AEI / Affiliated Engineers presents the Energy Systems Integration Facility, a 182,500 square foot building that provides laboratory and research space for 200 scientists and staff working on promising clean energy technologies and testing their interaction with each other and the grid. Specific areas of research include: • Smart grids, power electronics. • Solar: interconnection, parabolic solar concentrators, building integration, and system optimization. • Buildings: sensors and controls, systems integration, modeling, and Zero Energy Building simulation. • Hydrogen: electrical interfaces, electrolyzers, storage, quality standards, fueling systems, fuel cell integration. • Wind: models, generation, and grid interaction, electrical grid analysis. • Vehicles: grid connected plug-in and vehicle-to-grid electrical integration, battery thermal management, and power electronics. • Biofuels: generator sets and engines. • Energy storage: electrical, mechanical, and thermal. • Microturbines. AEI’s work included the design of: • Research Electrical Distribution Bus (REDB): A first-of-its-kind, the REBD is a power integration circuit made up of two AC and two DC ring buses that interconnects testing components across the building’s 15 laboratories. Researchers can test new energy technologies on real and simulated power systems. • Supervisory Control and Data Acquisition (SCADA) System: Integrated throughout the facility, the SCADA monitors and controls the REDB operations and gathers real-time, high-resolution data for collaboration and visualization. The SCADA also monitors SIL-2 (Safety Integrity Level) rated laboratory PLCs providing emergency stop functionality, gas detection, alarming (horns and lights), and other required safety measures. These systems are all interconnected with the fire alarm, building automation system, and local lab equipment to provide a seamless facility response across systems to various conditions.

1. Emerging Hazards: Renewables and Microgrids
US Department of Energy, Energy Systems Integration Facility Case Study
Photo by Dennis Schroeder, NREL
Dave Sereno, PE, LEED AP
Kevin Krause, PE, LEED AP
2014 I2SL Annual Conference
Orlando, Florida

2. Learning Objectives
• Safety as a culture.
• Introduction to PHA (Process Hazards Analysis).
• Apply PHA to a micro grid/smart grid R & D Lab.

3. Presenters
Dave Sereno, PE, LEED AP
Principal
dsereno@aeieng.com
Kevin Krause, PE, LEED AP
Principal
kdkrause@aeieng.com

4. Why this topic?
1.Rise of Arc Flash
2.Rise of DC components due to:
a. NZB (Net Zero Buildings)
b. Data Centers
c. Transportation Infrastructure
d. Renewables

5. Q: Why NREL ESIF as a case study?
A: It has it all
Photo by Dennis Schroeder, NREL

6. DOE NREL South Table Mountain Campus
Golden, Colorado

7. Team Participants
DESIGN CONSTRUCTION
SmithGroupJJR
Affiliated Engineers, Inc
Martin & Martin
JE Dunn Construction Company
MTech Mechanical
Encore Electric, Inc.
Courtesy of SmithGroupJJR

8. Three Building Components:
East Elevation
Office Data Center
High Bay
Laboratories
Photo by Dennis Schroeder, NREL

9. Three Building Components:
West Elevation
Photo by Dennis Schroeder, NREL
OfficeData Center
High Bay
Laboratories

10. Conceptual Site Plan
H2
Fueling
Pad
H2
Storage
MVOTA LVOTA

11. Residential
Commercial
Utility/Grid/Industrial
Three Scales:
Residential, Commercial & Industrial/Grid

12. 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
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

13. Test and Evaluation of all types of distributed generation, storage and
interconnection systems
Grid Simulator
Load Simulators
Synchronous Generators
PV Array
3ACBuses
Utility Grid
Battery Banks
3 DC Buses
Inverters
Fuel Cells
Electrolyzer
Microturbines
Wind Turbines
PHEV/V2G
ESIF Genesis: DERTF Precursor Facility

14. Distributed Energy Research Test Facility (DERTF)
Example Projects – Interconnection System Testing
Distributed Energy
Resources
Interconnection
Technologies
Electric Power Systems
Fuel Cell PV
Microturbine Wind
Generator
Inverter
Switchgear, Relays,
& Controls
Functions
• Power Conversion
• Power Conditioning
• Power Quality
• Protection
• DER and Load Control
• Ancillary Services
• Communications
• Metering
Microgrids
Energy
Storage
Loads
Local Loads
Load Simulators
Utility
System
PHEV - V2G
ESIF Genesis: DERTF Precursor Facility

15. Learning Objectives
• Safety as a culture.
• Introduction to PHA (Process Hazards Analysis).
• Apply PHA to a micro grid/smart grid R & D Lab.

16. Safety as a Culture
1. End Goal:
a. Minimize lost man hours during construction
b. Increase design phase impact
c. Minimize risk for all parties
d. Optimize/accelerate AHJ reviews
2. The Safety Minute:
a. Benefits beyond safety
b. Resources
c. Sustaining enthusiasm
3. Differentiate:
a. Proactive safety systems
b. Reactive safety systems
c. And how they relate to PHA and budget

17. Safety Programming:
Proactive and Reactive

18. Hydrogen Storage Pad
45’= 3-Stories
45’
Safety Programming:
Proactive and Reactive

19. Safety Common Interface: Pier Detail
Gas Detection
E-Stop
BNC
Temperature
Multi Conductor
Configurable:
SCADA Interface
Configurable:
DUT
Communication
Interface
Configurable:
Hardwired Control
Interface

20. Safety Common Interface: Pier Plan

21. Safety Common Interface: Portable Carts

22. Learning Objectives
• Safety as a culture.
• Introduction to PHA (Process Hazards Analysis).
• Apply PHA to a micro grid/smart grid R & D Lab.

