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T&D R&D Gaining Attention

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Here are some high-level pointers to an array of resources related to ongoing developments in T&D research, sponsored by DOE, NSF and the CEC (Calif Energy Commission), which demonstrate a new level of attention to grid reliability and security.

Let me know if I can be helpful digging deeper into any of these areas.

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DOE – Office of Electricity Transmission and Distribution

The Dept. of Energy will announce, perhaps as early as next week, the creation of a new office for T&D reporting directly to the Secretary, as recommended in the National Transmission Grid Study* done last year. The Office of Electricity Transmission and Distribution will start with a budget of $85 million, however all but $8 or 9 million is already committed to earmarks ($27 M) and high temperature superconductors ($40 M). The office will be headed by Jimmy Glotfelty, an assistant to Abrahams. The staff currently in the Transmission Reliability Program in EERE will move over to the new office.

Meanwhile next week, a new Center will be dedicated at Oak Ridge:
http://www.ornl.gov/ORNL/Energy_Eff/nttrcdedication.htm

The dedication of the National Transmission Technology Research Center (NTTRC) and the Powerline Conductor Accelerated Facility (PCAT), the first working facility of four planned for the Center, will be held March 25. The Center, sponsored by ORNL, DOE, and TVA, will test and evaluate advanced technologies, including conductors, sensors and controls, and power electronics, under a wide range of electrical conditions without jeopardizing normal operations. The first component of the NTTRC, the PCAT facility, is initiating its first test protocol with 3M’s advanced Aluminum Conductor Composite Reinforced conductor.
— Overview of NTTRC:
http://www.ornl.gov/ORNL/Energy_Eff/PDFs/NTTRCoverview.pdf

The existing Transmission Reliability Program was reestablished by Congress in 1999 to conduct research on the reliability of the Nation’s electricity infrastructure during the transition to competitive markets under restructuring.

http://www.eere.energy.gov/der/transmission/
Go to “Documents and Resources” for recent studies and materials.

*(May 2002 http://www.energy.gov/NTGS/reports.html)

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Calif Energy Commission

The CEC Public Interest Energy Research program (PIER) has a very active effort underway in Transmission Research. They recently released a 140 page “Electricity Transmission Research and Development Assessment and Gap Analysis – Draft Consultant Report” — now available online along with other materials and presentations:
http://www.energy.ca.gov/pier/strat/strat_research_trans6.html

This report is one of two reports which were discussed at a public workshop held March 12, 2003 at the CEC.

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National Science Foundation
Directorate for Engineering, Elec. And Communications Systems
http://www.eng.nsf.gov/ecs/

1. Workshop on Modernizing the Electric Power Grid, Nov 02
— http://eent1.tamu.edu/nsfw/index.htm

Starting on slide 14 of James Momoh’s presentation there is a good overview of the EPNES initiative (next item)
http://eent1.tamu.edu/nsfw/documents/Presentation_JMo.ppt

2. NSF/ONR Partnership in Electric Power Networks Efficiency and Security (EPNES)
http://www.nsf.gov/pubs/2002/nsf02188/nsf02188.htm

This solicitation seeks to obtain major advances in the integration of new concepts in control, modeling, component technology, social and economics theories for electrical power networks’ efficiency and security. It also encourages development of new interdisciplinary research-based curriculum… Proposals were due Feb 3.

3. The Power Systems Engineering Research Center (PSERC)
PSERC is an NSF Industry/University Cooperative Research Center, involving a consortium of13 universities working with government and industry. The website has a huge array of reports and publications.
http://www.pserc.wisc.edu/

For the NSF’s “fact sheet”, see:
http://www.nsf.gov/pubs/2002/nsf01168/nsf01168ee.htm

Optic Fiber Inside Transm Cable Measures Temperature

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Here is most of the text of a summary prepared by the developers, Com Ed and Southwire. The complete Word document with graphics can be downloaded at:
http://www.ufto.com/clients-only/fotc.doc (password needed)

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**ComEd – Southwire Alliance Develops Novel Fiber Optic Transmission Conductor (FOTC)

In 1999, ComEd began work with Southwire to investigate a new concept to accurately determine the thermal behavior of overhead transmission lines during operation. It is the conductor temperature that dictates the thermal rating and available clearance under a line. However, as of yet no satisfactory method has been developed that measures conductor temperature axially throughout its length as well as radially.

A novel overhead transmission conductor system that uses optical fibers as an integral part of the phase conductor has been developed by ComEd and Southwire (Patent Pending) and placed in service on the ComEd system.

Operational since February 21, 2002, the 138 kV FOTC system uses distributed temperature sensing (DTS) to measure the temperature of the optical fibers that are embedded in the conductor. DTS allows accurate temperature measurement along the entire length of the FOTC line at different locations within the conductor.

