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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

A summary of the Hanford single-shell tank structural analysis of record - 15526

Washington River Protection Solutions, LLC (WRPS), the US DOE Hanford Site tank contractor, developed an enhanced Single-Shell Tank Integrity Project (SSTIP) in 2009 to better understand the integrity of the single-shell tanks (SSTs). A panel of experts from industry and academia was created to recommend project activities in four main areas: structural integrity, liner degradation, leak integrity and prevention, and contamination migration. One of the panel's primary recommendations was to perform a detailed structural integrity analysis of the SSTs. WRPS and the U.S. Department of Energy, Office of River Protection commissioned the Pacific Northwest National Laboratory (PNNL) to perform this structural integrity analysis of record for the Hanford single shell tanks. This is one of seventeen panel recommendations that form the M-45-10-1 Change Package for the Hanford Federal Agreement and Compliance Order; also known as the Tri-Party Agreement. Finite element analysis was used to predict the structural response of the SSTs to the historical thermal and operating loads, plus design basis seismic loads. Bounding thermal histories were established from waste temperature records and applied to the model to include the thermal degradation of concrete modulus and strength, plus cracking due to differential thermal expansion while under in situ static loading conditions. PNNL contracted with Becht Engineering to evaluate the dynamic response of the tanks to a design basis earthquake. The degraded stiffness of the reinforced concrete was also incorporated in the seismic analysis. The combined response to static and seismic loads was then evaluated against the design requirements of the American Concrete Institute standard, ACI-349-06, for nuclear safety-related concrete structures. Specific analyses were performed for the four major tank designs.This paper presents an overview of the analysis methods used and it summarizes the major analytical findings that are common to the tanks and others that are specific to the individual tank designs. The analyses of record determined that including the bounding effects of their operating histories, each tank design currently satisfies the ACI-349-06 structural integrity design requirements. Although leak tightness is not directly addressed in the structural integrity analysis, this analysis will be a key input in the formal tank integrity assessment due in 2018. (authors)

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DOE OSTI2013

Risks from Past, Current, and Potential Hanford Single Shell Tank Leaks

Due to significant delays in constructing and operating the Waste Treatment Plant, which is needed to support retrieval of waste from Hanford’s single shell tanks (SSTs), SSTs may now be required to store tank waste for two to three more decades into the future. Many SSTs were built almost 70 years ago, and all SSTs are well beyond their design lives. Recent examination of monitoring data suggests several of the tanks, which underwent interim stabilization a decade or more ago, may be leaking small amounts (perhaps 150–300 gallons per year) to the subsurface environment. A potential leak from tank T-111 is estimated to have released approximately 2,000 gallons into the subsurface. Observations of past leak events, recently published simulation results, and new simulations all suggest that recent leaks are unlikely to affect underlying groundwater above regulatory limits. However, these recent observations remind us that much larger source terms are still contained in the tanks and are also present in the vadose zone from historical intentional and unintentional releases. Recently there have been significant improvements in methods for detecting and characterizing soil moisture and contaminant releases, understanding and controlling mass-flux, and remediating deep vadose zone and groundwater plumes. To ensure extended safe storage of tank waste in SSTs, the following actions are recommended: 1) Improve capabilities for intrusion and leak detection. 2) Develop defensible conceptual models of intrusion and leak mechanisms. 3) Apply enhanced subsurface characterization methods to improve detection and quantification of moisture changes beneath tanks. 4) Maintain a flux-based assessment of past, present, and potential tank leaks to assess risks and to maintain priorities for applying mitigation actions. 5) Implement and maintain effective mitigation and remediation actions to protect groundwater resources. These actions will enable limited resources to be applied to the most beneficial actions. A systems-based approach will support extended safe storage of tank waste, reduce the risks from tank leaks, and protect human health and the environment.