23. PHA: Process Hazards Analysis
• Most frequently applied to Process Industry,
refineries, chemical mfg, drug mfg, etc…
• Simple Matrix: Severity and Likelihood
• (2) Common Methodologies:
• Point to Point , aka P & ID
• “What if”
• Software PHA tools
• Subjectivity removed
• Automated documentation

24. PHA: Let’s talk risk

25. PHA Starting Point: Owners Risk Policy
LIKELIHOOD
LIKELIHOOD
PER YEAR
SEVERITY
Catastrophic Critical Marginal Negligible
$1M $100K - $1M $10K - $100K $10K
Death Severe Injury Minor Injury No Injury
Frequent >1 High High Moderate Routine
Reasonably 1 to 0.1 High High Moderate Routine
Occasional 0.1 – 10-2 High Moderate Low Routine
Remote 10-2 – 10-4 Moderate Low Low Routine
Extremely Remote 10-4 – 10-6 Low Low Routine Routine
Impossible <10-6 Routine Routine Routine Routine
High Risk  Moderate Risk  Low Risk  Routine Risk

26. PHA: Safety Integrity Level (SIL) Metric
SIL Availability
Probability of Failure
on Demand (avg)
Mean Time Between
Failures
4 >99.99% 10-5 to < 10-4 100000 to 10000
3 99.9% 10-4 to < 10-3 10000 to 1000
2 99-99.9% 10-3 to < 10-2 1000 to 100
1 90-99% 10-2 to < 10-1 100 to 10
High Risk  Moderate Risk  Low Risk  Routine Risk

27. Learning Objectives
• Safety as a culture.
• Introduction to PHA (Process Hazards Analysis).
• Apply PHA to a micro grid/smart grid R & D Lab.

28. Residential
Home
Energy
Distributed
Energy
Storage
Bulk Energy
Storage
Advanced
Solar
Inverters
Hydrogen
Technologie
s
Commercial
Buildings
Wind
Energy
Hydrogen
and Electric
Vehicles
Microgrids
Energy
Efficiency
Technology
ESIF Mission to Enable “Smart Grid”
SMART GRID

29. Research Electrical Distribution
Bus (REDB)
AC
• Rated 600Vac 3ϕ, 2ϕ, or 1ϕ
• 5-wire design: neutral with
selectable ground bonding
location
• 16 Hz to 400 Hz
• 250A and 1600A installed
• 250A and 2500A planned
(future)
• Experiment connection via
cart CB, bus plug CB or fuse,
or direct (main lug only)
• Connects PSIL, SPL, ESL,
GSE, LBE, LVOTA, MVOTA,
ESIL
DC
• Rated ±500Vdc or 1000Vdc
• 4-wire design: positive,
negative, common, and
ground
• Any pole may be tied to
ground at selectable location
• 250A and 1600A installed
• 250A and 2500A planned
(future)
• Experiment connection via
cart contactor/fuse or direct
(main lug only)
• Connects PSIL, SPL, ESL,
PVE, LVOTA, MVOTA, ESIL

30. Research Electrical Distribution
Bus (REDB)

31. REDB: 20,000 Circuit Permutations
• Unconstrained:
Total # Circuits (all Combinations)
1.33499E+95 !!!
• One Constraint:
Total # Circuits (all Combinations)
3.96141E+28!!
• Three Constraints:
Total # Circuits (all Combinations)
1.932E+4!
(19,320)

32. REDB: One Permutation Example

33. Proactive System: Kirk Key LOTO

34. REDB Room
DC REDB
Equipment Room
AC REDB
Equipment
Room
House Power
Equipment Room

35. Proactive System: REDB Access Control

36. Everything in Loop Must Meet SIL Level
• Instrument Measuring (Unknown SIL rating)
• PLC (Easy to find to SIL-3 Ratings)
• Relay (Easy to find for SIL-3 Ratings)
• Shunt Trip Breaker (Like SIL-2 Rating)
• Communications between different vendor systems
are not SIL rated.
High Risk  Moderate Risk  Low Risk  Routine Risk

37. REDB: PHA Conclusion
• Multiple layers of defense are needed to get to the
statistical frequency required by NREL Safety
• Breakers in series, redundancy, (10-2 * 10-2 = 10-4)
• PLC/normal instrumentation (10-1)
• SOP (10-1)
• Total = 10-6
High Risk  Moderate Risk  Low Risk  Routine Risk

38. Emerging Hazards: Renewables and Microgrids
US Department of Energy, Energy Systems Integration Facility Case Study
QUESTIONS
2014 I2SL Annual Conference
Orlando, Florida
Dave Sereno, PE, LEED AP
Kevin Krause, PE, LEED AP
Photo by Dennis Schroeder, NREL