Prior to the field demo, the FOTC system was tested and characterized by the NEETRAC {see UFTO Note, 17Jan02} and Oak Ridge National Lab (ORNL). Significant discoveries on the temperature behavior of the transmission conductor under various test conditions were found. For example, the impact of wind on radial temperature drop across a conductor and the impact of solar radiation on a conductor varied significantly from IEEE Std 738 during extreme weather conditions.

Field Trial Installation: The Fiber Optic Transmission Conductor (FOTC) was installed using a special dead-end assembly and an optical insulator. The installation method was the same as a conventional one, except that special care was taken to separate and protect the optical fibers from the conductor at the dead-end location.

The graph shows an example of the temperature data that is available in real-time from the FOTC system. With the FOTC system it is a simple matter to show the temperature of any desired interval lengths of the FOTC line. [graphic: Temperature versus Time Profile of 138 kV FOTC Line]

Utilities have a need to maximize the use of their assets. FOTC provides the medium for utilities to determine the real-time thermal operating limit of a transmission conductor in the most accurate way possible. It also provides the means to transmit data or voice communications. As the utility industry continues to evolve through transmission open access, new innovations such as FOTC will help pave the way to competitive advantage.

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Southwire will pursue the development and commercialization of FOTC under a license from ComEd. A market study is underway, and in particular the partners want to learn more about how much FOTC can increase transmission capacity, and how utilities will judge the merits and value for use on their own systems.

Contacts for Additional Information
Jim Crane, ComEd, 630-576-7034, james.crane@exeloncorp.com
Gene Sanders, Southwire, 770-832-4988, gene_sanders@southwire.com

JTEC New Solid State Heat to Electricity

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The Johnson Thermo-Electric Conversion (JTEC) system is a solid state, thermodynamic, energy conversion device that operates on the Ericsson cycle, which is equivalent to the Carnot cycle. It can be configured to operate as either a heat engine (for power production) or a heat pump (for cooling). As a heat engine, the JTEC can use any source of heat, e.g. combustible fuels (external combustion), solar energy, or waste heat. Several proof of concept, component level experiments have been successfully conducted to establish its feasibility.

The JTEC employs fuel cell technology, however, is not a fuel cell. Hydrogen is the working fluid, not the fuel. As a sealed solid state system that generates electricity from heat, it is better compared to thermoelectric converters, but with significantly higher efficiency.

JTEC is at an early development stage, however there is reason to believe progress could be relatively rapid. The company has laid out a multi-year plan, with working prototypes “soon”.. Details are closely guarded — I have executed an NDA and visited the company — the concept appears to be quite solid.

Texaco has funded the company to do a brief study of commercialization prospects. The company is looking for investors and strategic development partners.

Johnson Electro-Mechanical Systems, LLC (JEMS), is a spinoff of Johnson Research & Development, Atlanta GA, a technology development company involved in a number of areas. Another spinoff, Excellatron, has a licensed lithium thin film battery technology from Oak Ridge National Lab. The founder, Lonnie Johnson, followed a distinguished career in aerospace with the development of the SuperSoaker, one of the best selling toys of all time.

Contact: Lonnie Johnson 770-438-2201
http://www.johnsonrd.com

Startup Company to Develop Wireless Sensors

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The June 1998 UFTO Report on Oak Ridge National Lab has this brief entry in the section on Instrumentation & Controls:

… “Wireless Sensors: Spread-spectrum technology is being used in conjunction with sensors-on-a-chip to eliminate instrumentation-related wiring in a plant. Sensors can be added or moved as needed. There is a potential for coupling with global positioning system (GPS) technology, so that the sensor can report its exact location, in addition to other measured data. ” …

I recall being intrigued with the idea that sensors could be deployed inexpensively, almost on the spur of the moment, and in as many inaccessible places as you wanted, throughout a power plant or substation — to monitor temperature, noise, vibration or any other parameter. It makes a lot of sense.

The group at Oak Ridge has continued work on the concept, but hasn’t been able to move forward on building actual devices, for lack of funding and external partners. A nice presentation can be found at http://www.ornl.gov/orcmt/wireless.
An acrobat presentation of theirs can be downloaded at:
http://www.ornl.gov/orcmt/wireless/measurement&control.pdf

Independently, a new company, Sensitron, was formed here in Silicon Valley. The founders had come up with the same concept, and they’re pursuing it vigorously. Oak Ridge has indicated they’re more than willing to work with them to turn this into a reality.

Their schedule is ambitious: 3 months to breadboard demo, 12 months to field testing of prototype, 18 months to production, 24 months to integrated 2nd generation design.

One of the principals approached me (at our daughters’ Y-Basketball game!) to explore whether UFTO utilities might be interested in working with them (a good example of how UFTO is always on the lookout!).

