Program Name or Ancillary Text eere.energy.gov

Physical Characterization Capabilities at ESIF

Kevin Lynn

Director, EERE Grid Integration

Kevin.Lynn@ee.doe.gov
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Addressing the challenges of large-scale integration of clean 

energy technologies into the energy systems 

infrastructure 

NREL Energy Systems Integration Facility

http://www.nrel.gov/eis/facilities_esif.html

Laboratories HPC - DC Offices

• NREL’s largest R&D facility 

(182,500 ft2 /20,000 m2) 

• Space for ~200 NREL staff 

and research partners

• Petascale HPC and Data 

Center supports all research 

at NREL

• Labs focus on R&D of 

integrated energy systems 

• Electricity

• Fuels

• Transportation

• Buildings & Campus 

• Integrated electrical, 

thermal, fuel, and data 

infrastructure

“This new facility will allow for an even stronger partnership with 

manufacturers, utilities and researchers to help integrate more 

clean, renewable energy into a smarter, more reliable and more 

resilient power grid.” - Energy Secretary 

Ernest Moniz
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ESIF’s Unique Advanced Capabilities

• Multiple parallel AC and DC experimental 

busses (MW power level) with grid 

simulation

• Flexible interconnection points for electricity, 

thermal, and fuels

• Medium voltage (15kV) microgrid test bed

• Virtual utility operations center and 

visualization rooms

• Smart grid testing lab for advanced 

communications and control

• Petascale HPC and data mgmt system in 

showcase energy efficient data center

• Hardware-in-the-loop (HIL) simulation 

capability to test grid scenarios with high 

penetration of RE and EE technologies
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ESIF Laboratories

High Performance Computing, Data 

Analysis, and Visualization

16. ESIF Control Room

17. Energy Integration Visualization 

18. Secure Data Center

19. High Performance Computing 

Data Center

20. Insight Center Visualization

21. Insight Center Collaboration 

Fuel Systems Laboratories 

9. Energy Systems Fabrication

10. Manufacturing

11. Materials Characterization

12. Electrochemical 

Characterization

13. Energy Systems Sensor

14. Fuel Cell Development & 

Test

15. Energy Systems High 

Pressure Test

Thermal Systems Laboratories

6. Thermal Storage Process and 

Components

7. Thermal Storage Materials

8. Optical Characterization

Electrical Systems Laboratories

1. Power Systems Integration

2. Smart Power

3. Energy Storage

4. Electrical Characterization

5. Energy Systems Integration

The future of energy is 

integrated systems 
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ESIF Research Infrastructure

Research Electrical Distribution Bus – REDB (AC 3ph, 600V, 1200A and DC +/-500V, 1200A)

Thermal Distribution Bus

Fuel Distribution Bus

Supervisory Control and Data Acquisition (SCADA) 

1MW Grid Simulator 

250A DC

1600A DC

250A AC

1600A AC
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Visualization 

Interface

Simulation and Visualization at ESIF

HIL I/O

Interface

Hardware-in-the-Loop: Connecting Experiments to Simulations

Actual hardware at ESIF

Subdevelopment with 

PV at end of circuit

Utility Substation

Simulation loop 

closed with actual 

hardware

Replicated into 

Larger Simulation

Simulation validated 

with real field data

Load Banks

Grid Simulator

Device Under 

Test

(e.g. inverter, energy 

storage, EV, load, 

etc.)

Grid Simulator

Solar Simulator

6

1.5MW

1 MW 1 MW
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High Performance and Highly Efficient Computing

3D Simulation model of Polymeric organic 

nitroxide radical (PTMA) film for battery 

applications

This computer-generated simulation shows the turbulent 

nature of wind turbine wakes. The simulation helped uncover 

potential differences in output between downstream 'waked' 

turbines and upstream turbines.

• High performance computing (1.2 peteflops) 

provides a multi-faceted basis for simulating 

future integrated energy innovations that would 

otherwise be too expensive, too lengthy, too 

dangerous, or otherwise impossible to study by 

direct experimentation

• Highly Energy Efficient (PUE under 1.06)

• HPC also has integrated energy control (run 

scheduling) and waste heat capture

0

1000

2000

3000

4000

5000

12:00 AM 6:00 AM 12:00 PM 6:00 PM 12:00 AM

Power (kW)

Time of Day

HPC Demand Controller: 12.5% 

Limit of Previous Month's Peak

Peak Load reduction
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Lab Functions

• Main test lab for conducting MW-scale 

electrical system integration activities. 

• Research explores a variety of 

operating configurations including: grid 

connected stand-alone, microgrids, and 

hybrid power systems. 

