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**Subtask 4.1.1 - Lean NO~x~ Trap (LNT) Development**

**Jim Parks,** **<parksjeii@ornl.gov>, (865) 946-1283**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The main objective of this project is to study lean NOx trap catalysis
for emissions control from natural gas (NG) engines. Key emission
control areas of interest include: NOx reduction efficiency, operational
(fuel) penalty, durability, and cost basis of lean NOx traps for ARES
applications. Experiments for the study are performed on a Cummins C8.3G
NG engine dynamometer platform at ORNL.

-   In FY04, NOx reduction in engine exhaust was demonstrated. **ARES
    program target emission levels of \<0.1 g/bhp-hr NOx were
    demonstrated**, and NOx reduction efficiencies of \>90% were
    obtained with the lean NOx trap catalyst.

-   In FY05, full characterization of the utilization of NG (**fuel
    efficiency**) for catalyst regeneration was performed. Methane
    oxidation and reforming chemistries were characterized for various
    conditions.

-   In FY06, the focus shifted to **durability issues** and the impact
    of sulfur on the *partial oxidation and reforming catalysts* was
    investigated. Results indicated levels of sulfur commonly found in
    NG could be tolerated.

-   In FY07, a catalyst service process will be investigated as a
    potential solution of the negative effects of sulfur on the
    durability of *lean NOx trap catalyst* *system*.

[Highlights]{.underline}

Engine-based experiments for the FY07 task to study servicing of lean
NOx traps to remove sulfur accumulated during accelerated aging were
completed in Q1. Results were positive and indicated that catalyst
washing is a feasible technique for maintaining catalyst durability
against sulfur poisoning.

[Technical]{.underline} [Progress]{.underline}

The goal for FY07 is to determine the feasibility of increasing catalyst
durability and lifetime via a catalyst wash service process for the
removal of sulfur poisons. Experiments toward this goal have been
conducted on the Cummins C8.3G+ engine dynamometer platform at ORNL
during Q1FY07. The following experimental phases were completed:

1.  [Baseline Characterization:]{.underline} Baseline lean NOx trap
    catalyst system performance was characterized.

2.  [Rapid Sulfur Aging:]{.underline} Accelerated Sulfur aging of the
    catalysts was conducted using bottled SO~2~.

3.  [Catalyst Washing:]{.underline} The lean NOx trap catalysts were
    washed with aqueous based solutions, and new sorbate media were
    applied to effectively refurbish the lost sulfur poisoned
    components.

4.  [Post Characterization:]{.underline} Repeat of catalyst performance
    characterization performed for baseline.

Results show that the catalyst washing process is extremely effective in
restoring lost NOx reduction performance due to sulfur poisoning. The
sulfur aging degraded NOx performance from \>90% NOx reduction
efficiency to \~50% NOx reduction efficiency, but the washing process
recovered performance to \>90% NOx reduction efficiency levels. ***Thus,
the washing process is a feasible technique for maintaining catalyst
durability against sulfur poisoning in lean NG engine applications.***

Detailed analysis of the data obtained in Q1 continued in Q2 FY07. The
analysis is ongoing with expectations that report generation will begin
in Q3.

[Status of Milestone(s)]{.underline}

\(1\) Complete the Lean NOx Trap (LNT) development work with the
conclusion of the sulfur poisoning study and disseminate the results to
the engine community (September 2007): - On Track (engine experimental
work completed; analysis ongoing and reporting pending).

[Industry Interactions]{.underline}

-   An abstract entitled "Mitigation of Sulfur Effects on a Lean NOx
    Trap Catalyst by Sorbate Reapplication" has been submitted for the
    ASME Fall Technical Conference on Internal Combustion Engines in
    Charleston, SC on October 14-17, 2007.

**Subtask 4.1.2 - Spark Plug Erosion and Failure**

**Mike Brady, <bradymp@ornl.gov>, (865) 574-5153**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Spark plug lifetimes in advanced natural gas (NG) engines are on the
order of only 1000-4000 h, which result in loss of performance and
necessitate frequent, costly downtime maintenance. Spark plug durability
will become even more critical as future engines are pushed to
leaner-burn conditions to reduce emissions. The goals of this effort are
to gain insight into spark plug life- limiting wear processes, and to
use this understanding to develop new electrode alloys to achieve
lifetimes of ≥ 8000 h.

[Highlights]{.underline}

Two new ORNL developmental high thermal conductivity electrode alloys
were manufactured and delivered to Woodward for NG spark plug
manufacture.

[Technical Progress]{.underline}

Plates of two ORNL developmental high thermal conductivity Ni-base
electrode alloys were manufactured and delivered to Woodward for
manufacture into NG spark plugs. These plugs will utilize a prototype
Woodward design. NG engine testing is planned to establish 1) the
viability of the current Woodward design and 2) whether the ORNL alloys
offer improved performance over conventional Ni-electrode alloys. The
Woodward spark plug design is not available in a size amenable to the
ORNL Cat NG engine. Discussions have therefore been initiated to
collaborate for the engine testing of these spark plugs at Colorado
State.

[Status of Milestone(s)]{.underline}

(1 ) Submit an open literature paper reporting on the engine test
results of developmental spark plug electrode alloys (September 2007):
Status uncertain (see below)

Significant delays have been encountered at Federal Mogul (FM) in
manufacture of NG spark plugs for testing at ORNL, as well as in
completion of laboratory engine testing at FM. These delays may impact
our ability to complete the milestone on schedule and are beyond our
control. Collaborations with Woodward may result in a suitable
alternative path to meet this milestone.

[Industry Interactions]{.underline}

> Conference calls and email communications with Dan Tribble of Woodward
> regarding manufacture of Woodward NG spark plugs from ORNL alloys.
> Conference calls and email with Jim Lykowski at FM to discuss progress
> in collaborative work at FM.
>
> **Subtask 4.1.3 -- Siloxane Mitigation for Advanced Natural Gas
> Engines**

**John Storey, <storeyjm@ornl.gov>, (865) 946-1232**

**Tim Theiss,** **<theisstj@ornl.gov>, (865) 946-1348**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Reciprocating engines remain the most logical distributed generation
choice for reducing the peak demand on an electrical feeder due to their
ease of siting and good economics. However, utilities and distributors
are often reluctant to interconnect or rely on reciprocating engines for
peak load reduction due to a real or perceived lack of reliability,
availability, maintainability (RAM) and/or emissions concerns. The
objective of this project is to consider the use of reciprocating
engines from an end-user perspective and address their long-term
reliability, availability, and maintainability under peak-load-reduction
conditions. Initial work will focus on a thorough assessment of the RAM
of reciprocating engines and specific areas that need improvement. The
assessment will include both existing and new products and will consider
engine control and perceived lack of availability. A key issue is to
determine if existing engines can be used on congested feeders for peak
demand reduction and the necessary developments (emissions reduction,
remote controls and dispatching, etc.) for utilities to rely on and
control these existing resources.

[Highlights]{.underline}

Work has not yet begun during this reporting period.

[Technical Progress]{.underline}

Work has not yet begun during this reporting period.

[Status of Milestone(s)]{.underline}

\(1\) Investigate engine conditions at which burning landfill/digester
gas in reciprocating engines produces siloxane deposits which may damage
the engine. (September 2007): On Track

[Industry Interactions]{.underline}

-   Waukesha Engine Dresser (WED) has expressed interest in the siloxone
    issue in reciprocating engines and discussed potential mitigation
    strategies with ORNL.

-   ORNL is discussing the siloxane issues with a firm who specialize in
    the design of waste-water treatment plants.