Here is their summary. Please let me know if you’re interested.
Or you can contact: Blake Putney, 650-960-5948, putneyb@hotmail.com

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Wireless Monitoring Systems to Reduce Utility Maintenance Costs while Increasing Reliability

Recent developments in semiconductor, spread spectrum communications and micro-sensor standards and technology have made it possible to create complete wireless monitoring systems (WMSs) on a single chip the size of a dime. These sensor systems will be capable being cheaply deployed and connected with computer networks. Users will be able quickly deploy these systems to monitor virtually anything anywhere. Our system uses unlicensed communications bands that can be deployed on a site by site basis, without requiring an investment in a wide area cellular communications network. The potential market for these sensors in enormous, from industry, military, hospitals to home applications. The widespread availability of these systems has the potential to impact society in a similar manner as the Internet.

Although the technical feasibility of these systems has been demonstrated, a number of barriers exist for this technology to become a viable business. Existing markets are fragmented, revenue streams from near term applications are insufficient to attract investments from large organizations, and few sensor-oriented companies have the expertise in the technologies necessary to create an integrated product in silicon.

The initial market chosen for the sensors is to monitor conditions of equipment, and locations within electric utilities’ facilities. Deregulation is forcing electric utilities to get the most out of their equipment and staff. Our system will provide a utility the ability to track the health of all their assets remotely and provide the immediate access to information via their computer network. The sensors needed include temperature, vibration, and stress monitors.

This market was chosen because of the simple design requirements for the sensors, high value of these facilities, and the large expense of installing existing instrumentation solutions (up to $1000 per foot of cable). By reducing the cost of connecting a sensor to less than $150 per point, our wireless system will revolutionize maintenance practices at these facilities. The sales potential for WMSs in this market is over $250M at very high margins.

A key aspect of success is to create a complete system that minimizes the needs for components to be developed by third parties. Our system will involve subsystems for the sensor, field deployment and database configuration, and a receiver that collects data and is connected to an Ethernet. For the sensor subsystem, we are creating a modular CMOS chip design including each of the required elements (Micro Electro-Mechanical Systems (MEMS), Controllers, and R-F). The installation of this system will be simple enough to be deployed directly by end-users.

Sensitron is looking to attract utility partners that are interested in deploying wireless sensors to reduce operations and maintenance costs, while enhancing system reliability. Our utility partners will gain early benefits of deploying the system, and have the opportunity for equity participation in our enterprise.

CERTS – New DOE Prog in Elec. Reliability

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The Consortium for Electric Reliability Technology Solutions (CERTS) has been tasked by DOE to undertake a major new $2.5 million program in electric power system reliability research and technology development. (Congress re-established a budget for Transmission Reliability research in FY 1999, in DOE’s newly renamed “Office of Power Technologies” (OPT), formerly called the Office of Utility Technologies, under Deputy Assistant Secretary, Dan Adamson.)

The members of CERTS include:
Lawrence Berkeley National Laboratory (LBNL)
Edison Technology Solutions (ETS)
Oak Ridge National Laboratory (ORNL)
Pacific Northwest National Laboratory (PNNL)
Power Systems Engineering Research Center (PSERC)
Sandia National Laboratories (SNL).
The program is an important element in DOE_s response to the recommendations and findings of the SEAB Task Force on Electric System Reliability final report. (See UFTO Note, Oct 8, 1998, or go to: http://www.hr.doe.gov/seab.)

PSERC is a group of universities that have formed a cross-disciplinary team dedicated to solving the challenges arising from power system restructuring. It’s worth a visit to their website at: http://www.pserc.wisc.edu.

CERTS organizers are committed to a high degree of involvement by stakeholders. In particular, there will be a Technical Advisory Committee (see below), and numerous opportunities to participate in the research itself. A website is in preparation to provide public access to program details and developments.

KEY CONTACTS:

Joe Eto, LBNL, Program Office Manager for the Consortium
jheto@lbl.gov, 510-486-7284

Phil Overholt, DOE/OPT, T&D Reliability Program Manager
philip.overholt@ee.doe.gov, 202-586-8110

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Introduction and Overview–(excerpted from CERTS proposal)

The U.S. electric power system is in transition from one that has been centrally planned and controlled to one that will be increasingly dependent on competitive market forces to determine its operation and expansion. Unique features of electric power, including the need to match supply and demand in real-time, the interconnected networks over which power flows, and the rapid propagation of disturbances throughout the grid pose unique challenges that are likely to be exacerbated in the future. As the physical events of 1996 and the market events of 1998 demonstrate, the reliability of the grid and the integrity of the markets it supports are integral to the economic well-being of the nation.

The Consortium for Electric Reliability Technology Solutions (CERTS) was formed to develop and commercialize new methods, tools, and technologies to protect and enhance the reliability of the U.S. electric power system under the emerging competitive electricity market structure.

CERTS organizes its activities under four major areas: (1) Reliability Technology Issues and Needs Assessment; (2) Real Time System Control; (3) Integration of Distributed Technologies; and (4) Reliability and Markets. The first area encompasses strategic planning; the remaining three areas involve research and technology development. (See individual projects described below).

