Development of Sustainable Power for Electrical Resources SuPER System

1
Development of Sustainable Power for Electrical
Resources SuPER System

• EE 563 Graduate Seminar
• September 30, 2005
• James G. Harris, Professor
• EE Department and CPE Program

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Outline

• Background
• Technical Description of SuPER System
• Feasibility Analysis
• Five Year Plan for Development
• Faculty Participating in SuPER Project
• Student Involvement
• Facilities, Equipment, and Resources
• Status and Plans

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Background - Electrification

• Electrification National Academy of
  Engineerings top engineering achievement for the
  20th Century
• Estimated 1/3 of population (now, 6B) do not have
  access
• Significant proportion of remainder does not have
  reliable access to battery or grid
• 18,000 occupied structures on Navajo Nation lack
  electrical power (2001 legislation)

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Background - Significance

• Impact of electrification significant
• Transformation of Western world
• Thomas Hughes Networks of Power
• People who caused change
• Social Impact standard of living
• Recognized by National Renewable Energy
  Laboratory in late 1990s
• Village Power Program
• Development of microfinancing

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Background Solar Insolation

• Goal to provide electrical resources to people in
  underdeveloped countries
• Leapfrog technology no need for 100 years of
  development
• Example of cell phone in Asia
• Review of global insolation map
• Poorest people (1-2 a day income)
• Within plus or minus 30 degree of latitude
• Highest values of solar insolation (minimum W
  hr/sq m/day)

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Background DC Power

• Solar photovoltaic systems inherently DC
• History of DC (Edison) versus AC (Westinghouse
  and Tesla) at end of 19th century
• DC versus AC for generation, distribution, and
  utilization
• Initially, applied to lighting
• Lighting today
• 60W incandescent bulb and 20W compact fluorescent
  bulb lumens
• Equivalent to 3W LED technology, and improving

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Background DC power loads

• Efficiency of electrical motors few horsepower
• Permanent magnet DC motors
• Electrical appliances
• Computer 50W laptop (DC)
• TVs, radios use DC power
• RV 12V DC market kitchen appliances
• Portable power tools battery powered (DC)
• Computers wireless connection
• Internet, phone (voice over IP), TV, radio,
• Education MIT Media Lab 100 laptop project

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Background Moores Law

• Stand-alone solar photovoltaic system technology
  is mature, e.g., Sandia Handbook
• Application of Moores Law to development of
  SuPER system
• Solar cell development commercial and research
  lab
• Estimate 5 per decade with base of 16 in 2005
• Implies 25 efficiency in 2025
• DARPA RFP 1000 units of 50 efficiency

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Commercial Module Range
Laboratory Cells Histories of Silicon
Photovoltaic Module and Cell Efficiencies Ref.
Martin A. Green "Silicon Photovoltaic Modules A
Brief History of the First 50 Years" Prog.
Photovolt Res. Appl. 2005 13447455 (Published
online 18 April 2005 in Wiley InterScience
(www.interscience.wiley.com). DOI
10.1002/pip.612)
11
April Allderdice and John H. Rogers Renewable
Energy for Microenterprise National Renewable
Energy Laboratory November 2000
12
Antonio C. Jimenez, Tom Lawand Renewable Energy
for Rural Schools National Renewable Energy
Laboratory November 2000
13
Jonathan O.V. Touryan and Kenell J. Touryan
Renewable Energy for Sustainable Rural Village
Power Presented at the American Scientific
Affiliation Conference Arkansas August 1,
1999 National Renewable Energy Laboratory
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Background Solar and DC Power

• Conclusion
• Solar photovoltaic is poised for leapfrog
  technology
• Many development tools available
• Expectation of future efficiencies
• Sustainable power source
• Digital control of standalone system
• DC is power of future
• Decentralized
• Matched to source and loads

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Technical Description of SuPER System

• Modular design four subsystems
• Stand-alone solar photovoltaic system design very
  mature

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Technical Description of SuPER System approach
and goals