**Subtask 4.2.1 -- Microstructural Characterization of CFCCs and
Protective Coatings**

**Karren More,** **<morekl1@ornl.gov>, (865) 574-7788**

**Peter Tortorelli,** **<tortorellipf@ornl.gov>, (865)** **574-5119**

**Oak Ridge National Laboratory**

[Objective]{.underline}

SiC/SiC continuous-fiber ceramic composite (CFCC) combustor liners with
a BSAS-based environmental barrier coating (EBC) have been exposed in
several Solar Turbines engine tests for \>10,000 h. The engine-exposed
combustor liners have been characterized microstructurally and
mechanically at ORNL to evaluate degradation of both CFCC liner
materials and the EBC system. Simulated exposures of analogous materials
systems were previously conducted in ORNL's Keiser Rigs at high
water-vapor pressures. More recently, an oxide/oxide outer liner, A/N720
CMC + FGI, and a GE SiC/SiC MI pre-preg + BSAS inner liner, have been
exposed in a Solar Turbines Centaur 50S gas turbine at the ChevronTexaco
engine test site in Bakersfield, CA. Coupons of the same materials were
exposed in the Keiser Rig and were evaluated post-exposure. The primary
objective of this project in FY2007 will be to characterize damage and
elucidate degradation mechanisms of the two long-term engine-exposed
CFCC liners for comparison with previous engine-exposed liners and
laboratory-exposed coupons.

[Highlights]{.underline}

The engine-exposed ATK-COIC oxide/oxide ceramic matrix composite outer
liner, designated hybrid A/N720 CMC+FGI, was received at ORNL for
characterization on March 14, 2007. This hybrid liner was exposed in the
Solar Turbines Centaur 50S turbine for a total of 25,404 h with 109
starts. Thus far, the fully-intact outer liner and a quarter arc of a
similarly-processed (but not engine-exposed hybrid outer liner, i.e.,
baseline material) have been photographed and are currently being
subjected to thickness measurements using the coordinate measurement
machine (CMM). In addition to thickness measurements, the liner will be
sectioned for extensive microstructural and mechanical characterization
during the next Quarter.

[Technical Progress]{.underline}

Since the engine-exposed hybrid liner and its unexposed baseline
counterpart, have just been received at ORNL, a liner sectioning plan
has only recently been sent out to all interested parties for approval.
The sectioning plan for the liner includes representative samples from
areas exhibiting surface recession of the FGI, regions of exposed CMC,
"patched" FGI areas that show improved behavior, and a through-thickness
hole. Each region of interest will be examined closely using electron
microscopy and tensile test from representative areas will also be
conducted and compared to the baseline material. It is anticipated that
thickness measurements and sectioning of the liner will be completed by
early May 2007.

[Status of Milestone(s)]{.underline}

\(1\) Report results from the analysis of \>25,000 h engine-exposed
ceramic matrix composite combustor liners (oxide/oxide+FGI and/or GE
Pre-Preg) and compare with data for similarly-exposed composite material
in the Keiser Rig (August 2007): In progress

[Industry Interactions]{.underline}

1\. Attended meeting at ATK-COI Ceramics on February 15, 2007, to
discuss sectioning plan for hybrid outer liner. Representatives from
Solar Turbines Inc. and Siemens Westinghouse were also in attendance.

**Subtask 4.2.2 -- Mechanical Reliability Evaluation of Ceramic
Composites and Components with Environmental Barrier Coatings**

**H-T Lin,** **<linh@ornl.gov>, (865) 574-8857**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The objective of this subtask is thus to evaluate the protection
performance of oxide-based EBC systems with ceramic composite substrates
under a combined applied stress and steam environment. The results of
this work will allow end users to verify their component design and
probabilistic lifetime prediction methodologies, facilitate the
implementation of ceramic and composite components, and further optimize
the EBC performance.

[Highlights]{.underline}

The setup of a flexure test system capable of externally applying a low
cycle fatigue stress during the high temperature steam exposure has been
successfully completed. The objective of the system setup is to provide
a facility that would allow end users to evaluate the effect of
externally applied stress on the material recession and degradation, and
thus mechanical performance of SiC-SiC or oxide CMC with EBCs under a
simulated combustion environment. Also, it would provide important
database for life prediction of the CMC components.

[Technical Progress]{.underline}

Detailed microstructure analysis of SiC-SiC CMC with an oxide EBC after
500h low-cycle fatigue test under a low-speed steam environment at
1200°C was successfully completed. Note that the applied stress levels
were close to the proportional limit of composite. SEM examinations
showed that the CMC without EBC experienced substantial environmental
attack in both the fibers and matrices and thus significant loss in
mechanical performance as anticipated due to the steam exposure. On the
contrary, the CMC with EBC did not show any material change even under
the low-cycle mechanical loading condition. The post fracture surfaces
still exhibit pullout of reinforcing fibers and no reaction layer
observed at the fiber-matrix interface due to oxidation. Observations
suggest the EBC system employed could have long-term potential to
protect the oxide CMC under a combined steam and applied stress
condition. Nonetheless, much longer test time up to 2000h will be
carried out to ensure its long-term stability and performance. SEM
analysis of a pre-strained FGI oxide-oxide CMC specimen (up to 0.25%)
after 500h steam jet exposure at 1288°C was also completed during this
reporting period. Observations showed that there was minor recession in
the subsurface FGI region, which was similar to those observed in
specimen after 500h exposure at 1200°C. Results suggest that the FGI
could have potential for much higher temperature applications, but more
extensive studies are needed.

[Status of Milestone(s)]{.underline}

\(1\) Complete characterization of EBC-composite systems under a
combined stress and steam jet test condition (September 2007): On track

[Industry Interactions]{.underline}

1\. Communications and conference calls with Venkata Vendula and David
Jarmon at UTRC on the results of SEM examinations of those SiC-SiC CMCs
after 500h steam exposure.

2\. Communications with Chris Campbell and Jay Morrison at Siemens Power
Generation on the updates of SEM analysis and steam test results of on
the FGI oxide-oxide CMC at 1288°C.

3\. Communication and conference calls with Xiaoqun Chen, Mark van
Roode, and Jeff Price at Solar Turbines on the results of thermal
properties characterization of TBC discs with different compositions and
heat treatment history, and discussions on the new TBC test plans.

**Subtask 4.2.3 -- Environmental Protection Systems for Ceramics in
Microturbines and** **Industrial Gas Turbine Applications**

**Beth Armstrong, <armstrongbl@ornl.gov>, (865)** **241-5862**

**Kevin Cooley, Mike Brady, and H.-T. Lin**

**Oak Ridge National Laboratory**

[Objective]{.underline}

In order to be cost competitive, microturbines will have to meet
aggressive durability targets. Currently ceramic components without an
EBC will not be able to meet the goals of \> 20,000 operation hours. An
EBC may enable these components to meet the expected lifetimes provided
the EBC can be applied at low cost. The goal of this project is to
continue to develop a low cost, slurry-based process to apply protective
coatings for silicon based ceramic materials for use in microturbine
and/or industrial gas turbine applications. This effort will be
coordinated with industrial partners to assist in the development of an
ideal coating material or material system for steam and high velocity
resistance

[Highlights]{.underline}

A study of the effect of contamination(s) upon slurry and coating
properties has been initiated. Slurry development of a partners'
material systems will continue.

[Technical Progress]{.underline}

> Work (rheology, dipping, and sintering studies) began to ramp up again
> on the candidate material systems. Work was put on hold last quarter
> due to equipment issues. Due to contamination issues identified
> previously on collaborators' material system development, the focus of
> the slurry development for the remainder of the fiscal year will be on
> evaluating the effect of common elements of contamination from water
> and additive sources on zeta potential, rheology, dipping behavior,
> coating thickness, and coating microstructure. This work will compare
> the effects of deionized and deionized and distilled water as well as
> the effects of varying and known concentrations of contaminant
> species. Sodium, potassium, barium, calcium, chlorine and fluorine
> have been selected as the candidate species for initial studies. Two
> coating material systems, yttrium monosilicate and yttrium disilicate,
> will be used to evaluate the sensitivity of the material system's
> structure with contamination.

[Status of Milestone(s)]{.underline}

\(1\) Evaluate the effect of contamination upon slurry and resulting
coating properties for a doped rare-earth silicate system (September
2007): On track.

[Industry Interactions]{.underline}

-   Collaboration with Honeywell continues.