CERTS Organization

LBNL operates a Program Office for CERTS with day-to-day responsibilities for managing CERTS projects and activities acting under direction from the Management Steering Committee.

ETS operates a Commercialization Office for CERTS with responsibilities for preparing commercialization plans and, when appropriate, implementing commercialization activities for CERTS projects and activities.

CERTS is also working with DOE to create a Technical Advisory Committee, consisting of 10+ industry stakeholders and experts to review the activities of the consortium and provide guidance on research direction.

FY 99 activities for DOE include work in five areas

1. Grid of the Future

The first year of a two year planning study to identify emerging gaps in reliability technology R&D. In the first year, CERTS will lay the groundwork for the development of a federal R&D roadmap by preparing six white papers, which will be the basis for industry-wide stakeholder workshops on: (1) alternative scenarios for the future of the electric power system, including a detailed articulation of the technological assumptions underlying each of these futures; (2) assessment of the technology and control R&D needs for widespread integration of distributed resources; (3) recent reliability issues review, including in-depth analysis of technological and institutional aspects of recent reliability events (e.g., summer 1996 WSCC events; winter 1997 northeast ice storms; winter 1998 San Francisco outage, etc.); (4) review and assessment of the current structure of U.S. bulk power markets and provision of reliability services (including 1998 price spikes in mid-west and west, and absence of meaningful opportunities for demand response); (5) assessment of the technology and control R&D needs for real time system control; (6) assessment of the treatment of uncertainty in planning and operational models.
2. Distributed Technologies Test Bed

The first year of a major multi-year effort to design and ultimately, with industry and other stakeholder partners from industry, operate an in-field distributed technologies test bed. The objective of this work is to develop and demonstrate the technologies and control strategies needed to support widespread integration of distributed resources into the grid.

During the first year, CERTS will: (1) specify the information needed to conduct system simulation studies of distributed technologies, assemble available information, and develop a plan for additional laboratory bench tests to gather missing information; (2) conduct simulation studies of the different scenarios of distributed technology penetration using available data and models to evaluate distribution system reliability impacts and identify micro-grid control issues; and (3) develop a multi-year demonstration plan for a distributed technologies test bed.

3. Reliability Market Monitoring, Design, and Analysis

The first year of a multi-year effort to improve the design and operation of markets for the provision of reliability services in a restructured electricity industry. An integrated set of data development, simulation, and design activities will provide both immediate and longer-term benefits to emerging competitive markets.

During the first year, CERTS will: (1) collect data on ancillary services market compliance for the CA ISO and evaluate alternative user interfaces for using these data; (2) use these and other data to examine the performance of the market and, where warranted, suggest directions for fundamental changes in the design of these markets; (3) use experimental economic methods and other methods to simulate the performance of both current and proposed market designs; and (4) analyze customer-side technical requirements for provision of reliability services

4. Smart VAR Management System

Develop and demonstrate a software tool that will allow system operators to measure, communicate, and process real-time data to perform a VAR analysis of the WSCC grid and provide system operators with voltage profiles and reactive reserve margins at key substations. Had this tool been available, the 1996 outages on the Western grid could have been prevented.

During the first year, CERTS will develop, prototype, and field-test hardware and software that can be integrated with current energy management systems to provide operators with necessary information, contingency simulation, performance tracking, and report generation on voltage and reactive reserve margins.

5. Distributed Control

The first year of a multi-year effort to develop and demonstrate the appropriate role for distributed controls in management of the operations of regional power systems. During the first year, CERTS will initiate a demonstration of the ability and comparative performance of autonomous reasoning agents to maintain power system reliability compared to conventional centralized control methods.

Technology Transfer Opportunities – Oak Ridge National Laboratory

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UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the Federal Laboratories

Oak Ridge National Laboratory

Oak Ridge, Tennessee

June 1998

Prepared for:

Utility Federal Technology Opportunities (UFTO)

By:

Edward Beardsworth

Consultant

Contents:
Summary
Overview & Organization
Technologies & Programs

This report is part of a series examining technology opportunities at National Laboratories of possible interest to electric utilities

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This report is proprietary and confidential. It is for internal use by personnel of companies that are subscribers in the UFTO multi-client program. It is not to be otherwise copied or distributed except as authorized in writing.

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Summary

This report details findings about technology and technology transfer opportunities at the Oak Ridge National Laboratory that might be of strategic interest to electric utilities. It is a major update and revision materials developed previously, and is based on a visit to the lab in April 1998, and also draws from various publications, collateral information and website content.

Acknowledgments:

A special note of thanks to Marilyn Brown for arranging the agenda and her gracious and tireless support, and to all the ORNL staff who gave generously of their time and attention.

Also to Mr. Scott Penfield of Technology Insights, who accompanied the visits (as a representative of one of the UFTO utilities) and kindly provided his written account of the meetings for use in the preparation this report.

