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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Electrical Submersible Pumps: A System Modeling Approach for Power Quality Analysis With Variable Frequency Drives

This article proposes a high-level engineering guide to develop an integrated system model for power quality analysis in electrical submersible pump (ESP) applications with variable frequency drives (VFDs). Such analyses are troublesome in the industry due to the complexity of these systems. In this article, simple steps to perform system integration analyses of such arrangements, including torsional analysis, are developed. A simplified VFD-ESP model suitable for coupled electrical and mechanical analysis in steady state is proposed in all their configurations of practical interest. Such a model can be easily implemented in common simulation software, significantly reducing engineering efforts for implementation and analysis. The focus of the proposed model is the prediction of ESP failures that might result from a poor power quality caused by VFDs. Analytical expressions of different types of harmonics in these systems, as well as their accurate locations in the frequency domain, including their interharmonics and common-mode harmonics, are derived for this purpose. Further, the effectiveness of the proposed model is verified through offline and real-time hybrid simulation results. Finally, a comparison between simulation results obtained using the proposed model and measurements collected on a down-scale laboratory prototype is carried out to demonstrate the accuracy of the suggested modeling approach.

42 ENGINEERING↗
DOE OSTI2025

Variable Frequency Drive (VFD): Emphasizing Energy Savings and Efficiency in Industrial Applications

This project explores the energy saving potential of using a VDA in an industrial pumping application. A 24-horsepower pump, 3-phase centrifugal pump powered by 480V AC supply analyzed under variable frequency control using an ABB ACS880-31-052A-5 VFD. by modulating the motor speed between 30Hz and 60Hz, the VFD enables precise control of power consumption based on system set speed. The article is intended for public cause of the poster session and presentation session. INL/Exp-25-86570

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Fully Integrated High Speed Megawatt Class Motor and High Frequency Variable Speed Drive System

This project involved developing a fully integrated high speed megawatt class motor and high frequency variable speed drive system that serve as a commercially viable and technically sound methodology for high speed industrial system applications. The project team organizations consist of Clemson University and TECO Westinghouse Motor Company (TWMC) formed an academic and industrial collaboration that combines the design, analysis, manufacturing and testing experience required for a large research project of this magnitude. The project resulted in an integrated high speed megawatt class medium voltage motor drive system that is at a TRL 6 with a clear path for commercialization. The fully integrated prototype system has been manufactured by TWMC in its Round Rock, Texas facility and tested at full power on a dynamometer at the Clemson University’s eGRID Center in North Charleston, South Carolina.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

A Universal Converter for DC, Single-phase AC, and Multi-phase AC Systems (Final Report)

The goal of this project was to develop a new class of universal power converters that utilize the unique properties of WBG switches, including high reverse voltage blocking and fast switching, to achieve superior performance in universal converters. Some of the features of the proposed converter are as follows: 1) Significantly longer lifetime, higher power density, lower costs associated with bill of materials, and lower shipping, installation, and repair costs compared to the existing WBG-based solutions, 2) Very flexible operation for transferring power between any type of source (dc, single-phase ac, or multi-phase ac) and any type of load (dc, single-phase ac, or multi-phase ac) without using large passive components or additional stages/components, even when the instantaneous values of input and output power are not the same, and 3) High performance operation at all power levels. Considering its advantages and wide range of applications, the proposed converter has the potential to create a new paradigm in power electronics. Among numerous applications of this converter are electric vehicles, wind energy systems, PV systems, industrial motor drives, residential variable frequency drive systems, and nanogrid applications. This project focused on the application of this converter for residential PV, residential motor drive, and industrial motor drive applications, and evaluated the performance of this converter for these applications.

42 ENGINEERING↗
DOE OSTI2020

Performance Evaluation of Three RTU Energy Efficiency Technologies

This project was part of an effort by CLEAResult and ComEd to evaluate the energy saving potential of emerging technologies in the Chicago area. This project focused on evaluating emerging technologies related to rooftop units (RTUs). An RTU with a single-stage compressor and a constant-speed fan with an induction motor was selected as the baseline for technology comparison. Three retrofit strategies were investigated. The first two involved replacing the single-stage compressor of an RTU by either a two-stage or variable-speed compressor and adding a variable frequency drive (VFD) to the constant speed fan. The use of a multi-/variable-stage compressor improves the part-load efficiency of the compressor which will ultimately result in annual energy savings as well as peak demand shaving in some cases where the design capacity of the RTU is larger than the maximum cooling load of the building space that it is serving. The third technology was the use of a high rotor pole switched reluctance motor (SRM) as a replacement for the constant-speed supply fan. The SRM was applied in single-speed, two-stage and variable-speed compressor RTUs. SRM motors run via reluctance torque. Their stator poles are driven by direct current (DC) power and require an inverter as well as active control when using alternating current (AC) power. This inherent property results in high efficiency over a range of operating conditions. It also exhibits higher efficiency compared to variable frequency drives (VFDs) since its switching frequency is much slower (SCE, 2018).The three technologies investigated are summarized below: 1) Replacing the single-speed compressor with a two-stage compressor and adding a VFD to the supply fan. 2)Replacing the single-speed compressor with a variable-speed compressor and adding a VFD to the supply fan. 3) Replacing the constant-speed induction motor of the supply fan with a high rotor pole SRM. DOE’s building simulation platform EnergyPlus and its graphical user interface OpenStudio were used to evaluate the energy-saving potential of upgrading RTUs, by leveraging experimental data from previous research.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