• Approach to design from first principles
• Created set of five sets of requirements
• Overall, and a set for each subsystem
• Overall goal
• Mean time between failures (MTBF) 25 years
• Mean time to repair (MTTR) 1 hour
• Design lifecycle of 20 years
• Cost less than 500 for 1 sq m PV module
  including battery replacements

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Technical Description of SuPER System -
requirements

• Overall system requirements (abbreviated)
• Total power/energy budget input, storage, output
• Measurements and definition of state
• Safety NEC/standards code, grounding
• Mechanical design enclosure/packaging
• Startup and shutdown, error detection/recovery
• Documentation General Public License (Open
  Source)

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Technical Description of SuPER System -
requirements

• Solar Panel requirements (abbreviated)
• Size 1, 2, 4 sq m modular design
• Voltage (DC) 12V, 24V, 48V
• Fixed tilt _at_ latitude or 15 deg
• Modularity parallel/series, interface DC sources
• Maintenance
• Measurements voltage/current spectral and
  temporal characterization temperature

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Technical Description of SuPER System -
requirements

• Energy storage requirements (abbreviated)
• Type deep cycle, AGM-gel, Ni-Cd
• Maintenance minimal (clean terminals)
• Replacement schedule every 5-10 years
• Safety and sustainability
• Measurements charging and discharging
• Grounding and mechanical

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Technical Description of SuPER System -
requirements

• DC interface requirements (abbreviated)
• Single or multiple DC outputs model of AC 110V
  input service bus with multiple circuits
• Currents use of AWG 12 or 14 implies 15A
• Circuit breakers, GFI, overload for motors
• Characterization of DC electrical loads
• Modular design for load growth
• Forum for DC standarization model of Internet
  Engineering Task Force (IETF)

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Technical Description of SuPER System-
requirements

• Control and status module requirements
  (abbreviated)
• Digital development technology example is Altera
  FPGA/NIOS with uclinux OS, internet I/F
• Switching of array power with conditioning
• User display/interface
• Digital control algorithms maximum power point
  tracking (MPPT), softstart for power switching
• Safety and grounding
• Enclosure with environmental conditioning

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Feasibility Analysis

• Worst case global solar radiation 4 KW h / sq m
  per day
• Solar cell efficiency of 10 yields 400 W h / sq
  m
• Solar module of 1 sq m for 400 W h per day
• Energy storage at 12V with discharge of 50
  yields 66 A h battery
• Car/truck battery
• Five year replacement

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Feasibility Analysis

• Lighting 5 LED lamps _at_ 3W for 4 hours yields 60
  W h
• Water pump ¼ HP (187 W) for one hour
• 565 liters at maximum heigth of 7.62 m (garden
  hose)
• Computer and communication 50 W for one hour
• Refrigerator (12V DC) _at_ 50 W h
• Portable battery charging _at_ 50 W h

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Feasibility Analysis
Daily Source (W h) Solar energy
production 400 Total energy use allocation
397 Lighting 60 Pump/motor 187 Com
puter/communications 50 Refrigerator
50 Portable battery charging 50 Energy
storage 12V AGM lead acid battery rated at 66 A
h (one day supply for 50 discharge)
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Feasibility Analysis

• Commercial Off The Shelf (COTS)
• SunWize Systems model DC30 75/100
• Manufacturer suggested retail price 1469
• Solar power generator system
• Self-contained 12V DC with battery storage
• 190 W h with input solar radiation of 4 K w h /
  day
• Marketed for emergency power applications
• AC output models available

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Five Year Plan for Development

• Summary of development process
• First three years for prototype development
• Three generations at one year for each
• Use of Electric Power Institute for
  administration
• Last two years for field testing
• Five years for completed design and testing
• Includes business plan, documentation and
  dissemination

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Five Year Plan for Development

• First year activities
• First generation functional design
• Use of 20-101 power senior project lab
• Set up development environment
• FPGA and uclinux OS
• Using EE/CPE senior project and thesis
• Prototype goal satisfy all functional
  requirements
• Marketing plans with OCOB students
• Winter 06 client for BUS 454 Developing and
  Presenting Marketing Plans/Senior Project
• At least three marketing plans proposed
• USA investors for SuPER development
• Indigenous entrepreneurs business opportunity
• Indigenous consumers for SuPER system