**Subtask 4.2.4 -- Spark Plug Electrode Alloy Development**

**Mike Brady, <bradymp@ornl.gov>, (865) 574-5153**

**H.-T. Lin and Mike Kass**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Spark plug lifetimes in advanced natural gas (NG) engines are on the
order of only 1000-4000 h, which result in loss of performance and
necessitate frequent, costly downtime maintenance. Spark plug durability
will become even more critical as future engines are pushed to
leaner-burn conditions to reduce emissions. The goals of this effort are
to gain insight into spark plug life- limiting wear processes, and to
use this understanding to develop new electrode alloys to achieve
lifetimes of ≥ 8000 h.

[Highlights]{.underline}

Two new ORNL developmental high thermal conductivity electrode alloys
were manufactured and delivered to Woodward for NG spark plug
manufacture.

[Technical progress]{.underline}

Plates of two ORNL developmental high thermal conductivity Ni-base
electrode alloys were manufactured and delivered to Woodward for
manufacture into NG spark plugs. These plugs will utilize a prototype
Woodward design. NG engine testing is planned to establish 1) the
viability of the current Woodward design and 2) whether the ORNL alloys
offer improved performance over conventional Ni-electrode alloys. The
Woodward spark plug design is not available in a size amenable to the
ORNL Cat NG engine. Discussions have therefore been initiated to
collaborate for the engine testing of these spark plugs at Colorado
State.

[Status of Milestone(s)]{.underline}

(1 ) Submit an open literature paper reporting on the engine test
results of developmental spark plug electrode alloys (September 2007):
Status uncertain (see below)

Significant delays have been encountered at Federal Mogul (FM) in
manufacture of NG spark plugs for testing at ORNL, as well as in
completion of laboratory engine testing at FM. These delays may impact
our ability to complete the milestone on schedule and are beyond our
control. Collaborations with Woodward may result in a suitable
alternative path to meet this milestone.

[Industry Interactions]{.underline}

> Conference calls and email communications with Dan Tribble of Woodward
> regarding manufacture of Woodward NG spark plugs from ORNL alloys.
> Conference calls and email with Jim Lykowski at FM to discuss progress
> in collaborative work at FM.

**Subtask 4.2.5 -- Alloy Development and Optimization for Increased
Corrosion Resistance in High Temperature Exhaust Gas Environments**

**Bruce Pint,** **<pintba@ornl.gov>, (865) 576-2897**

[Objective]{.underline}

The goal is to finalize experimental work designed to improve the
understanding of alloy composition effects on corrosion resistance of
stainless steel components used in microturbine recuperators. Due to the
linear kinetics of Cr loss by evaporation in the presence of water vapor
in the exhaust gas, the maximum operating temperature and lifetime of
high-alloy steels is limited. Encouraging results have been obtained
with Al additions to Fe-base alloys. The focus is on acquiring
sufficient laboratory experimental results on Al additions and/or
low-cost Al coatings for this application.

[Highlights]{.underline}

Foil was produced from Fe-14Cr-16Ni+Al and Fe-14Cr-20Ni+Al alloys.
Testing of these and similar materials are continuing in humid air at
650°-800°C in order to compare their behavior with conventional
austenitic alloys.

[Technical Progress]{.underline}

Laboratory testing is continuing on various model alloys in order to
better understand the effect of water vapor in exhaust gas on oxidation
of Al-containing steels over a range of temperatures and compare their
behavior to chromia-forming steels. The laboratory-rolled foil material
has not performed well, likely due to problems controlling the surface
chemistry and finish.

[Status of Milestone(s)]{.underline}

\(1\) Submit an open literature publication reviewing the potential for
Al alloying additions and/or low-cost coatings to improve oxidation
lifetimes of recuperator alloys (September 2007): Completed by:

B. A. Pint, J. P. Shingledecker, M. P. Brady and P. J. Maziasz, (2007)
"Alumina-Forming Austenitic Alloys for Advanced Recuperators," ASME
Paper #GT2007-27916, presented at the International Gas Turbine &
Aeroengine Congress & Exhibition, Montreal, Canada, May 14-17, 2007.

Y. Yamamoto, M. P. Brady, Z. P. Lu, P. J. Maziasz, C. T. Liu, B. A.
Pint, K. L. More, H. M. Meyer and E. A. Payzant, "Creep-Resistant,
Al2O3-Forming Austenitic Stainless Steels," *Science*, 316 433 (2007).

[Industry Interactions]{.underline}

Completed laboratory testing of protective oxide coatings on commercial
type 347 foil specimens for N. Garrett with C3 International,
Alpharetta, GA.

**Subtask 4.2.6** -- **Materials Selection for Hostile
Microturbine/Engine Environments**

**Jane Howe, <howej@ornl.gov>, (865) 241-9745**

**Rosa Trejo and Edgar Lara-Curzio**

**Oak Ridge National Laboratory**

[Objective]{.underline}

> The project is to carry out corrosion and mechanical property studies
> as a function of the test environment (i.e. natural gas byproducts,
> and with additional contaminants, such as SOx), and report gas
> sampling of exhaust gases as a function of operation time.

[Highlights]{.underline}

> The ORNL Microturbine Recuperator Test Facility with Fuel-Flexible
> Environment (MRTFFE) is designed to perform the following tasks for a
> given type of fuel:

-   Measure the temperature and gas species at selected locations inside
    the microturbine

-   Evaluate materials degradation by placing coupons inside the
    microturbine

-   Measure the SOx, NOx, CO/CO~2~, etc in the exhaust

-   Evaluate the degradation of candidate turbine/microturbine
    structural materials by exposing samples in a natural gas exhaust
    stream that is maintained at the desired test temperature, and doped
    with toxic species or components that make the gas stream
    characteristic of the exhaust when nontraditional fuels are burned.

[Technical Progress]{.underline}

> A 1000-hour recuperator material test started in end of March 2007 to
> continue the long term evaluation of 2025-3.2mils, HR120-3.2mils, and
> AL-625-4mils. The Controlled Environment Test Chamber (CETC) is an
> extension to the microturbine, as a slip stream of the exhaust gas
> will be diverted out of the microturbine from the aft removable dome,
> controlled by a gate valve, then into a 2"-dia test chamber. The gate
> valve and the main part of the CETC assembly was attached to the
> microturbine. Designing of the sample holders of CETC was finished.
> Gas sampling and analysis were carried out with assistance of NTRC
> collaborators. Alumina forming alloy samples, which have been
> developed at ORNL, are being prepared to be evaluated in the
> microturbine.

[Status of Milestone(s)]{.underline}

\(1\) Complete a report summarizing the results of corrosion and
mechanical property studies a function of the test environment
(September 2007): On track

[Industry Interactions]{.underline}

-   A technical report of Ingersoll Rand's microturbine specimens was
    delivered and received positive feedbacks.

-   Communication with Chinese Coal Information Institute (CCII)
    regarding the proposal entitled, "Demonstration of Power Generation
    Using Low Quality Coal Mine Methane, Emission Monitoring, and Engine
    Performance Analysis". The proposal was revised upon EPA's request.

**Subtask 4.3.1a** **-- Packaged/Modular IES Development**

**Robert DeVault,** **<devaultrc@ornl.gov>, (865) 574-2020**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The objective of this proposed subtask is to develop and deploy highly
efficient IES and include these as an essential element within the scope
of the OE/DE Program. IES focuses on technologies that have broad
utilization potential such as cooling, dehumidification, humidification,
water heating, steam heating, drying, and shaft power from heat energy.
Key program elements are packaged/modular IES development, DG thermal
recovery research, IES field evaluations and end-use integration, and
analytical tools/validation.

[Highlights]{.underline}

UTRC -- Plans for facility modifications to enable testing of the
Simultaneous Chiller in the UTRC CHP Facility were developed.

[Technical Progress]{.underline}

UTRC is developing plans for facility modifications to integrate the
simultaneous chiller into its microturbine-based CHP facility.
Modifications include adding the capability to process hot water (175 F)
and chilled water (44 F) simultaneously and return each stream to the
chiller at appropriate temperatures. The simultaneous (or
"tri-generation") chiller is expected to arrive at UTRC in July once
tests are completed at Carrier Korea (CKO) in June. The Capstone C60
microturbines will be used for power generation and to provide thermal
energy into the new chiller. This "Trigeneration" capability is
advantageous for buildings with multiple zones having independent
thermal loads, e.g., buildings where some zones have constant cooling
loads while other zones of the building have seasonally-varying thermal
loads. Another application benefiting from this technology is buildings
that are located in climates requiring daytime cooling and nighttime
heating.