WIPP Safety Significant Confinement Ventilation System (SSCVS) HEPA Filtration System - 20165

Construction and major equipment fabrication are underway for a new ventilation exhaust system at the Waste Isolation Pilot Plant (WIPP). The new system will provide continuous High Efficiency Particulate Air (HEPA) filtration of the exhaust from the WIPP underground while meeting the ventilation demands for expanded waste emplacement and mining operations over the next 40 years. The integrated system design provides for reducing the salt, clay and diesel particulates from the exhaust airflow from the mine, prior to full filtration using Nuclear Safety Significant HEPA filters. The SSCVS design and equipment provides for continuous HEPA filtration over a wide range of operating and environmental conditions. The new exhaust system connects to the existing underground exhaust shaft, and the exhaust air flows from the underground through Salt Reduction Units (SRUs) to protect the final filter banks from excessive moisture and rapid salt/dust buildup. Each of the six (6) SRUs consists of a demister to remove entrained moisture, a dry salt remover unit to filter approximately 90% of the entrained salt/dust, and an automated water treatment system to periodically clean the demisters and to remove salt from the SRU filters. At the maximum expected exhaust flowrate of 540,000 Cubic Feet per Minute (CFM) / 255 Cubic Meters per Second (m{sup 3}/s), five (5) salt removal units will be in operation with one unit in standby or maintenance. An in-line variable frequency drive booster fan will offset pressure losses through each SRU and reduce the relative humidity of the air exiting the SRUs. In the event of a high radiation alarm from the underground Continuous Air Monitors (CAMs), the SRUs will be automatically bypassed, which places the SRS and building outside of the Safety Significant confinement boundary. From the SRUs, the exhaust is directed to the HEPA filter banks located in the New Filter Building. The exhaust system is designed to provide continuous HEPA filtration prior to release to the exhaust stack. There are 22 HEPA filter banks rated at 27,000 CFM / 12.75 m{sup 3}/s each. Each filter bank has two stages of pre-filters and two stages of HEPA filters. The filtered air from each of the 22 filter banks discharges into a common concrete plenum, which is maintained under a negative pressure by the main exhaust fans. Six 1,000 HP variable frequency drive exhaust fans are provided on the south side of the plenum. At the maximum expected exhaust flow of 540,000 CFM, four exhaust fans and twenty filter banks will be in operation. The fans discharge vertically to a separate concrete exhaust plenum. The filtered exhaust is routed from the exhaust plenum to a 125-foot-tall exhaust stack via a 13-foot diameter duct. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Variable-Speed Pump Efficiency Calculation For Fluid Flow Systems with and without Static Head

To accurately calculate pump energy savings gained from implementing variable frequency drive (VFD) controls, the variation of pump efficiency must be considered when operating conditions transition from the design operating point to new operating points. Many software tools require users to specify the new pump efficiency, or it is assumed to be unchanged. Unfortunately, many users have challenges of estimating the pump efficiency at new operating points. This paper presents a simplified method of estimating centrifugal pump efficiency at new operating speeds when the pump is controlled by a VFD. This methodology applies to systems with and without static head when the system curve is not affected by the change, and also systems where the change in operation changes the system curve.A hypothetical fluid flow system and centrifugal pump were used to demonstrate the calculation process for these scenarios. For this hypothetical system, the pump’s efficiency at new operating points was up to 5.4% lower than the design operating point.

42 ENGINEERING↗
DOE OSTI2022

Evaluation of nonlinear control performance of air handling units under variable operation conditions using root distribution approach

The control systems at Air handling units (AHUs) have nonlinear nature, resulting potentially in sluggish, aggressive, or oscillatory responses under variable operation conditions. This paper is to develop an approach for evaluating the nonlinear control performance of AHUs under variable operation conditions and for identifying the impact of varying multiple operation parameters which guides controller design. To do so, an operation parameter-based root distribution technique, intended to sketch the paths traced by closed-loop poles as multiple operation parameters are varied, is first introduced. The technique—which may be viewed as an extension of conventional, single-variable root locus—is then applied to a fan speed control system that includes a motor with a variable frequency drive and a supply fan with an air duct under variable fan speed and duct static pressure. Using the technique, the system’s stability region is graphically identified. The system is also found to be aggressive and gradually lose its stability as the fan speed decreases and the duct static pressure increases, which is validated by the field tests. Here, the root distribution approach is an effective tool to evaluate the performance of any nonlinear control systems at AHUs with multiple variable operation parameters without requiring time-domain simulations.