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Five Year Plan for Development

• Second year activities
• Second generation prototype addressing
• modularity, manufacturing, reliability,
  maintainability, cost, packaging
• Development of involvement of student clubs
• Extensive system testing and evaluation
• Initiation of business plan
• Establishment of DC standards forum

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Five Year Plan for Development

• Third year of activities
• Third generation SuPER prototype addressing
• Packaging
• Satisfies all functional and performance
  requirements
• Cost requirements satisfied
• Extensive testing and evaluation
• Complete open source documentation of SuPER
  System GPL compliant
• Growth of DC standard forum development
  activities
• Business plans disseminated
• Targeted entrepreneurs within countries of
  interest
• Plan for field testing in fourth year
• Potential of Navajo Nation developed

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Five Year Plan for Development

• Fourth and fifth year of activities
• Assessment of SuPER system
• Improvement of design and construction
• MTBF of 25 years, MTTR of 1 hour
• 20 year lifecycle cost
• Update of SuPER system open source documentation
• Pilot projects initiated and evaluated
• DC standards forum publishes DC standard
• Revised business plan disseminated

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Faculty Participating on SuPER Project

• Administrated by Electric Power Institute
• Dr. Ahmad Nafisi, Director
• Collaboration with CENG Center for Sustainability
  in Engineering
• Dr. Deanna Richards, Director
• EE/CPE faculty initially involved
• Drs. James G. Harris, Ahmad Nafisi, Ali Shaban,
  Taufik
• OCOB faculty initially involved
• Dr. Doug Cerf, Associate Dean
• Dr. Norm Borin, Chair of Marketing Area

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Student Involvement

• EE graduate students for thesis work in system
  engineering
• Overall system requirements, design, integration
  and testing
• System design for status and control
• EE and CPE students for senior projects in
  subsystem development
• Design and testing of subsystems
• OCOB students for senior projects in BUS 454 for
  marketing plans
• Development of a Cal Poly SuPER team

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Student Involvement

• Initially work with resources available
• Adequate for start, just lengthens schedule
• Plan to acquire support for not only additional
  resources, but also students
• Faculty to provide continuing direction through
  generations of students working on SuPER
  project

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Facilities, Equipment and Resources

• Solar panel system available in EE Department
  see photo
• Development laboratory to be established in power
  senior project laboratory (20-101)
• Resources of Power Electronics Laboratory
  available (20-104)
• Basic infrastructure for system development
  exists at Cal Poly

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450-W 24-V Solar Panels on mobile station, 40-Amp
charge controller, Solar Boost MPPT, and 2 Deka
Solar Sealed Electrolyte Batteries lab also has
a 3.5 kW Outback All-In-One (MPPT, Charge
Controller, and Inverter) to accommodate future
expansion of the solar panel system.
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Status and Plans - foundations

• Support solicited over summer from foundations
• MacArthur
• Rockefeller Brothers
• Energy Foundation
• Ford
• Hewlett
• Packard
• Clairborne (Liz) and Art Ortenbery
• Gates
• Kaufman
• it does not fall within either of their current
  funding priorities and/or guidelines.

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Status and Plans - NSF

• Submitted proposal to National Science Foundation
  on September 23, 2005
• RUI Development of Sustainable Power for
  Electrical Resources SuPER System
• Research in Undergraduate Institutions (RUI)
  Program Announcement within its Faculty Research
  Projects area for three years and total of 240K
• Submitted to Control, Networks Computation
  Intelligence (CCNI) program within Electrical
  Communications and Systems (ECS) Division of the
  Engineering Directorate

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Status and Plans - start

• Initiate the effort with existing resources
• Senior projects and thesis work
• Engineering technical
• Business economic
• Establish DC web-based forum
• Continue to involve other faculty and students

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Why? Broader Impact of SuPER Project

• Provides family owned electrical power source
• Only electrical power source for family
• Increasing power resource with time
• With financial business plan 2-3 per month for
  all electrical power needs
• Decentralized, sustainable development of
  electrical power in poorest countries
• SuPER system potential resource for raising
  standard of living of poorest to par with rest of
  world

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Broader Impact

• Priority and focus on developing sustainable
  electrical resource for poorest people
• Success will provide model for people in
  developed nations
• Recognize commitment to status quo
• Centralized AC power generation with distribution
• Review current PGE bill
• Replace with sustainable distributed DC power

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Interested in Participating?