[Status of Milestone(s)]{.underline}

(1)Complete draft report on the UTRC Phase II readiness assessment of
performance, cost, and reliability for a reciprocating engine/hybrid
chiller system (TBD \[when UTRC submits task description\]): On
schedule.

\(2\) Draft case study Seton Dell Children's Hospital IES system
(September 2007): On schedule

[Industry Interactions]{.underline}

N/A

**Subtask 4.3.2a,b -- DG Thermal Recovery and Integration Research at
University of Maryland**

**Patti Garland,** **<garlandpw@ornl.gov>, (865) 574-0738**

**Dr. Reinhard Radermacher, University of Maryland**

[Objective]{.underline}

The objectives of the integration research being conducted at ORNL and
at the University of Maryland are:

-   Demonstrate the benefits of integrated CHP systems in commercial
    building applications

-   Identify and help resolve problems that occur when combining
    different components into an integrated system

-   Identify, develop and demonstrate system improvements

-   Provide educational opportunities

This project will be completed in 2007, with the following work
activites:

-   Completion of testing of the newly designed low-flow conditioner
    components for liquid desiccant dehumidifier \[work to be done in
    partnership with NREL\]

-   Completion of testing of the newly installed Broad absorption
    chiller with internal cooling tower

-   Development of course material on absorption chiller systems
    operation and integration into CHP Systems for Buildings

 

ORNL works closely with the project team at the University of Maryland
to analyze system data, to prepare presentations on test results and
lessons learned, to write peer-reviewed technical papers, to provide
project updates to DOE, to update the U of M website, and to find
opportunities to disseminate lessons learned to the public.  ORNL will
facilitate cooperation and test plan development with other DOE national
labs.

[Highlights]{.underline}

-   The close-out plan was completed and the contract is being modified
    to include the final work.

-   ORNL comments on the annual report were provided to U of M. Comments
    are being incorporated into the final report.

-   The CHP Consortia Meeting was held March 22^nd^ at the University.

[Technical Progress]{.underline}

The March 22^nd^ Consortia Meeting was open to members only. Founding
members include: U of M, DOE, and ORNL. Supporting members include:
Broad Air Conditioning, Inc, Baltimore Aircoil, Capstone Turbine
Corporation, Daikin Industries, LTD, U.S. Environmental Protection
Agency, Honeywell International Inc., Kathabar Inc, Propane Exceptional
Energy, Tridium, Trigen, Trion Inc, and StulzATS. Information on the
consortia and work activities can be found at:

<http://www.enme.umd.edu/ceee/chp/>

[Status of Milestone(s)]{.underline}

Complete close-out plan for system shutdown (April 2007): complete

[Industry Interactions]{.underline}

Partners include members noted above.

> **Subtask 4.3.2c,d -- DE Integration Lab and Analysis**
>
> **Abdi Zaltash,** **<zaltasha@ornl.gov>, (865) 574-4571)**
>
> **Oak Ridge National Laboratory**

Objective

It is essential to industrial partners that we understand technical
issues related to optimal integration of components as well as optimal
operating conditions for DE and HVAC equipment and systems. ORNL offers
the unique capability of benchmarking equipment throughout the full
range of operating conditions in a closely controlled laboratory
environment or in precisely controlled environmental test chambers.
Equipment from manufacturers can be operated and tested in precisely
controlled environmental conditions to assist those manufacturers in
optimizing equipment and component matching and operational control of
the equipment. This work can also be used to help develop or test
rating/certification test procedures and standards.

Highlights

Performance and emission tests on GEDAC #16 have been completed in the
environmental chambers. Data is available on the password protected web
site for remote monitoring by our industry partner using Web Control and
web camera (to monitor the frosting pattern on the outdoor coil during
heating tests).

Performance evaluation of the hot water-fired Rotartica lithium
bromide/water air-cooled absorption unit (1.3-ton or 4.5 kW chiller)
with rotating heat exchanger has been completed. Automated Logic Control
and Web Control have been used successfully for sharing performance
evaluations with the manufacturer. A draft report entitled "Performance
Evaluation of a 4.5 kW (1.3 Refrigeration Tons) Air-Cooled Lithium
Bromide/Water Solar Powered (Hot-Water-Fired) Absorption Unit" has been
prepared and is under review. This report will be submitted to the 2007
ASME conference. Future plans are to document performance improvement
for rotating heat (and heat/mass) exchangers based on the Rotartica unit
and then assess the technical potential for using rotating heat
exchangers in other applications.

Technical Progress

Performance and emissions of GEDAC #16 unit (10-ton packaged rooftop
heat pump unit) has been completed in the ORNL environmental chamber at
various heating and cooling modes Evaluation is following ARI Standard
210/240 with the cooling mode in the range of 67ºF to 120ºF at
intermediate speed and at high speed. The heating mode is conducted in
the range of 17ºF to 62ºF at intermediate speed and 17ºF to 47ºF at high
speed.

After initial evaluations of GEDAC #16 with its original indoor coil (3
rows), GEDAC was evaluated with a modified indoor coil (4 rows) received
from our industry partner. This change was to improve GEDAC performance
in both heating and cooling modes. The capacity in heating mode
increased by approximately 14% at high speed and 47ºF rating condition.
The gas COP at 47ºF rating condition exceeded the goal of 1.6 at both
high and intermediate speeds. Improvement in cooling capacity at 95ºF
rating condition was found to be approximately 4% at high speed and 8%
at intermediate speed. Gas COP in cooling mode also exceeded the goal of
1.2 at 95ºF rating condition.

Defrost cycle was also evaluated at 35ºF outdoor dry-bulb (DB)
temperatures. GEDAC is currently using time cycle for the defrost cycle.
Results suggest that this timed defrost may cause a number of
unnecessary defrost cycles which reduces the energy efficiency of GEDAC
#16. The plans are to investigate a demand defrost method. Demand
defrost method could be easily integrated into the PLC.

Based on the results of the CFD modeling that showed potential energy
savings by using one fan instead of the two fans for the outdoor coil,
the two outdoor fans were replaced with a single fan. These evaluations
have also been completed in both cooling and heating modes. Results
showed no significant difference in the performance and total power used
by the GEDAC unit.

Performance evaluation of the Rotartica unit has been completed. A draft
report entitled "Performance Evaluation of a 4.5 kW (1.3 Refrigeration
Tons) Air-Cooled Lithium Bromide/Water Solar Powered (Hot-Water-Fired)
Absorption Unit" has been prepared and is under review.

Status of Milestone(s)

\(1\) Completed performance and emissions evaluation of the GEDAC #16
(March 2007).

\(2\) Complete draft report on testing of InterRotex (Rotartica unit)
heat pump (April 2007).

Industry Interactions

• Partners include: Southwest Gas, Team Consulting, BME, and Rotartica.

**Subtask 4.3.8 -- Industry Collaboration, Crosscutting Activities**

**Robert DeVault,** **<devaultrc@ornl.gov>, (865) 574-2020**

**Oak Ridge National Laboratory**

[Objective]{.underline}

ORNL will monitor the progress of the various CHP projects and provide
technical direction to the subcontractors. As the tasks progress,
lessons learned and technical results will be compiled and disseminated
to the stakeholder community. In addition, ORNL will facilitate dialogue
with industry stakeholders to encourage the consideration and use of DE
in high-tech applications. Barriers to application of DE/CHP will be
identified with the intent of reducing or removing them. ORNL will
continue working with existing CHP design and evaluation software tools
and will work with stakeholders to ensure their awareness of the tools
and to assist in their use in studying potential DER/CHP applications.
ORNL will continue to assist DOE with participation at crosscutting
conferences and events such as PowerGen, ASHRAE, ASHE, etc. This work
activity supports the technical guidance and analysis provided by the
CHP Group Leader.

Highlights

None.

Technical Progress

No progress this quarter.

[Status of Milestone(s)]{.underline}

\(1\) Provide summary of all IES projects with lessons learned (June
2007): On schedule.