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DOE OSTI2012

Evolution of chemical conditions and estimated solubility controls on radionuclides in the residual waste layer during post-closure aging of high-level waste tanks

This document provides information specific to H-Area waste tanks that enables a flow and transport model with limited chemical capabilities to account for varying waste release from the tanks through time. The basis for varying waste release is solubilities of radionuclides that change as pore fluids passing through the waste change in composition. Pore fluid compositions in various stages were generated by simulations of tank grout degradation. The first part of the document describes simulations of the degradation of the reducing grout in post-closure tanks. These simulations assume flow is predominantly through a water saturated porous medium. The infiltrating fluid that reacts with the grout is assumed to be fluid that has passed through the closure cap and into the tank. The results are three stages of degradation referred to as Reduced Region II, Oxidized Region II, and Oxidized Region III. A reaction path model was used so that the transitions between each stage are noted by numbers of pore volumes of infiltrating fluid reacted. The number of pore volumes to each transition can then be converted to time within a flow and transport model. The bottoms of some tanks in H-Area are below the water table requiring a different conceptual model for grout degradation. For these simulations the reacting fluid was assumed to be 10% infiltrate through the closure cap and 90% groundwater. These simulations produce an additional four pore fluid compositions referred to as Conditions A through D and were intended to simulate varying degrees of groundwater influence. The most probable degradation path for the submerged tanks is Condition C to Condition D to Oxidized Region III and eventually to Condition A. Solubilities for Condition A are estimated in the text for use in sensitivity analyses if needed. However, the grout degradation simulations did not include sufficient pore volumes of infiltrating fluid for the grout to evolve to Condition A. Solubility controls for use in a flow and transport model were estimated for 27 elements in each of the chemical stages generated in the grout simulations plus local groundwater. The grout simulations were run with the initial infiltrating fluid in equilibrium with atmospheric oxygen to account for degradation of the reduction capacity of the grout. However, a lower Eh was used in pore fluids in the oxidizing conditions used to estimate solubilities to be more consistent with measured Eh values and natural systems. Solubilities of plutonium are affected by this decision, but those of other elements are not. In addition, the baseline for H-Area tanks is that they will be washed with oxalic acid prior to being filled with grout. Hence, oxalate was included in the pore fluids by assuming equilibrium with calcium oxalate. Solubility estimates were done by equilibrating a solubility controlling phase for each element with the pore fluid compositions using The Geochemist’s Workbench®. Condition B pore fluids are similar to Condition D. Therefore, solubilities for Condition B were not estimated, but assumed to be the same as in Condition D. In general solubility controlling phases were selected to bias solubilities to higher values. Several elements had no solubility controls and solubility estimates for other elements were omitted because the elements had short half-lives or were present in residual waste in very low amounts. For these it is recommended that release from the tank be instantaneous when the tank liner is breached. There is considerable uncertainty in this approach to enabling a flow and transport model to account for variable waste release. Yet, it is also flexible and requires much less computing time than a fully coupled reactive transport model. This allows some of the uncertainty to be addressed by multiple flow and transport sensitivity cases. Some of the uncertainties are addressed within this document. These include uncertainty in infiltrate composition, grout mineralogy, and disposition of certain components during the simulations. Uncertainty in the solubility estimates is addressed in part by examining sensitivity of solubilities for four key elements to uncertainty in thermodynamic data, pH, Eh, total inorganic carbon concentration, and oxalate concentration. In addition, the solubilities for the elements estimated here are compared to two other compilations of solubilities in cementitious materials.

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DOE OSTI2014

Lifecycle Verification of Tank Liner Polymers

This report describes a method that was developed for the purpose of assessing the durability of thermoplastic liners used in a Type IV hydrogen storage tank during the tank s expected service life. In the method, a thermoplastic liner specimen is cycled between the maximum and minimum expected working temperatures while it is differentially pressurized with high-pressure hydrogen gas. The number of thermal cycling intervals corresponds to those expected within the tank s design lifetime. At prescribed intervals, hydrogen permeation measurements are done in situ to assess the ability of the liner specimen to maintain its hydrogen barrier properties and to model its permeability over the tank lifetime. Finally, the model is used to assess whether the steady-state leakage rate in the tank could potentially exceed the leakage specification for hydrogen fuel cell passenger vehicles. A durability assessment was performed on a specimen of high-density polyethylene (HDPE) that is in current use as a tank liner. Hydrogen permeation measurements were performed on several additional tank liner polymers as well as novel polymers proposed for use as storage tank liners and hydrogen barrier materials. The following technical barriers from the Fuel Cell Technologies Program MYRDD were addressed by the project: D. Durability of on-board storage systems lifetime of at least 1500 cycles G. Materials of construction vessel containment that is resistant to hydrogen permeation M. Lack of Tank Performance Data and Understanding of Failure Mechanisms And the following technical targets1 for on-board hydrogen storage systems R&D were likewise addressed: Operational cycle life (1/4 tank to full) FY 2017: 1500 cycles; Ultimate: 1500 cycles Environmental health & safety Permeation and leakage: Meets or exceeds applicable standards Loss of useable H2: FY 2017: 0.05 g/h/kg H2; Ultimate: 0.05 g/h/kg H2

