SAGE + AMP Overview and Integration

1. SAGE + AMP Overview and Integration • Andrew Friedl Sr. Electrical Engineer, Energy Branch US Army ERDC-CERL Andrew.p.friedl@usace.army.mil 02 May 2014 Distribution Statement A - Approved for public release; distribution is unlimited.

2. Overview • My Background • Your Background • Content/Pics • Problem 1 • Problem 2 • More pictures • Q&A Me at the Museum of Science and Industry in Chicago

3. My Background Education: • UIUC Alum- BSEE ‘07, MSEE ’09 • UIUC BME, STM Certificates • Stanford, Management Sci. & Eng. Grad Certificate- In progress • Fall 2014  MIT, S.M. in System Design and Management EE Work Experience: Texas Instruments Intern: Applications Engineer, Design Verification Tester USACE ERDC-CERL: Sr. Electrical Engineer • Building Automation Systems (BAS) manager • NZI- Energy Modeler • Wind energy harvesting device (can’t talk about due to forthcoming patent disclosure) • Other things I can’t talk about!

4. Background, cont’d • Took this same class before it had a permanent number- ECE 398RES • Took almost all of the power area courses • Only missed out on a few power systems courses… • Advice: Take some CS & physics classes- they’re cool!

5. Your Background? • Who has had: • 1) ECE 430- Power 101? • 2) ECE 464/469- Power Electronics/Lab? • 3) ECE 431- Electric Machines? • 4) ECE 476- Power Systems? • All GREAT classes to understand how “power systems” work

6. USACE ERDC-CERL • Near I-57/ 74 intersection

7. So What’s the Problem?? • The DoD spends ~$10B every year on jet fuel (JP-5, JP-8) • Much of it is on diesel generators • The cost overseas (forward operating base) is ~$60/gallon • At this price the economics look very favorable for renewables, regardless what type they are • Good for PV/ alternative energy systems

8. Army’s Fuel Problem • Current costs are $60/gallon for diesel fuel • Soldiers die transporting fuel • Insurgents target fuel trucks • Current M.O. is oversizing generators and deploying them “The bigger the generator the better!” – Typical commander

9. Army’s Fuel Problem, cont’d • Why is this an issue? • The generators are running at ~10-20% load • Optimal efficiency is at 80-85% load Want to run at optimal efficiency all of the time! ***Need energy storage***

10. What the Army Has • A few different microgrid systems spread throughout the nation • One that CERL works with regularly (since it is so close) is CBITEC @ Ft. Leonard Wood

11. Ft Leonard Wood- CBITEC • Contingency Basing Integration Technology Evaluation Center (CBITEC) • An experimental contingency base at Fort Leonard Wood to promote sustainable design and construction

12. CBITEC

13. CBITEC, cont’d

14. CBITEC • Has 1+ MW Diesel Gen Sets that came back from Afghanistan, unused for 1-2 yrs (AMP) • Has 100kW PV system tested in California • Bought 250kWh battery system + bi-directional inverter & 3 x 100 kW Generators from Caterpillar (SAGE) • Integrate these to get: Largest Microgrid in the Army! ***

15. Smart AND Green Energy (SAGE)

16. SAGE, cont’d • “SAGE technologies would reduce annual fuel demand by 50 percent in small to medium-sized base camps (300 - 5,000 Soldiers) and as much as 80 percent in very small camps (50 - 299 Soldiers).” http://www.army.mil/standto/archive_2013-12-19/

17. Afghanistan Microgrid Project (AMP) • 4* x 500kW Generators that are “smart”

19. AMP, cont’d • The four large generators in the microgrid system are turned on and off automatically by the system as peaks and valleys • Captures fuel usage and fuel efficiency and generates load profiles. • Generators are rotated automatically by the system's computer to balance the number of hours on all engines

20. SAGE + AMP + PV Integration • Will result in the capability of “silent mode” operation • Will have close to 2MW of generation • Right now we are running the lights, AC, heating, control boards • Full power with everything on is ~11kW

21. Pdise

23. Marines’ Pdise

25. Ft. Leonard Wood System • SAGE: Bi-directional Inverter + Battery System (Master), 3 x 100kW Gen sets • Pdise connectors (grid- 208V 400A bus) • 75kVA 3 phase 480V/208V transformer • 100kW PV + 100kW 480V inverter (slave)

26. Problems to Solve! • 2 Problems to solve Why?? • Good for practical experience • 5-10% of my time is calculations, the rest is things like these problems • I suspect that many jobs are similar

27. Problem 1 • Boss: “Inverter not working… Go figure out how to make it work” … OK… • 1) What does that mean, “not working?” • 2) Is there power? How does it power up?

28. Flip Switch…

29. Power’s on!

30. Ok, ~575V, ~15A = roughly? ?

31. ***CLICK*** ***CLICK*** Fault?!?

32. MPPT 24 5 6 strings in parallel

33. PV ~30V * 24 col*5 row/6 strings in parallel = 600V. 600V max DC input on inverter Why is it tripping?!?!

34. PV Connection Terminal

35. What can be done? • Do you need any more information? Ask me questions! • Take 3 minutes to discuss possible options with your neighbors

36. (At Least) Three Solutions • 1) Increase input DC voltage threshold (cheapest) • 2) Giant Buck-boost converter (expensive) • 3) Burn off power with resistive load 

37. Ft. Leonard Wood System • SAGE: Bi-directional Inverter + Battery System (Master), 3 100kW Gen sets • Pdise connectors (grid- 208V 400A bus) • 75kVA 3 phase 480V/208V transformer • 100kW PV + 100kW 480V inverter (slave)

38. Problem to Solve, Q2 1) Operating light turned on 2) Inverter switching noise noticeable for 3-20 s 3) Inverter turned off (operating light off) 4) Voltage may have passed 10% over 480V (528V) and shut down. WHY?

39. What can be done? • Do you need any more information? Ask me questions! • Take 3 minutes to discuss possible options with your neighbors

40. Issues/Conclusion • The string of PV panels put out ~600V DC, but can go over! • Systems might not play well together…Master (SAGE) vs. Slave (PV) • Need a large transformer to transform 480V 3 phase to 208V 3 phase • Appropriate wire gauge sizing to handle currents (100A vs. 400A) • Syncing issues- Three things needed to sync, what are they?

41. Cool Army Stuff

45. Other Pictures

46. Q&A Thanks!