[Industry Interactions]{.underline}

**Subtask 4.3.13 -- Research Survey/History of DOE Program**

**Mike MacDonald, <macdonaldjm@ornl.gov>, (865) 574-5187**

**Oak Ridge National Laboratory**

Objective

Over the last few decades, DOE has provided considerable funding in
support of development of technologies for improving energy efficiency.
There have been several technical analyses completed on potential for
energy savings in a variety of technology applications. Although
documentation on previous work activities has been completed, it can be
difficult to find the relevant work because of passing time or lack of a
centralized reference list. In 2006, ORNL created a database that
contains over 300 reports. In 2007, the following activities will be
completed: an additional 75+ reports on ORNL BCHP work will be included,
enhanced search capabilities will be added, and copyright questions will
be resolved.

Highlights

Work on the database was completed in December 2006.

No progress to report this quarter.

Technical Progress

There are abstracts for over 500 reports on-line with links to PDF files
for all of the publicly available publications (copyrighted material
does not have links to the journal articles, although PDF files for
those publications are on-line, they just are not available to the
public; they can easily be made available if ASHRAE and ASME gave
ORNL/DOE permission to do so).

The publications cover the time frame of 1974-2006 including
electrically driven heat pumps, thermally-activated technologies,
advanced appliance research, distributed energy and CHP, district
heating, and a few lesser categories.

The reports can be accessed at:

[[http://www.ornl.gov/sci/engineering_science_technology/eere_research_reports/index.html]{.underline}](http://www.ornl.gov/sci/engineering_science_technology/eere_research_reports/index.html)

As well as through Google type searches (turns up better if EERE is
included in the search string).

There is a site map as well as a keyword index.

Status of Milestone(s)

\(1\) Add additional \~75 technical papers as requested by DOE sponsor
on September 7, 2006 (April 2007): Complete

Industry Interactions

N/A

**Subtask 4.4.1a -- Ritz Carlton Hotel/GTI, San Francisco, California**

**Therese Stovall[,]{.underline}** **<stovalltk@ornl.gov>,** **(865)**
**574-0329**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The FY04 solicitation sought proposals for projects that utilized
pre-engineered, packaged IES systems that both generate electricity and
make effective use of the thermal energy produced. Target applications
for this procurement were healthcare and education facilities, hotels,
and supermarkets. Two of these projects, under subcontract to GTI, are
included in this subtask: (1) The Ritz Carlton Hotel, San Francisco,
California has installed a UTC Pure Comfort System (with four Capstone
microturbines) to generate 240 kilowatts and operate a 110 ton
absorption chiller. Partners on this project are UTC Power, Pacific Gas
& Electric, Carrier Commercial Systems, and Ritz Carlton. (2) Basin
Electric, North Dakota will utilize waste heat from an existing pipeline
compressor station's gas turbine to generate electricity via an organic
Rankine cycle. Due to a change in DOE priorities, two other projects
were replaced with a new effort focused on grid integration in a New
York utility area with a fully networked (as opposed to radial) grid
topology.

[Highlights]{.underline}

The draft final report was completed by the subcontractor and delivered
to ORNL..

[Technical Progress]{.underline}

The draft final report was completed by the subcontractor and delivered
to ORNL..

[Status of Milestone(s)]{.underline}

(1)Complete final project documentation (September 2007): On track

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.1b -- Basin Electric/GTI, Flasher, North Dakota**

**Therese Stovall,** **<stovalltk@ornl.gov>, (865) 574-0329**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The FY04 solicitation sought proposals for projects that utilized
pre-engineered, packaged IES systems that both generate electricity and
make effective use of the thermal energy produced. Target applications
for this procurement were healthcare and education facilities, hotels,
and supermarkets. Two of these projects, under subcontract to GTI, are
included in this subtask: (1) The Ritz Carlton Hotel, San Francisco,
California has installed a UTC Pure Comfort System (with four Capstone
microturbines) to generate 240 kilowatts and operate a 110 ton
absorption chiller. Partners on this project are UTC Power, Pacific Gas
& Electric, Carrier Commercial Systems, and Ritz Carlton. (2) Basin
Electric, North Dakota will utilize waste heat from an existing pipeline
compressor station's gas turbine to generate electricity via an organic
Rankine cycle. Due to a change in DOE priorities, two other projects
were replaced with a new effort focused on grid integration in a New
York utility area with a fully networked (as opposed to radial) grid
topology.

[Highlights]{.underline}

Data collection is complete and the final report is in progress.

[Technical Progress]{.underline}

The site's installation and data collection has been completed.

[Status of Milestone(s)]{.underline}

(1)Complete final project documentation (September 2007): On track

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.1c -- Grid Integration Study for Two Feeders in New York**

**Therese Stovall,** **<stovalltk@ornl.gov>, (865) 574-0329**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The FY04 solicitation sought proposals for projects that utilized
pre-engineered, packaged IES systems that both generate electricity and
make effective use of the thermal energy produced. Target applications
for this procurement were healthcare and education facilities, hotels,
and supermarkets. Two of these projects, under subcontract to GTI, are
included in this subtask: (1) The Ritz Carlton Hotel, San Francisco,
California has installed a UTC Pure Comfort System (with four Capstone
microturbines) to generate 240 kilowatts and operate a 110 ton
absorption chiller. Partners on this project are UTC Power, Pacific Gas
& Electric, Carrier Commercial Systems, and Ritz Carlton. (2) Basin
Electric, North Dakota will utilize waste heat from an existing pipeline
compressor station's gas turbine to generate electricity via an organic
Rankine cycle. Due to a change in DOE priorities, two other projects
were replaced with a new effort focused on grid integration in a New
York utility area with a fully networked (as opposed to radial) grid
topology.

[Highlights]{.underline}

The advisory committee, including members from NYSERDA, the New York
City administration, Con Edison, ORNL, and others, completed their
review of the project analysis assumptions, including the selection of
the six buildings for detailed modeling. Applicable building codes were
also identified and reviewed.

[Technical Progress]{.underline}

Six buildings, out of the 50 in the Harvard Yards Development Project,
were selected as representative of the development in terms of building
size, type, and occupancy. The applicable gas and electric rate
structures were modeled and used to complete a preliminary screening of
combined heat and power economics.

[Status of Milestone(s)]{.underline}

\(1\) Complete assessment (September 2007): Significant utility data has
been received but a few critical billing records for residential
buildings are still expected. If these data are delivered within a
reasonable time period, the project will be completed according to the
schedule.

[Industry Interactions]{.underline}

Hudson Yard developers, CHP project developers, and Con Edison are all
actively participating in the New York grid project.

**Subtask 4.4.2 -- Butler Hospital/Providence, Rhode Island**

**Randy Hudson,** **<hudsoncrii@ornl.gov>, (865) 574-0578**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Provide field data on and analyze use of a UTC Pure Comfort System (with
four Capstone microturbines) to generate 240 kilowatts and operate a 110
ton absorption chiller. Partners on this project are UTC Power, Carrier
Corporation, Witham & Associates, New England Gas, and CDH Energy Corp.

[Highlights]{.underline}

The final report documenting the project was submitted, and the final
invoice has been paid.

[Technical Progress]{.underline}

The final report was submitted to ORNL on November 13, 2006 and has been
provided to DOE-HQ.

[Status of Milestone(s)]{.underline}

\(1\) Complete final project documentation (September 2007): All
milestones have been completed.

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.3 -- Eastern Maine Medical Center in Bangor, Maine**

**Randy Hudson,** **<hudsoncrii@ornl.gov>, (865) 574-0578**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Complete construction and begin testing of a Solar gas turbine to
generate 4.4 MW, generate 24,000 lb/hour of steam and drive a 500 ton
absorption chiller. Partners are Solar Turbines, Cianbro Corporation,
Vanderweil Engineers, University of Maine, and International District
Energy Association.

[Highlights]{.underline}

The system was fully operational on October 16, 2006, following a
ribbon-cutting open house on site to celebrate completion of
construction and startup. Operations data are being collected by CDH
Energy, and performance statistics are available for review on the web
at [http://www.emmccogen.org](http://www.emmccogen.org/).