hydrogen permeation polymer temperature cycling du↗
DOE OSTI2013

Testing of Alternative Abrasives for Water-Jet Cutting at C Tank Farm

Legacy waste from defense-related activities at the Hanford Site has predominantly been stored in underground tanks, some of which have leaked; others may be at risk to do so. The U.S. Department of Energy’s goal is to empty the tanks and transform their contents into more stable waste forms. To do so requires breaking up, and creating a slurry from, solid wastes in the bottoms of the tanks. A technology developed for this purpose is the Mobile Arm Retrieval System. This system is being used at some of the older single shell tanks at C tank farm. As originally planned, access ports for the Mobile Arm Retrieval System were to be cut using a high- pressure water-jet cutter. However, water alone was found to be insufficient to allow effective cutting of the steel-reinforced tank lids, especially when cutting the steel reinforcing bar (“rebar”). The abrasive added in cutting the hole in Tank C-107 was garnet, a complex natural aluminosilicate. The hardness of garnet (Mohs hardness ranging from H 6.5 to 7.5) exceeds that of solids currently in the tanks, and was regarded to be a threat to Hanford Waste Treatment and Immobilization Plant systems. Olivine, an iron-magnesium silicate that is nearly as hard as garnet (H 6.5 to 7), has been proposed as an alternative to garnet. Pacific Northwest National Laboratory proposed to test pyrite (FeS 2 ), whose hardness is slightly less (H 6 to 6.5) for 1) cutting effectiveness, and 2) propensity to dissolve (or disintegrate by chemical reaction) in chemical conditions similar to those of tank waste solutions. Cutting experiments were conducted using an air abrader system and a National Institute of Standards and Technology Standard Reference Material (SRM 1767 Low Alloy Steel), which was used as a surrogate for rebar. The cutting efficacy of pyrite was compared with that of garnet and olivine in identical size fractions. Garnet was found to be most effective in removing steel from the target; olivine and pyrite were less effective, but about equal to each other. The reactivity of pyrite, compared to olivine and garnet, was studied in high-pH, simulated tank waste solutions in a series of bench-top experiments. Variations in temperature, degree of agitation, grain size, exposure to air, and presence of nitrate and nitrite were also studied. Olivine and garnet showed no sign of dissolution or other reaction. Pyrite was shown to react with the fluids in even its coarsest variation (150-1000 μm). Projected times to total dissolution for most experiments range from months to ca. 12 years, and the strongest control on reaction rate is the grain size.

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DOE OSTI2019

Investigation of thermolytic hydrogen generation rate of tank farm simulated and actual waste