ORNL — Overview & Organization

Oak Ridge National Laboratory (ORNL) is a “GOCO” lab (government-owned, contractor operated). Lockheed Martin Energy Research Corp. is the contractor that manages ORNL. (Lockheed Martin also manages the Y-12 Plant in Oak Ridge, Idaho National Engineering Lab and Sandia National Lab.)

ORNL has a matrix organizational structure, where “divisions” aligned primarily by discipline have the people, and “programs” have the projects and budgets. On some occasions, divisions do get funds and projects of their own. ORNL finds that matrix management can work well if there is a balance of power and the right incentives.

Both divisions and programs live in research “ALD’s” or Associate Laboratory Directorates, headed by Associate Lab Directors who along with other administrative and support groups report to the Laboratory Director (Alvin Trivelpiece).

ORNL’s four research ALD’s are:

=> Energy and Engineering Sciences — Gil Gilliland 423-574-9920

(Div: Engineering Technology, Fusion., Instrum & Control)

(Prog: Energy Effic/Renew Energy, Energy Technology, Fossil Energy, Nuc Technol)

=> Life Sciences and Environmental Technologies

(Div: Chemical Technol, Energy, Environmental Sci, Life Sciences)

=> Adv. Materials, Physical and Neutron Sciences

(Div: Metals & Ceramics, Physics, Solid State, Chemical/Analytical Sci . . .)

=> Computing, Robotics, and Education

(Div: Computer Science and Mathematics, Robotics and Process Systems…)

There is work in all four ALDs of potential interest to utilities. The point of contact for this study was established through the Energy Efficiency and Renewable Energy Program, which oversees activities involving 11 different research divisions. Contact was also made with the Fossil Energy Program, with a similarly broad scope. Divisions encountered include Engineering Technology, Instrumentation & Control, Metals & Ceramics, and others.

Staffing level is now at approximately 5000, of which 1500 are scientists, of which about 1/2 are PhDs. ORNL’s 1997 budget was about $550 million. Of this amount, the largest program areas were Energy Research (28%), Environmental Management (25%) and Energy Efficiency (16%). Nuclear programs, which were once the principal focus of the Laboratory, are identified at a level of 4% in the overall budget; however, when supporting research topics (e.g., High Flux Isotope Reactor (HFIR), materials, NRC Programs, etc.) are included, some $100 million can still be identified as nuclear related.

A major new initiative at ORNL is the Spallation Neutron Source facility. The 1999 budget year will constitute a major test for this project, as it will include a construction line item for the first time. If approved, construction is expected to take 6-7 years. A new ORNL directorate has been established to oversee the Spallation Neutron Source project.

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Key Contacts:

Website: http://www.ornl.gov

Primary UFTO contact:

Energy Efficiency and Renewable Energy Program:

A.C.(Tony) Schaffhauser, Director, 423-574-4826, schaffhausac@ornl.gov

Marilyn Brown, Deputy Director, 423-576-8152, brownma@ornl.gov

Working with ORNL:

Technology Transfer: (Licensing and CRADAs)

Dean Waters, Acting Director, Office of Technology Transfer,

423-576-8368, watersda@ornl.gov

Sylvester Scott, Director, Licensing, 423-576-9673, scotts@ornl.gov

Partnerships: (CRADAs, User Program, Personnel Exchanges, Guest Research Assignments)

Louise B. Dunlap, Director, Office of Science and Technology Partnerships,

423-576-4221, dunlaplb@ornl.gov

Public Relations: Joe Culver, Director, Public Affairs,

423-576-0235, culverjw@ornl.gov

Partnership Mechanisms

ORNL makes use of an increasingly broad array of contracting mechanisms, including CRADAs, Work for others, User Facility Agreements, etc. Greater use of simpler standard formats makes the process much quicker than in the past.

They are seeing an increasing number of “100% funds-in CRADAs” (i.e. no cost sharing by the lab) from industry, as a cheaper alternative to work-for-others with essentially equivalent intellectual property rights. The Lab also will have as many as 4000 guest assignments per year, 1/4 of which are from industry, where visitors use the facilities or work with staff on CRADAs, etc.

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Energy Efficiency and Renewable Energy Program

Tony Schaffhauser, Director 423-574-4826 schaffhausac@ornl.gov

Marilyn Brown, Deputy Director 423-576-8152 brownma@ornl.gov

The EE/RE Program is a matrix organization that draws on several line divisions at ORNL for the majority of its personnel and technical facility resources, to set up multi disciplinary teams. DOE is the sponsor for most of the work, but they see industry and the public as the real customer.

ORNL budget expenditures controlled through the EE/RE Program office amount to some $80 million. The ORNL Energy Efficiency/Renewable Energy (EE/RE) budget was lower in 1996, but the level now appears to be stable.

Major Research and Development Areas

=> Transportation systems, including advanced automotive technologies, advanced materials, utilization of alternative fuels including biofuels, and transportation data.