[Technical Progress]{.underline}

For the first quarter of 2007, the plant provided 98.5% of the
hospital's electricity, generating 5,967 MWh of electricity, while
recovering 33,402 MMBtu of useful heat. The overall total CHP efficiency
during this period was 78.2 percent.

[Status of Milestone(s)]{.underline}

(1)Complete final project documentation (September 2007): As plant
operations did not start until October 2006, a final report including a
full year of operating data, per the contract, will not be available
until the first quarter of FY08. A report on operational results will be
prepared in September to cover the period of operations through that
point.

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.4 -- East Hartford High School**

**Randy Hudson,** **<hudsoncrii@ornl.gov>, (865) 574-0578**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Install a UTC Pure Comfort system in the East Hartford (Connecticut)
High School that will have black-start capability. United Technologies
Research Center is the subcontract partner.

[Highlights]{.underline}

The system had an 85% capacity utilization, generating 442,000 kWh at an
average electric efficiency of 28% during the first quarter of 2007.
Overall fuel efficiency, including heat recovery, was 70%.

[Technical Progress]{.underline}

System performing as expected.

[Status of Milestone(s)]{.underline}

(1)Complete final project documentation (September 2007): A project
profile has been prepared by SENTECH and is being reviewed by the
subcontractor prior to posting on the DOE website and completing the
subtask.

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.5 -- Madera Hospital/RealEnergy**

**Randy Hudson,** **<hudsoncrii@ornl.gov>, (865) 574-0578**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Install an integrated reciprocating engine and absorption chiller system
at the Madera Community Hospital in Madera, California. The system will
have capacities of 600 kW and 115 RT. The subcontract partner is
RealEnergy, LLC.

[Highlights]{.underline}

Due to hospital facility expansion (independent of the CHP system), the
CHP plant construction has been postponed.

[Technical Progress]{.underline}

None

[Status of Milestone(s)]{.underline}

\(1\) Initiate on-site construction (September 2007): It is not clear at
this time when, or if, the project will be completed.

[Industry Interactions]{.underline}

N/A

**Subtask 4.4.6 -- SEMCO Incorporated/Lindale, Georgia**

**Randy Hudson,** **<hudsoncrii@ornl.gov>,** **(865) 574-0578**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Utilize a 200 kilowatt reciprocating engine generator coupled with an
integrated active desiccant system in a high school in Floyd County,
Georgia. Partners are C&M Engineering, Floyd County Schools, Deutz
Engines, and WW Williams electrical generation equipment. Develop an
islanded Integrated Energy System (IES) design that will function
independently of the grid to provide adequate building air conditioning
and ventilation in the event of a local disaster, blackout, or terrorist
attack.

[Highlights]{.underline}

The system was commissioned in September, 2006 at the new high school.
The rooftop desiccant systems have been running well, but problems with
the Deutz engine controls and electronics have resulted in only being
able to run the engine for short periods of time. Fortunately, the
desiccant units do not require the engine to be operating in order for
them to function.

[Technical Progress]{.underline}

The system is now operational. Problems with engine controls and
electronics are being investigated.

[Status of Milestone(s)]{.underline}

\(1\) Complete final project documentation (September 2007): On schedule

[Industry Interactions]{.underline}

N/A

**Subtask 4.5.12 -- Evaluation of CHP Market Potential As It Relates to
Renewable Portfolio Standards**

**Patti Garland,** **<garlandpw@ornl.gov>, (865) 574-0738**

**Oak Ridge National Laboratory**

[Objective]{.underline}

This project consisted of several tasks:  Collect and summarize
opportunity fuels information for fuels that already are or could be
used in CHP applications, Evaluate CHP Technology Options, and Analyze
Potential Market Impacts and Develop Recommendations.  This work was
completed in FY05 with publication of the final task report, which can
be found on the DOE DE website.

 

In FY06, one task was added to the contract:  Satisfying of Renewable
Portfolio Standards with Opportunity Fuels and CHP.  In this effort, a
state-by-state analysis of the impact of state level renewable portfolio
standards will be performed, using state target dates and impacts as
well as emerging values of renewable energy certificates (RECs).  This
analysis will build off of the Phase I work.  It will analyze the
potential capacity from opportunity fuels that would satisfy the state
renewable portfolio standards, based on availability of fuel, economics
of opportunity fueled CHP, and prospects for wind and solar renewables.

[Highlights]{.underline}

-   The following white paper was completed: \"Project Considerations
    for Distributed Generation using Opportunity Fuels\"

-   The report "Potential Impact of Renewable Portfolio Standards on
    Biomass Combined Heat and Power Applications" has been drafted.

[Technical Progress]{.underline}

# The report "Project Considerations for Distributed Generation using Opportunity Fuels" was completed. This white paper outlines the differences between the each of the four primary opportunity fuels (biomass gas, anaerobic digester gas, landfill gas, and solid wood waste) and their natural gas and coal counterparts, highlighting any special considerations that must be made for opportunity fueled distributed generation (DG) projects. The information was collected from research on opportunity fuels, as well as interviews with manufacturers and discussions with project developers and operators. In addition, whenever possible, actual cases with project experience are used as examples to illustrate how these differences can affect real-world DG applications. The first section of this paper discusses the differences in fuel properties, such as composition, heat rate, pressure and flow rate. The next section addresses the contaminants typically found in these fuels, and their potential effect on prime mover systems and DG projects in general. Then, considering the differences in the fuels and the contaminants they contain, the necessary modifications and additional maintenance for prime mover equipment is analyzed. In the final section of the memorandum, the current market considerations for opportunity fuels are examined, including how the purchase of specialized equipment, fuel treatment systems, warranties, and O&M contracts can affect businesses.

[Status of Milestone(s)]{.underline}

(1)Complete final report on barriers to Installing CHP associated with
renewable portfolio standards (September 2007): On schedule

[Industry Interactions]{.underline}

This project is being completed in partnership with Resource Dynamics.

**Subtask 4.5.16 -- Coordination of Regional CHP Application Centers**

**Subtask 4.5.17 -- Project Direction and Technical Support**

**Patti Garland, <garlandpw@ornl.gov>, (865) 574-0738**

**Oak Ridge National Laboratory**

**Ted Bronson, <tlbronsonpea@aol.com>, (630) 248-8778**

**Power Equipment Associates**

[Objective]{.underline}

ORNL is working the DOE CHP Regional Application Centers and with Power
Equipment Associates, Energetics, EEA, Discovery Insights, USCHPA,
Sentech, and Resource Dynamics to provide oversight and guidance of
continued CHP Projects. ORNL will provide a critical technical review
and provide analysis for verification of subcontracted activities. As
the tasks progress, lessons learned and technical results will be
compiled and disseminated to the stakeholder community. Results of these
projects will be disseminated through the use of the DOE DE Website or
the DOE CHP Regional Application Centers.

As part of the CHP Roadmap activities, ORNL supports development and
updates of the CHP Action Plan in response to the Roadmap.

[Highlights]{.underline}

-   A CHP RAC face-to-face meeting has been scheduled for May 24-25,
    2007 in Golden, Colorado.

## A compilation of Metrics for CHP RAC progress over through the history of the program has been compiled and provided to DOE Program Sponsors.

[Technical Progress]{.underline}

Due to an increased interest in the CHP RACs, several meetings have been
held with DOE's Industrial Technologies Program to discuss activities
and capabilities.

[Status of Milestone(s)]{.underline}

(1) Complete report on 2006 RAC accomplishments and lessons learned
    (April 2007): Completed as part of the Historical Metrics Report to
    DOE.

(2) Publish monthly financial reports on subcontracted and in-house
    activities (On-going): On going.

[Industry Interactions]{.underline}

See above

**Subtask 4.5.18 -- CHP Regional Application Center Technical Support**

**Subtask 4.5.19 -- Provide Support to HUD on an "As-Needed" Basis**

**Mike MacDonald <macdonaldjm@ornl.gov> (865) 574- 5187**

**Patti Garland, <garlandpw@ornl.gov>, (865) 574-0738**

**Oak Ridge National Laboratory**

[Objective]{.underline}

ORNL is providing technical assistance in performing screening and
optimization calculations on an as-needed basis to the CHP Regional
Application Centers. ORNL will train CHP Regional Application Center
staff on the use of the BCHP screening tool.