• Check out SuPER website http//www.ee.calpoly.edu
  /jharris/research/research.html
• Announcement of opportunities
• White Paper
• Graduate Seminar Presentation
• Visit with faculty involved
• EE Jim Harris, Ahmad Nafisi, Ali Shaban, Taufik
• OCOB Doug Cerf, Norm Borin

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References

• 1. George Constable, Bob Somerville A Century of
  Innovation Twenty Engineering Achievements that
  Transformed our Lives National Academy of
  Engineering 2003 overview available at
  http//www.greatachievements.org/
• 2. Jonathan O.V. Touryan, Kenell J. Touryan
  "Renewable Energy for
• Sustainable Rural Village Power" Presented at
  the American Scientific Affiliation
• Conference Arkansas August 1999, available from
  NREL as NREL/CP-720-26871
• hybrid system for nrel village power program
  report
• 3. Begay-Campbell, Sandia National Laboratories
  "Sustainable Hybrid System Deployment with the
  Navajo Tribal Utility Authority" NCPV and Solar
  Program Review Meeting 2003 NREL/CD-520-33586
  Page 541 available at http//www.nrel.gov/ncpv_pr
  m/pdfs/33586073.pdf estimated date 2003,
  describes program resulting from "On November 5,
  2001, President Bush signed the Navajo Nation
  Electrification Demonstration Program (Section
  602, Public Law 106-511) into Law. This law
  directs the Secretary of Energy to establish a
  5-year program to assist the Navajo Nation in
  meeting its electricity needs for the estimated
  18,000 occupied structures on the Navajo Nation
  that lack electric power."
• 4. Thomas P. Hughes Networks of Power
  Electrification in Western Society, 1880-1930
  Baltimore Johns Hopkins University Press, 1983
• 5. Thomas P. Hughes American Genesis A Century
  of Invention and Technological Enthusiasm
  1870-1970 Penguin Books 1989
• 6. David Nye Electrifying America Social
  Meanings of a New Technology, 1880-1940 MIT
  Press 1990

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References

• 7. Antonio C. Jimenez, Tom Lawand "Renewable
  Energy for Rural Schools" National Renewable
  Energy Laboratory November 2000
• report from village power program at nrel
  covers all renewable sources
• 8. April Allderdice, John H. Rogers Renewable
  Energy for Microenterprise NREL November 2000
  available from http//www.gvep.org/content/article
  /detail/8508
• microfinance introduction for renewable energy
  in underdevelopment countries
• 9. Ulrich Stutenbaumer, Tesfaye Negash, Amensisa
  Abdi "Performance of small scale photovoltaic
  systems and their potential for rural
  electrification in Ethiopia" Renewable Energy
  18 (1999) pp 35-48
• authored by locals, but dated example of
  early recognition of possibilities
• 10. Sunwize Technologies http//www.sunwize.com/
  insolation map available at
  http//www.sunwize.com/info_center/insolmap.htm
• on-line catalog and interactive planning
  support global insolation map
• 11. Evan Mills "The Specter of Fuel-Based
  Lighting" Science v. 308, 27 May 2005, pp
  1263-1264
• 12. E. Fred Schubert, Jong Kyu Kim "Solid-State
  Light Sources Getting Smart" Science v. 308, 27
  May 2005, pp 1274-1278
• 13. Thurton, J.P. and Stafford, B "Successful
  Design of PV Power Systems for Solid-State
  Lighting Applications" Fourth International
  Conference on Solid State Lighting 3-6 August,
  2004, Denver. Colorado / Proc. of SPIE v. 5530
  2004 pp284-295
• mainly lessons learned