=> Efficient building systems and for state and community programs, including heating, cooling, and refrigerating equipment; roofs, walls, and foundations; insulating materials; technology transfer; and retrofit of existing residential and commercial structures.

=> Industrial processes, such as bioprocessing, electric motor systems, advanced turbine systems, advanced materials, industrial heat pumps, and evaluations of energy-related inventions.

=> Utilities, including high-temperature superconductors (for transformers and transmission cables), power transmission and distribution systems, electric and magnetic field effects, biomass for power generation, and international programs (including IEA and APEC programs).

Technologies & Programs

Superconducting Technology Program for Electric Energy Systems

Fossil Energy Technologies

Real-Time Corrosion Monitoring

Hot Gas Filters

Materials R&D

Furnace Wall Corrosion with retrofit low-NOx burners

Effects of Coal impurities on fireside corrosion

Improved Stainless Steels

“Perfect Microstructures”

Nickel-Aluminide Alloys

Sulfidation Resistant Alloys

Building Technology Center

Frostless Heat Pump

High Efficiency Refrigerator (1 kwh/day)

Power Systems Technology Program

Energy Conservation Standards for Distribution Transformers

Flywheels and Energy Storage Technologies

Utility Restructuring and Electric Power Ancillary Services

Grid Reliability-Control Center Survey

Electric and Magnetic Fields Bioeffects

Research and Public Information Dissemination (RAPID) Program

Advanced Turbine Systems

Bioenergy Program

Motor, Steam, and Compressed Air Challenge Programs

Oak Ridge Centers for Manufacturing Technology (ORCMT)

Electric Machinery Center

Power Electronics Technology Center and Inverter Technology

Instrumentation & Controls

Machine Condition Monitoring and Diagnostics

Electrical Signature Analysis (ESA) for Utility Applications

Nonlinear data analysis–Component Failure Prediction

NRC/INPO plant database

Photonics and Hybrid Lighting

Superconducting Technology Program for Electric Energy Systems

Bob Hawsey 423-574-8057 hawseyra@ornl.gov

Web sites: http://www.ornl.gov/HTSC/htsc.html

http://www.eren.doe.gov/superconductivity/

(See special report and series of articles on “Superconductivity in Electric Power,”

pp 18-49, IEEE Spectrum, July 1997)

The discovery of high-temperature (i.e., above the boiling temperature of liquid nitrogen) superconductor materials dates to 1986. Since that time, the challenge has been to develop these brittle, ceramic-based materials into a form that can be produced and practically used. DOE research in this area has taken a major step increase, from $19 million in 1997 to $32 million in 1998. (By comparison, Japan is investing $100 million/year in superconductor research.)

DOE HTS Program

Contacts:

Jim Daley, Team Leader, 202-586-1165, james.daley@ee.doe.gov

or Joe Mulholland, Utility Liaison

202-586-1491, joseph.mullholland@hq.doe.gov

The DOE HTS program supports a balanced technology development effort. Wire and device technologies are developed through a large number of collaborative projects between U.S. national laboratories and industry, and systems technologies are supported through the SPI and other vertically integrated project teams.

DOE’s Superconducting Partnership Initiative (SPI) is a systems technology program designed to accelerate the development of HTS electric power systems. Begun in the fall of 1993, the SPI encourages the formation of vertically integrated teams comprised of partners who usually do not interact in the development cycle, involving close collaboration among system integrators, wire and device manufacturers, end-users (typically electric utilities)

Major projects include

– 5,000 hp high-temperature superconducting (HTS) motor

– 100 MVA HTS generator,

– 115 kV and 12.5 kV HTS transmission cable (2 projects)

– 5/10 MVA HTS transformers (2 projects)

– 15 kV HTS fault current limiter (2.4 kV successfully tested in 9/95 at a utility host site)

Fault Current Limiter

Later this year, pre-commercial (alpha) prototype will be tested by So Cal Edison and Lockheed Martin. Rating is 15-kV, normal 2 kA, intercepts/reduces by 80% a 20-kA peak symmetric or 45 kA peak assymmetric fault. Also functions as a 1/2 cycle circuit breaker. If demo successful, Edison will install it at a substation, and anticipates $1million in savings from avoiding need for a second bus. Next stage will be beta units.

Contact: Eddie Leung, Lockheed Martin program manager

619-874-7945, ext. 4636, eddie.leung@lmco.com

ORNL is participating in two of these partnerships.

Transformers — There is a strong need for medium power transformers (10-150 MVA) that are smaller, more efficient and free of fire hazard, to meet the growth in urban power density. These transformers will go inside building and in multistory substations, and provide higher ratings from existing substations.