ORNL also provides technical support to Bob Groberg at Housing and Urban
Development (HUD) on an as-needed basis.  Current work includes
recommendations on the accuracy of the CHP calculator based on for the
Cogen Manual for Multi-Family Housing, Appendix A. Additional work will
include collaboration with HUD, and HUD \"partners\", in identifying and
applying the best tools for evaluating CHP in multi-family housing.
Among others, these partners include Sebesta Blomberg & Associates of
Arlington, Virginia and Dougherty and Associates of Alexandria, Virginia
who are under contract to HUD to evaluate combined heat and power for
multifamily housing. A data template and utility data files will be
produced for use with the BCHP Screening Tool to assess its potential
for use in studying combined cooling, heating, and power in multifamily
housing.

[Highlights]{.underline}

-   Version 2 of the HUD CHP screening tool was provided to the Regional
    Application Centers for comment and suggestions.

-   Steve Fischer has retired from ORNL. Mike MacDonald, who has
    experience with the BCHP screening tool as it relate to Federal
    Facilities, is taking over Steve's role in supporting the CHP
    Regional Application Centers and HUD.

[Technical Progress]{.underline}

Mike MacDonald and Patti Garland have held teleconferences with Bob
Groberg of HUD to discuss recommended changes to the HUD screening tool.
Mike is making those changes.

Mike MacDonald and Patti Garland have held several meetings with Steve
Fischer to transfer the source code of both the BCHP and HUD screening
tools. Further meetings are scheduled to complete the knowledge
transfer.

[Status of Milestone(s)]{.underline}

(1)Provide technical support to the CHP Regional Application Centers
(RACs) (On-going): On going

\(2\) Provide support to HUD on an as-needed basis (On-going): On going.

[Industry Interactions]{.underline}

N/A

**Subtask 4.6.1 -- Distributed Resources Grid Integration Impact on
Power Quality and Reliability**

**Therese Stovall,** **<stovalltk@ornl.gov>, (865) 574-0329**

**Stan Hadley,** **<hadleysw@ornl.gov>, (865) 574-8018**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Perform DE benefit analyses to: (1) provide the foundation for informed
program management decisions, (2) facilitate the deployment of advanced
technologies developed under the program mantle by conveying the full
extent of potential benefits and the role of DE in the energy market,
and (3) support cooperation and partnership with other DOE offices and
other government agencies.

[Highlights]{.underline}

The public comment version of the Energy Policy Act 1817 report was
reviewed and a lengthy report describing necessary revisions was
submitted.

[Technical Progress]{.underline}

A number of significant problems in the Energy Policy Act 1817 report
were discovered after the reports processing by a variety of editing
teams. These errors include attribution omissions (i.e., plagiarism) and
technical errors.

[Status of Milestone(e)]{.underline}

(1) 

(2) \(1\) Complete the calculation tool that defines the value of the
    grid-integrated DE's contribution of improved power quality and
    reliability (August 2007): Work is underway to meet the milestones,
    although we delayed starting some portions of the work due to
    congressional budget uncertainties.

[Industry Interactions]{.underline}

N/A

**Subtask 4.6.2 -- Diversified Capacity Valuation Protocol Development
for Grid-Integrated DE**

**Therese Stovall,** **<stovalltk@ornl.gov>, (865) 574-0329**

**Stan Hadley,** **<hadleysw@ornl.gov>, (865) 574-8018**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Perform DE benefit analyses to: (1) provide the foundation for informed
program management decisions, (2) facilitate the deployment of advanced
technologies developed under the program mantle by conveying the full
extent of potential benefits and the role of DE in the energy market,
and (3) support cooperation and partnership with other DOE offices and
other government agencies.

[Highlights]{.underline}

Plug-in hybrid vehicles have been a topic of interest and a preliminary
analysis was previously reported.

[Technical Progress]{.underline}

Progress has been made to expand the modeling tool used for these
analyses to more accurately represent changes in demand. The model has
also been updated to more easily model all 13 NERC regions.

[Status of Milestone(e)]{.underline}

(1)Complete a report describing the protocol and calculation methodology
to accurately calculate the diversified reliability contribution of
grid-integrated DE (September 2007): Work is underway to meet the
milestones, although we delayed starting some portions of the work due
to congressional budget uncertainties.

(1) 

[Industry Interaction]{.underline}

N/A

**Subtask 4.6.5 -- Coordinate Industry Efforts with the DOE/OE Program**

**Therese Stovall,** **<stovalltk@ornl.gov>,** **(865) 574-0329**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Perform DE benefit analyses to: (1) provide the foundation for informed
program management decisions, (2) facilitate the deployment of advanced
technologies developed under the program mantle by conveying the full
extent of potential benefits and the role of DE in the energy market,
and (3) support cooperation and partnership with other DOE offices and
other government agencies.

[Highlights]{.underline}

Discussions were held discussing a possible joint venture. The status is
still exploratory.

[Technical Progress]{.underline}

Discussions were held discussing a possible joint venture. The status is
still exploratory.

[Status of Milestone(s)]{.underline}

(1) 

(1)Complete subcontractor report describing industry coordination
efforts (September 2007): Work is underway to meet the milestones,
although we delayed starting some portions of the work due to
congressional budget uncertainties.

[Industry Interactions]{.underline}

N/A

**Subtask 4.6.6 -- MADRI Support Activities**

**Therese Stovall, <stovalltk@ornl.gov>, (865) 574-0329**

**Brad Johnson, Consultant**

[Objective]{.underline}

Perform DE benefit analyses to: (1) provide the foundation for informed
program management decisions, (2) facilitate the deployment of advanced
technologies developed under the program mantle by conveying the full
extent of potential benefits and the role of DE in the energy market,
and (3) support cooperation and partnership with other DOE offices and
other government agencies.

[Highlights]{.underline}

Participated in PJM metering sub-group focused on developing metering
interoperability standards in support of DR program settlement
activities. Planned workshop with DC public utility commissioners to
focus on advanced meter infrastructure business case considerations and
dynamic pricing.

[Technical Progress]{.underline}

Worked with the MADRI Steering Committee to finalize the public release
of Brattle Locational Marginal Pricing study; refine and coordinate
state input for the 3% DR goal; and address interconnection standards.

Coordinated key MADRI activities through Maryland working group
activities regarding advanced meter infrastructure and distributed
resources business case and cost/effectiveness criteria.

[Status of Milestone(s)]{.underline}

\(1\) Complete a report describing MADRI advances and how they can be
applied to other regions (August 2007): Work is underway to meet the
milestones, although we delayed starting some portions of the work due
to congressional budget uncertainties.

[Industry Interactions]{.underline}

N/A

**Subtask 4.7.1 -- Evaluate Methods for Voltage Regulation and Analyze
Techniques for Voltage Collapse**

**John Kueck** **<kueckjd@ornl.gov>, (865) 574-5178**

**Fran Li, and Y. We**

**Oak Ridge National Laboratory**

[Objective]{.underline}

Develop methods for local, independent control of Distributed Energy
(DE) Resources so that they may provide dynamic voltage regulation with
minimal communication requirements for a distributed control system.

[Highlights]{.underline}

Several technical papers are in preparation or have been recently
accepted describing our methods for dynamic, DE-based, voltage
regulation. We are proposing the development of a controlled voltage
droop characteristic for DE which will actually increase the margin to
voltage collapse. We will be testing our methods here in the Distributed
Energy Communications and Controls (DECC) Laboratory

[Technical Progress]{.underline}

We have prepared a detailed test plan for the year.  We also have
agreement from Southern California Edison (SCE) to use the WECC GE PSLF
model in combination with our DE control algorithm; the confidentiality
agreement has been signed and DECC staff members have taken PSLF
training. This will allow us to perform simulations of our voltage
control method to increase the margin to voltage collapse and assess its
effective for micro-voltage collapse events experienced by SCE during
the summer.  In regards to restarting testing at DECC, we have the new
inverter cooling system installed and we have tested the inverter up to
100 amps peak. We have also operated the Capstone microturbine and we
are installing data acquisition on the Capstone.