• House infrastructure for DG research 

(AC and DC power supplies for REDB, 

chiller and boiler)

Major Lab Equipment

• 1 MW grid simulator

• 1.5MW PV Array Simulator

• 100kW PV Array Simulator

• Several 250kW DC power supplies

• 100 ton research chiller 

• 750MBH research boiler

• Connections to Research Electrical, Thermal, 

Fuel Buses

ESIF – Power Systems Integration Lab

Research in the Power Systems Integration Laboratory focuses on the development 

and testing of large-scale distributed energy systems for grid-connected, standalone, 

and microgrid applications. The laboratory can accommodate large power system 

components, such as inverters for PV and wind systems, diesel and natural gas 

generators, battery packs, microgrid interconnection switchgear, and vehicles. 
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Lab Functions

• Residential scale distributed resources, smart 

appliances, and HVAC evaluations

• Interoperability and communications testing

• Individual Test labs for development and 

testing of the power electronics components 

and circuits used in renewable energy 

integration

• Instrument development area for basic 

electronics work

ESIF – Smart Power Lab

Research in the Smart Power Laboratory focuses on the development and integration of smart, 

connected technologies, including distributed and renewable energy resources and smart energy 

management. The 5,300-ft2 laboratory is designed to be highly flexible and configurable to 

enable a range of smart power activities—from developing advanced inverters and power 

converters to testing residential- and commercial-scale meters and control technologies. 

Major Lab Equipment

• AC power supplies 

• 45kW and 15kW grid simulators

• Opal RT and RTDS Hardware-in-the-Loop 

Systems

• Connections to REDB

• 3 Smart home appliances (refrigerators, water 

heaters, dish washers, etc.)

• 2 environmental chambers to test small HVAC 

systems
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Smart Homes and Appliances

Hardwired PV

EV, EVSEs, & 

battery storage

Distribution 

Transforme

rs

Environmental 

Chambers for realistic 

HVAC loading

Thermal 

Energy 

Storage

Major 

Appliances

Hot Water use 

under simulated 

occupancy
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Lab Functions

• Testing energy storage 

components when 

integrated with renewable 

energy electrical systems:

• Performance

• Efficiency

• Safety 

• Model validation

• Long duration reliably 

ESIF – Energy Storage Lab

At the Energy Storage Laboratory, research focuses on the integration of 

energy storage systems (stationary and vehicle-mounted) and their 

interconnection with the utility grid. Includes batteries, ultra-capacitors, 

flywheels, compressed air, etc.

Major Lab Equipment

• DC Power Testing station 250 kW, up to 900 Vdc

• Grid Simulator connections

• REDB Connections

• Research Chiller & Boiler

• 600kW PV Simulator

• EV Chargers
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Lab Functions

• Assessment of the technical 

readiness, performance 

characterization, and research to 

help industry move these 

systems towards optimal 

renewable-based production and 

efficient utilization of hydrogen

• Testing of electrolyzers, fuel 

cells, compression equipment, 

delivery systems

ESIF – Energy Systems Integration Lab 

The Energy Systems Integration Laboratory provides a flexible, renewable-ready 

platform for research, development, and testing of state-of-the-art hydrogen based 

and other energy storage systems. Focus on Fuel Cells and Electrolyzers.

Major Lab Equipment

• Gas Chromatograph

• Ion Chromatograph

• PEM electrolyzer

• Alkaline electrolyzer

• Fuel cell

• H2 high pressure compressor

• Two high pressure testing bays fully rated for 

testing systems to 15,000 psig
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ESIF –Outdoor Test Areas

MV Major Lab Equipment

• 1MVA 13.2kV to 480 Y-Y 

transformers

• Connections to REDB, Utility

• Distribution transformers

• EV Chargers

LV Major Lab Equipment

• 80kW and 125kW Gensets

• 100kW, 250kW load banks

• Capstone Microturbine

• Connections to REDB

ESIL Major Lab Equipment

• H2 storage vessels

• H2 IC engine testing

• H2 Vehicle fueling station

The outdoor test areas at the ESIF allow for testing either at 480 Volts or 13.2kV 

kiloVolts
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Integrated System Experimentation

Smart Power Lab

Buildings & Loads

Power Systems

Integration Lab

PV Simulator

Energy Systems

Integration Lab

Fuel Cells, Electrolyzers

Outdoor Test Area

EVs, Power Transformers

Rooftop PV Energy Storage Lab

Battery, EVs, Thermal
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ESIF – Summary

ESIF Provides

• End-to-end System 

Experimentation

• Across electrical, thermal, 

fuel, and communications 

systems

• Evaluation of MW scale 

systems

• High performance computing 

and advanced analytics

• Integration of hardware and 

simulation environments