42 ENGINEERING↗
DOE OSTI2026

LAC Attachments Modernization

This document details the proposed plan to modernize the existing set of cutting attachments in use with the Liquid Abrasive Cutter (LAC). This effort will leverage the replacement of the LAC power generating unit (PGU), which is to be completed by the end of FY25. The PGU modernization will transition away from a diesel direct drive of a high pressure pump to the use of a variable frequency drive, which will be powered by electricity from the existing generator in use by our DOD customers. The existing PGU and a model of the planned replacement is shown below in Figure 1.

42 ENGINEERING↗
DOE OSTI2021

Irrigation system

A gravity irrigation system includes a distribution piping having apertures to distribute water to a field, and a valve located upstream of the distribution piping. The valve limits a pressure of the water being delivered to the distribution piping. The system also includes a sump to receive the water at a lowest elevation of the field, a depth sensor disposed within the sump, and a return pump disposed at least partially within the sump to move the water to an elevated portion of the field. The system also includes a motor to drive the return pump, and a power source coupled to a variable frequency drive that powers the motor and controls a motor speed proportionately to an indication of the depth sensor. The system also includes a transfer piping to bring the water from the return pump to a check valve and to the distribution piping.

Henry, Christopher G.↗
DOE OSTI2021

Overall chilled water system energy consumption modeling and optimization

The emergence of increasingly affordable variable-speed drive technology has changed the approach used to control chilled water systems equipped with these drives. The purpose of this research was to develop an integrated chilled water modeling technique that can determine the optimal system setpoints and estimate the energy saving potential of chiller system. The chiller system equipped with Variable Frequency Drives (VFDs) on cooling tower fans and condenser water pumps. To accomplish the objective, physical component models of the centrifugal chiller, cooling tower and condenser water pump were established with the goal of incorporating the system’s condenser water flow rate and cooling tower fan speeds as optimization variables. Furthermore, a cooling load prediction algorithm was developed using a multiple non-linear regression model to approximate the building’s cooling load subject to a range of environmental conditions. The inputs and outputs of the individual component models were linked to estimate how adjusting the cooling tower fan and condenser water pump speed would influence the system’s comprehensive performance. Here, the overall system model was then optimized using a generalized reduced gradient optimization algorithm to determine the potential energy savings through speed control with VFDs and to ascertain a control logic strategy for the building automation system to operate the heating and cooling system. A case-study was performed on a single chiller system at a museum and the model was calibrated according to logged data collected over four months. Results showed that for the system analyzed, the energy saving of optimizing the cooling tower fan system was found to be 12–15%, while the energy saving potential of optimizing the condenser water pump with the cooling tower fan was negligible. Additionally, comparing different cooling tower fan control strategies showed that a wet-bulb approach-based cooling tower control strategy was shown to have the highest correlation to the optimized fan speed with an R 2 of 0.924.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

ComStock Measure Documentation: Heat Pump Rooftop Units with Standard Performance

This documentation focuses on a single end-use savings shape measure - heat pump rooftop units (HP-RTUs) with standard efficiencies that are prevalent in the current market. Today, these products are claimed as standard efficiency by the manufacturers and are most commonly installed. This document will primarily discuss the additional changes of performance and configuration of the standard efficiency HP-RTUs while a comprehensive overview of the fundamental modeling methodology and background of the HP-RTU measure, including applicability, sizing scheme, and other key assumptions can be found in the original documentation: Heat Pump RTU. The definition of "standard efficiency" can be a bit vague when considering detailed specifics other than efficiency metrics of a heat pump. Thus, we have focused on reflecting products where manufacturers claim as standard efficiency and products that are not top-of-the-line in their model lineup. Based on gathering information from eight products from four major manufacturers, there are some common (or relatively prevalent) characteristics and we have defined standard efficiency product as follows: direct drive outdoor unit fan, two stages of heat pump cooling, single stage heat pump heating (i.e., all compressors running at the same time), heat pump minimum lockout temperature of 0°F (-17.8°C), backup electric resistance heating, backup heating runs at the same time as heat pump heating , heat pump heating locking out below minimum operating temperature, IEER in between 11-13, and HSPF in between 8-8.9. There are cases where some of these products have other variations: a variable frequency drive fan, dual fuel (i.e., gas backup heating) option, three or more cooling stages, two stages of heat pump heating, no backup heating as default , etc. However, this work tried to reflect the most common and prevalent options for a standard efficiency product.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Assessing Dynamic Behaviors in Converter- Dominated Power Systems via RMS and EMT Simulations: A Study of Hawaii’s NELHA Microgrid