[Status of Milestone(s)]{.underline}

\(1\) Evaluate analytical techniques for using independently controlled
DE sources in parallel to supply dynamic reactive power (June 2007): We
are on track in evaluating our analytical techniques. Reports of
analysis are in various stages: complete and waiting for publication, in
preparation, and only in outline form. The following is a brief summary
of each:

*Dynamic Voltage Regulation in Multiple Distributed Energy Resources
Systems*, Abstract has been prepared and accepted at an IEEE conference,
the report is in preparation and due in September 07. Lead Author: Yan
Xu

*The Use of Distributed Energy Resources to Extend the Margin to Voltage
Collapse* This report has been prepared based on simulations, the report
is under review for publication in IEEE Transactions. Lead Author: Shawn
Henry

*Nonactive-Power-Related Ancillary Services Provided by Distributed
Energy Resources* This report of analysis and simulation at the reactive
power lab has been prepared and accepted for publication at an IEEE
conference. Lead Author: Yan Xu

*Use of a Voltage Schedule and Independent DER Control Algorithm to
Increase Margin to Voltage Collapse* This paper will be prepared based
on simulations run in PSLF. An outline has been prepared for a paper to
be co-authored by ORNL and SCE. The paper will be targeted for
policymakers. Lead Author: John Kueck

*Voltage and Current Unbalance Compensation Using a Parallel Active
Filter* This paper has been prepared and accepted for publication at an
IEEE conference. Lead Author: Yan Xu

[Industry Interactions]{.underline}

We are coordinating with Southern California Edison to simulate our DE
methods for voltage control using their distribution system model. We
will examine the impact of our method on the "micro voltage collapse"
events they have had in their system. They have provided us with a
number of technical papers they have written on the subject from past
events. The most number of these events was experienced this summer.

**Subtask 4.7.2 -- Conventional Control and New Methods in Parallel**

**Tom Rizy, <rizydt@ornll.gov>, (865) 574-5203**

**John Kueck, Jeremy Campbell, Fran Li, and Y. We**

**Oak Ridge National Laboratory**

[Objective]{.underline}

The objective of this milestone is to test the simultaneous operation of
multiple reactive power producing distributed energy (DE) resources at
the DECC Laboratory with them connected in parallel and providing local
dynamic voltage and power factor regulation at their local power panels
on the ORNL distribution system. The 150A inverter and 300kVar
synchronous condenser at the DECC laboratory will use our control
schemes to provide dynamic voltage regulation while operated in parallel
with a 30kW commercial Capstone microturbine.

[Highlights]{.underline}

Last Fiscal Year (2006), we began operating our 150A inverter in
parallel with our 300kVar synchronous condenser and were successful in
operating them simultaneously. We pushed the inverter to 45A rms (or 64A
peak) and were limited by the operating temperature of the inverter. The
temperature of the inverter's heat sink must be kept to around 75C in
order to ensure that the integrated bipolar-gate transistor (IBGT)
junctions of the inverter are within 100C. We have upgraded the cooling
system for the inverter allowing us to produce higher inverter currents
which we needed for higher dynamic voltage regulation.

[Technical Progress]{.underline}

The inverter cooling system has been improved with higher air flow fans
on the input and on the exhaust end of the cooling system. The inverter
is operational again but now at higher current output levels. We have
performed a new temperature characterization of the inverter operation
at different loadings to establish the critical inverter operating
amperage (the current level at which the heat sink reaches 75C). With
the new fans in place, we are able to achieve over 73Arms (or 100A peak)
from the inverter which is nearly 50% of the inverter rating. We can now
regulate voltage at its local power panel from 0.5 to 2.0 V by
controlling inverter current output from 20 to 100A peak. The 30kW
Capstone microturbine has been operated a couple of times to check its
working condition and instrumentation has been installed for measuring
its current and voltage. Dr. Li and his student are simulating a
localized, non-communication-based voltage regulation control scheme for
two DERs in a distribution network of 13-buses and will expand to more
DERs shortly.

[Status of Milestone(s)]{.underline}

\(1\) Operate multiple DE sources in parallel using the control methods
developed in subtask 4.5.1 (September 2007): The milestone is on track.
We plan to proceed with running all three devices (inverter, synchronous
condenser and microturbine) in the next few weeks.

[Industry Interactions]{.underline}

We have developed a complete test matrix for our planned CY07 DECC
laboratory testing activities and it has been provided to our industry
partners for review and comment. This milestone has been identified as
high priority. Southern California Edison (SCE) has provided us with
data from last summer's micro-voltage collapses (stalling of air
conditioning motors) for analysis. We are proceeding with GE PSLF
simulations to understand the dynamics of the SCE network and how
voltage dynamic control via DER can mitigate these events.

**Subtask 4.7.6 -- Modeling of Reliability of High Temperature Packaging
of SIC**

**A. A. Wereszczak, <wereszczakaa@ornl.gov> (865) 576-1169 and H.-T.
Lin**

**Oak Ridge National Laboratory**

Objective

  -----------------------------------------------------------------------
  SiC-based power electronics can enable module size and weight
  reductions, operating temperatures of up to 500°C, loss factor
  reductions of an order of magnitude, and increase power capabilities by
  two orders of magnitude. Even though the SiC has very attractive
  electrical capabilities and attributes for power converters, it remains
  a brittle ceramic (i.e., a class of material in which a deterministic
  approach to structural design is not reliable) that would be subjected
  to thermomechanical stresses during device manufacturing and high
  temperature service - conditions that can limit or decrease device
  operation and lifetime. The present subtask combines the use of
  established probabilistic design and lifetime prediction methods
  developed for structural ceramics, microstructural-scale finite element
  analysis, micromechanical characterization, and sensitivity analysis
  methods and adapts them to the analysis of lifetime and design
  optimization of SiC-containing power converter devices (e.g., insulated
  gate bipolar transducers or IGBTs)

  -----------------------------------------------------------------------

Highlights

  -----------------------------------------------------------------------
  Temperature and current increases as a function of time were quantified
  up through (intended) short-circuiting in a (Si-diode-containing)
  1200V/100A IGBT module.

  -----------------------------------------------------------------------

> Technical Progress

+-----------------------------------------------------------------------+
| Commercially available (Powerex) high-voltage, high-amperage          |
| (silicon-diode-containing) IGBTs were dissected, sectioned, and       |
| optically imaged. These IGBTs are not capable of operating with       |
| junction temperatures above 125-150°C because their diodes are        |
| silicon. Their photos are now being prepared for input into *µ‑FEA*   |
| and ANSYS for thermomechanical stress modeling, reliability           |
| evaluations, and for guidance of transitioning to the use of silicon  |
| carbide semiconductor technology (and the higher temperature          |
| capability its use affords).                                          |
|                                                                       |
| To enable the study of a material failure associated with device      |
| malfunction, an uncooled Powerex (Si‑diode-containing) 1200V/100A     |
| IGBT module was subjected to simultaneous constant collector emitter  |
| voltage and gate voltage until it electronically failed. Temperature  |
| and collector current were continuously monitored. The collector      |
| current increased from 10 to \~70 Amperes in approximately 45 minutes |
| while the temperature had increased from 20 to 190°C. The silicone    |
| gel inside this module had discolored. Its removal is underway and    |
| postmortem analysis will enable the source of the device failure to   |
| be identified.                                                        |
+-----------------------------------------------------------------------+

Status of Milestones

  -----------------------------------------------------------------------
  Demonstrate the use of *µ-FEA* for modeling the thermal-mechanical
  stresses prevalent in a current SiC-package. *On schedule.*

  -----------------------------------------------------------------------

Industry Interactions

+-----------------------------------------------------------------------+
| > None during present quarter. Met with staff in ORNL's Cooling,      |
| > Heating, and Power Group to discuss their inverter work, its        |
| > thermal management, and the potential use of alternative materials  |
| > to improve its cooling.                                             |
+-----------------------------------------------------------------------+