— Waukesha Electric Systems (WES), Waukesha, WI

For the Waukesha program, ORNL is responsible for the engineering, design and science of the cooling system, while Intermagnetic General is producing the HTSC coil. WES did the core, instrumentation tank, pumps and test rig. An initial 1 MVA prototype has been constructed and entered testing at WES in February 1998. Initial results are good–the first operational US HTSC transformer easily sustains 2X overloads. Rochester Gas & Electric (RG&E) and Rensselaer Polytechnic Institute (RPI) participated in this initial demonstration.

The next step will be a 5 MVA system, which will provide power to the WES plant beginning in 1999. A larger utility advisory group is participating in this second step (includes several UFTO members). The initial commercial target is a transformer in the range of 10-30 MVA.

Contact: Pat Sullivan, VP Marketing, Waukesha, 414-547-0121, x 1531.

There is a separate transformer development effort that involves ABB, EdF, Los Alamos National Lab (LANL) and American Superconductor.

Cable — HTSC Cables hold the promise of far greater capacity– 5X the power in the same 8″ diameter pipe of conventional buried cable, and without the losses, heat, oil and range limitations.

— Southwire,Carrolton, GA

The Southwire HTSC cable project is expected to culminate in an initial demonstration at Southwire in 1999. The planned 100 ft, 3-phase, 12.4 kV, 1250 Amp cable will provide power (30 MVA) to Southwire facilities. Southern Co, Georgia Transmission Co, and So Cal Edison are partners. DOE is providing half of the $14 million. Southwire has built a 200 ft clean room manufacturing facility, and recently delivered a 5 meter test cable to ORNL for testing.

Pirelli and Los Alamos are pursuing a parallel HTSC cable initiative, with participation by Detroit Edison. The initial objective is a 25 kV line.

Other HTSC development initiatives mentioned include motors/generators (including flywheel motors/generators under development at Boeing) and kaolin magnetic separation equipment being developed by Dupont for the paper industry.

NOTE- More uility participation is needed–to provide advice, and as partners, cofunders and beta test hosts. Any kind of innovative proposal is more than welcome.

RABiTS (TM) Process for Coated High-Temperature Superconductors

http://www.ornl.gov/~vhk/rabits.html

Oak Ridge researchers have produced a roll-textured, buffered metal, superconducting tape with a critical current density of 300,000 amperes per square centimeter in liquid nitrogen, which may pave the way for the future manufacture of practical yttrium- or thallium-based conductors for electric power applications.

To produce a superconducting wire sample, the ORNL researchers first developed a process called rolling-assisted biaxial textured substrates, or RABiTS(TM), which enables the superconducting materials to have a high degree of grain alignment in all directions, a necessary condition for more efficient current flow through the superconductor.

MicroCoating Technologies (MCT) in Atlanta and ORNL announced on April 16 that MCT has licensed key patents. “MCT scientists within a six-month period have successfully deposited both HTS coatings and oxide “buffer layers” on several single crystal oxide substrates. MCT also successfully deposited buffer layer on textured nickel. The epitaxy of some buffer layers is as good or better than with any other deposition technique to date. In addition, MCT’s open atmosphere process can meet or exceed industry-wide cost targets to enable commercial-scale production of superconductor technology.”

Other licensees include Midwest Superconductivity and Oxford Superconducting Technology, with two more pending.

Fossil Energy Technologies

Rod Judkins 423-574-4572 judkinsrr@ornl.gov

ORNL described some additional advancements in materials and technology for fossil and related applications that were not addressed in the ORNL survey of utilities (developed by Technology Insights and sent to UFTO members in mid 1997). Some examples are:

Real-Time Corrosion Monitoring: A flash of laser light is impinged on a fossil boiler wall. By observing the infrared response of the area, corrosion related effects, such as thinning, debonding and delamination can be inferred.

Hot Gas Filters: In partnership with manufacturers, ORNL has developed two distinct classes of hot gas clean up filters.

– A ceramic composite (SiC-based) filter developed with 3-M is primarily targeted to fluidized bed combustion applications. The filter has been tested in AEP’s Tidd Plant and a Studvik incinerator in S. Carolina. It is available through 3-M. Contact Ed Fisher, 612-736-1005

– A lower temperature (700 – 1000 deg C) iron-aluminide filter, with high resistance to sulfidation, has been developed in partnership with Pall Corp. (Portland NY) and is nearing commercial introduction. An alternative to ceramics, it can be made with standard manufacturing equipment. Tests at the University of Cinncinnati show excellent corrosion resistance. Coal gasification is the target application.

Materials R&D

Ron Bradley 423-574-6095 bradleyra@ornl.gov

Ian Wright, 423-574-4451 wrightig@ornl.gov

Furnace Wall Corrosion with retrofit low-NOx burners — root cause is flame licking walls, so that control of flame characteristics using sensor-feedback arrangements should be the best solution. Hence, there is a need to develop sensors to monitor flame condition as input to control mechanism. ORNL has approaches for this, using chaos theory to analyse the flame signatures, for instance (Stuart Daw, David Schoenwald). There will also be a continuing practical need for diagnostics, coatings, repair techniques, etc., since not all boilers will be amenable to combustion control, and the use of multiple and varying coal sources will lead to continuing corrosion problems in some parts of the furnace wall. Sulfidation-resistant ferritic alloys (ORNL’s iron aluminides) promising as overlay/cladding, but difficult to apply reproducibly. Development program with Lehigh Univ-utility boiler consortium (Prof. Arnie Marder) is showing good promise.

