -- Percent cpu_speed -- Speed in MHz of CPU -- MHz cpu_user -- Percent CPU user -- Percent cpu_wio -- The percentage of CPU Wait I/O -- Percent gpu0_bar1_memory -- Used GPU bar1 memory -- MB gpu0_decoder_util -- GPU decoder utilization -- Percent gpu0_ecc_db_error -- Total ECC error counts for the GPU -- Number gpu0_encoder_util -- GPU encoder utilization -- Percent gpu0_fan -- Fan speed -- RPM gpu0_fb_memory -- Used GPU framebuffer memory -- MB gpu0_graphics_clock_report -- Current clock speeds for the device -- MHz gpu0_mem_total -- Memory total -- MB gpu0_mem_util -- Memory utilization -- Percent gpu0_power_usage_report -- Power usage report -- Watts gpu0_temp -- GPU 1 temperature -- Celsius gpu1_bar1_memory -- Used GPU bar1 memory -- MB gpu1_decoder_util -- GPU decoder utilization -- Percent gpu1_ecc_db_error -- Total ECC error counts for the GPU -- Number gpu1_encoder_util -- GPU encoder utilization -- Percent gpu1_fan -- Fan speed -- RPM gpu1_fb_memory -- Used GPU framebuffer memory -- MB gpu1_graphics_clock_report -- Current clock speeds for the GPU -- MHz gpu1_mem_total -- Memory total -- MB gpu1_mem_util -- Memory utilization -- MB gpu1_power_usage_report -- Power usage report -- Watts gpu1_temp -- GPU 1 temperature -- Celsius ipmi_cpu1_temp -- CPU 1 temperature -- Celsius ipmi_cpu2_temp -- CPU 2 temperature -- Celsius ipmi_inlet_ambient_temp -- Temperature measured at intake -- Celsius ipmi_vr_p1_temp -- CPU 1 voltage regulator temperature -- Celsius ipmi_vr_p2_temp -- CPU 2 voltage regulator temperature -- Celsius mem_buffers -- Amount of buffered memory -- Bytes mem_cached -- Amount of cached memory -- Bytes mem_free -- Amount of available memory -- Bytes mem_shared -- Amount of shared memory -- Bytes mem_total -- Amount of available memory -- Bytes

97 MATHEMATICS AND COMPUTING