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References

• 14. MIT Media Lab http//laptop.media.mit.edu/
• 15. Sandia National Laboratories, Solar Programs
  and Technologies Department Southwest Technology
  Development Institute, New Mexico State
  University Daystar, Inc., Las Cruces, NM
  "Stand-Alone Photovoltaic Systems A Handbook of
  Recommended Design Practices" Sandia National
  Laboratories, SAND87-7023 Updated July 2003
• revised handbook first published in 1988
• 16. Kyocera Solar, Inc., Solar Electric Products
  Catalog , August 2005
• available on web prices for small modules
  only
• 17. IEA PVPS International Energy Agency
  Implementing Agreement on Photovoltaic Power
  Systems Task 3 Use of Photovoltaic Power Systems
  in Stand-Alone and Island
• Applications Report IEA PVPS T3-09 2002 "Use of
  appliances in Stand-Alone PV Power supply
  systems problems and solutions September 2002
• dos and don'ts for design
• 18. Alison Wilshaw, Lucy Southgate Rolf Oldach
  "Quality Management of Stand Alone PV Systems
  Recommended Practices" IEA Task 3,
  www.task3.pvps.iea.org
• another report of iea agreement
• 19. Martin A. Green "Silicon Photovoltaic
  Modules A Brief History of the First
• 50 Years" Prog. Photovolt Res. Appl. 2005
  13447455 (Published online 18 April 2005 in
  Wiley InterScience (www.interscience.wiley.com).
  DOI 10.1002/pip.612)
• history and use of moore's law with darpa rfp
  also figure
• 20. Defense Advanced Research Projects Agency
  (DARPA) BAA05-21 posted Feb. 25, 2005 RFPVery
  High Efficiency Solar Cell (VHESC) program
  announcement with deadline on 3/29/2005, which
  will be open at least a year from this date see
  http//www.darpa.mil/ato/solicit/VHESC/index.htm
  

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References

• 21. H. Spanggaard, F.C. Krebs "A brief history
  of the development of organic and
• polymeric photovoltaics" Solar Energy Materials
  Solar Cells 83 (2004) 125146
• overview in context of inorganic (si) pv's)
• 22. T. Givler, P. Lilienthal "Using HOMER
  Software, NRELs Micropower Optimization Model,
  to Explore the Role of Gen-sets in Small Solar
  Power Systems Case Study Sri Lanka" Technical
  Report NREL/TP-710-36774 May 2005.
• 23. David L. King, Thomas D. Hund, William E.
  Boyson, Mark E. Ralph, Marlene Brown, Ron Orozco
  "Experimental Optimization of the FireFly. 600
  Photovoltaic Off-Grid System" Sandia National
  Laboratories, SAND2003-3493 October 2003
• system and component test with ac inverter
  measurement parameters standards and codes
  identified, e.g., grounding
• 24. R. Akkaya, A. A. Kulaksiz "A
  microcontroller-based stand-alone photovoltaic
  power system for residential appliances" Applied
  Energy 78 (2004) 419431 available at
• www.elsevier.com/locate/apenergy
• microbased control, but focused on AC output

47
References

• 25. Angel V. Peterchev, Seth R. Sanders
  "Digital Loss-Minimizing Multi-Mode Synchronous
  Buck Converter Control" 2004 35th Annual IEEE
  Power Electronics Specialists Conference Aachen,
  Germany, 2004
• dc to dc for cell phone/computer using
  digital techniques
• 26. Jason Hatashita, "Evaluation of a Network
  Co-processing Architecture Implemented in
  Programmable Hardware." EE MS Thesis, February
  2002 available at http//www.netprl.calpoly.edu/f
  iles/phatfile/papers/masters/jasonH.pdf
• 27. Homepage for Cal Poly Marketing Program
  http//buiznt.cob.calpoly.edu/cob/Mktg/Borin/
  see client application in lower right hand space
• 28. EE 460/463/464 Senior Seminar/Senior Project
  Handbook available at
• http//www.ee.calpoly.edu/listings/29/sphand.pdf
  
• 29. Muhammad H. Rashid Power Electronics
  Circuits, Devices and Applications(3rd Edition)
  Prentice-Hall 2004