Effects of Coal impurities on fireside corrosion — Chlorine limits based on fundamental misunderstanding–only a problem when other combustion problems (flame impingement) present. Developing in situ probes to measure short-term corrosion.

ORNL 98

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The final report from the re-visit to Oak Ridge National Lab is now available.

It is a 24 page (100K) Word doc, so only the front matter is included below in this note. You can obtain the full text either:
— on line in the clients-only part of the UFTO website (html)
— on request as an email attachment (Word, RTF, or html)
— on request in hardcopy via snail mail

————————————————————–
| ** UFTO ** Edward Beardsworth ** Consultant
| 951 Lincoln Ave. tel 650-328-5670
| Palo Alto CA 94301-3041 fax 650-328-5675
| http://www.ufto.com edbeards@ufto.com
————————————————————–

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UFTO Final Report

Technology Transfer Opportunities in the Federal Laboratories

Oak Ridge National Laboratory
Oak Ridge, Tennessee

June 1998

Prepared for:
Utility Federal Technology Opportunities (UFTO)

By: Edward Beardsworth

This report is part of a series examining technology opportunities at National Laboratories of possible interest to electric utilities

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Summary

This report details findings about technology and technology transfer opportunities at the Oak Ridge National Laboratory that might be of strategic interest to electric utilities. It is a major update and revision materials developed previously, and is based on a visit to the lab in April 1998, and also draws from various publications, collateral information and website content.

ORNL — Overview & Organization

Oak Ridge National Laboratory (ORNL) is a “GOCO” lab (government-owned, contractor operated). Lockheed Martin Energy Research Corp. is the contractor that manages ORNL. (Lockheed Martin also manages the Y-12 Plant in Oak Ridge, Idaho National Engineering Lab and Sandia National Lab.)

Clean Power Road Map

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Clean Power Generation Technologies Road Map

DOE is embarking on a series of vision setting and planning exercises that may significantly impact the direction of Federal research. These “Roadmapping” exercises are underway or planned in the areas of environmental management, fossil energy and energy efficiency/ renewable energy programs, as well as other selected programs within the Office of Energy Research.

The “Clean Power Generation Technologies Road Map” will examine a full range of production options, plus end-use efficiency, power transmission and distribution and the effect of regulatory structures. The effort spans both fossil and efficiency divisions of DOE, to help government and industry to: – determine the technology requirements to produce clean, affordable, and reliable power generation options – identify the federal, state, and industry roles in technology development, and – define the timing of needed RD&D investments over the next several decades.

The road map is to cover all fuel forms, conversion and enabling technologies (e.g. storage), and waste streams and effluents related to stationary power generation, including both central and dispersed generation, and co-production of electricity with steam, fuels, chemicals and gases. In light of climate concerns, a long term view will reach to 2100, with emphasis on the 2020-2050 time frame.

The road map is due to be completed in 2Q 1999. Initial work will be by a core group of about 12 persons, who will develop the overall vision and “destinations”, and oversee the roadmap process. The first “visioning workshop” meeting of the core group will be held in Washington on June 10-11. A select group of senior executives from utilities and IPPs have been invited (Duke, AEP, SMUD, Enron, Trigen, Onsite, Edison Int’l, Calif Energy Commission). At this stage, DOE wants only top level people to attend (CEO’s, Sr. VPs, etc.) and not lower level representatives.

Participation will be broadened to other groups later on, in a series of RD&D planning workshops. Drafts will be circulated for comments.

Initial Implementation Team:
– Victor Der (Fossil Energy) 301-903-2700, victor.der@hq.doe.gov
– Doug Carter (Fossil Energy) 202-586-9684, douglas.carter@hq.doe.gov
– William Parks (Energy Effic/Renew) 202-586-2093, william.parks@hq.doe.gov
– Joe Galdo (Energy Effic/Renew) 202-586-0518, joseph.galdo@hq.doe.gov
– Trevor Cook (Nuclear Energy) 301-903-7046, trevor.cook@hq.doe.gov
– Gil Gilliland (Oak Ridge) 423-574-9920, ig7@ornl.gov
– **Richard Scheer (Energetics, Inc.) 202-479-2748, rscheer@energeticsinc.com
**suggested point of contact

(See New Technology Week, March 2, 1998 for additional background).

Note: Due to the potential impact on national research priorities, UFTO companies should be aware of these planning exercises and may want to offer their input and participation at the appropriate time. I am in contact with the organizers, and they are aware of our interest.