The transition from conventional power systems to converter-based microgrids has significantly advanced sustainability, clean energy integration, and operational reliability. However, this paradigm shift introduces operational challenges due to the intermittent nature of renewable energy sources and the non-linear characteristics of power electronic loads, inducing voltage fluctuations and harmonic distortions that complicate voltage and frequency regulation. Accurate dynamic modeling is hypothesized to be critical for capturing such effects, enabling reliable simulation and control strategy development. This study introduces an innovative dynamic modeling framework for a real-world converter-based microgrid, utilizing both root mean square (RMS) and electromagnetic transient (EMT) simulation methods. The microgrid was modeled in DIgSILENT PowerFactory, with simulations calibrated against high-resolution field measurements from SEL-735 power quality meters. Results show that RMS simulations effectively characterize steady-state dynamics, while EMT simulations are essential for capturing high-frequency transients and non-linear effects from photovoltaic inverters and variable frequency drives (VFDs). This complementary approach provides a comprehensive understanding of microgrid behavior, providing critical insights for improving simulation accuracy, advancing protection schemes, and improving resilience in future low-inertia power networks.

24 POWER TRANSMISSION AND DISTRIBUTION↗
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 OSTI2025

Modernization of PLC-Based Control Systems at SNS

When the SNS site was built around 20 years ago, the Conventional Facilities (CF) control systems were de-signed using 2 communication protocols to allow pro-grammable logic controllers (PLCs) to interface with motors, variable frequency drives (VFDs), and remote input and output (I/O) devices. The protocol chosen to control motors and VFDs is DeviceNet, a CANbus-based protocol developed by Allen-Bradley, a subsidiary of Rockwell Automation. The protocol chosen to communi-cate with remote I/O is ControlNet, another protocol developed by Allen-Bradley. Both of these protocols are obsolete and present reliability and maintainability is-sues, particularly DeviceNet. As the Control Systems Section at SNS is working to modernize control systems throughout the machine, a major goal for PLC-based systems is to remove the obsolete communication proto-cols in favor of standard, ubiquitous Ethernet. To this end, any new VFDs installed use Ethernet communica-tion. Many VFDs are currently being replaced in the Central Utilities Building (CUB) and the Central Exhaust Facility (CEF) and are being removed from DeviceNet in favor of Ethernet communication. Planning is underway to retrofit Eaton Intelligent Technology motor control centers (MCCs) in the Target Building to remove particu-larly troublesome DeviceNet adaptors and replace them with Ethernet adaptors for each motor starter. The Con-trolNet network in the CUB has been demolished, with I/O drops integrated into a local Ethernet network, im-proving sustainability and maintainability.

Beaushaw, Isaiah [ORNL]↗
DOE OSTI2021

Industrial Conveyor Motor Performance Evaluation

The purpose of this project is to estimate the energy savings potential from a switched-reluctance motor (SRM) compared to an induction motor equipped with variable frequency drive (VFD) in a straight belt conveyor application. To experimentally evaluate savings in a realistic scenario, a baseline motor and VFD were selected from one of ComEd’s manufacturing customers’ conveyor systems. It was desired to not only estimate savings in the selected conveyor system, but to evaluate potential savings from using the SRM in any straight belt conveyor. Therefore, NREL developed a conveyor system energy calculation tool to supplement the experimental results of this assessment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Final Technical Report of a Feasibility Investigation of a Hydropower Flexibility Upgrade Kit

The project studied the feasibility of a concept for a flexibility upgrade kit called h-Dynamyk to improve the flexibility of U.S. hydropower plants and assessed its potential impact on the U.S. hydropower industry. This concept addresses the growing need for grid flexibility amid rising renewable energy adoption, such as wind and solar, which often introduce intermittency. The upgrade kit is intended to address challenges posed by aging turbine designs in meeting modern grid demands for flexibility services like frequency response, voltage control, spinning reserve, and black-start capabilities. Key features of the h-Dynamyk kit include siphon turbine assemblies, medium-voltage variable frequency drives (VFDs), and smart controls integrated with plant systems to optimize operations and extend equipment life. This nine-month discovery project successfully achieved its objectives by defining a baseline design and performance metrics for the h-Dynamyk flexibility upgrade kit, analyzing this baseline, and incorporating lessons learned from this analysis into a modified set of metrics and recommendations for future design and testing, which were further guided by field site studies.

13 HYDRO ENERGY↗