To support resolution of Potential Inadequacies in the Safety Analysis for the Savannah River Site (SRS) Tank Farm, Savannah River National Laboratory conducted research to determine the thermolytic hydrogen generation rate (HGR) with simulated and actual waste. Gas chromatography methods were developed and used with air-purged flow systems to quantify hydrogen generation from heated simulated and actual waste at rates applicable to the Tank Farm Documented Safety Analysis (DSA). Initial simulant tests with a simple salt solution plus sodium glycolate demonstrated the behavior of the test apparatus by replicating known HGR kinetics. Additional simulant tests with the simple salt solution excluding organics apart from contaminants provided measurement of the detection and quantification limits for the apparatus with respect to hydrogen generation. Testing included a measurement of HGR on actual SRS tank waste from Tank 38. A final series of measurements examined HGR for a simulant with the most common SRS Tank Farm organics at temperatures up to 140 °C. The following conclusions result from this testing. HGR was measured for an actual-waste Tank 38 sample. The HGR measurements at 80, 90, 100, and 110 °C were 1.7×10 -7 , 4.7×10 -7 , 5.9×10 -7 , and 2.6×10 -6 ft 3 hr -1 gal -1 , respectively. The Limit of Detection and Limit of Quantification for the HGR measurements were 2.6×10-8 ft3 hr-1 gal-1 and 5.1×10 -8 ft 3 hr -1 gal -1 , respectively. HGR was measured in a high boiling point (HBP) simulant with major known SRS Tank Farm organic compounds. Testing used fresh organics and did not simulate the long-term exposure of these organics already experienced in the waste. Hence, testing is expected to provide high bias to the hydrogen generation rates. The final HGR measurements at 75, 100, and 140 °C were 6.2×10 -7 , 3.0×10 -6 , and 8.1×10 -5 ft 3 hr -1 gal -1 , respectively. Decreases in the HGR were noted at isothermal conditions with steady gas tracer concentration, which clouds development of a temperature dependent correlation for generation rate. While the simulant contains high concentrations of major SRS organics tested at high temperatures found in the 3H Evaporator, this limited data set may not fully bound values under all possible operating conditions. The HGR measurement apparatus was successfully employed to replicate hydrogen production rate experiments. Simulant without deliberately added organic carbon was found to contain approximately 200 mg/L of organic carbon from tramp organics in the reagents used to prepare the solution. The tests using such simulant generated hydrogen at rates consistent with, but somewhat lower than, those predicted at equivalent carbon and aluminum loadings by methods used at the Hanford Site. Prior to identifying the organic contaminants, potential sources of hydrogen in simulants without deliberately added organic carbon were examined. Testing determined that this hydrogen is not due to caustic reaction of organic materials of construction within the reaction vessel, electrolysis due to current leak, anode/cathode reactions, corrosion, or the method of heating employed in the experiment. During the HBP and Tank 38 testing, a peak was identified at a retention time greater than the retention time of the inert tracer of krypton. This peak has been identified as methane, and the data have been reexamined to obtain methane concentrations. For the HBP testing, methane concentration was constant at the highest temperature studied (140 °C) and higher than hydrogen. At the lower temperatures (100 and 75 °C), methane and hydrogen tracked closely, with methane concentration generally lower than hydrogen. For Tank 38, methane concentration was approximately 1/3 of the hydrogen concentration during testing (100 and 110 °C). At lower temperatures for Tank 38 testing (90, 80, and 27 °C), methane fell below the quantification range.

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DOE OSTI2020

ZAM Modeling Study to Support the Tank Closure Cesium Removal (TCCR) 1A Unit

Currently at the Savannah River Site (SRS), the Tank Closure Cesium Removal (TCCR) is an “at-tank” process designed to remove cesium from aqueous tank waste. Cesium will be removed by ion exchange using the engineered IONSIV® R9120 form of Crystalline Silicotitanate (CST) media. The current TCCR design has two columns online in a lead-lag configuration to optimize media usage and achieve the target decontamination. Once the lead column is saturated with cesium, it will be removed from service, the lag column will rotate into the lead position, and a new column with fresh ion-exchange media will be placed into the lag position. The TCCR process for cesium removal from Tank 10H is detailed in X-SOW-H- 00002. Demonstration of the system began in early calendar year 2019 with two batches of salt solution generated by dissolving saltcake in Tank 10H, followed by processing of these batches through the TCCR system. A third TCCR Tank 10H dissolved saltcake batch is scheduled for processing soon. Upon completion of the demonstration with Tank 10H dissolved saltcake, Tank 9H salt solution will be transferred to Tank 10H and subsequently processed through the TCCR unit with new CST media (referred to as R9120-B 30x60) added to new IX columns. The TCCR processing campaign of Tank 9H salt solution is referred to as TCCR-1A .

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DOE OSTI2021

Tank 48H Tetraphenylborate Mitigation: Simulant Studies using Sodium Permanganate

Tank 48H currently holds legacy material containing organic tetraphenylborate (TPB) compounds from the operation of the In-Tank Precipitation (ITP) process. TPB was added during the ITP process to precipitate the otherwise soluble cesium as insoluble cesium TPB (CsTPB), but excessive benzene generation from TPB degradation curtailed this treatment method. The contents of Tank 48H, which include approximately 26.000 kg of potassium TPB (KTPB) and trace CsTPB, are not compatible with the waste treatment facilities at the Savannah River Site (SRS) since the organic content and the associated flammability issues pose a challenge to the salt processing and sludge processing facilities within the liquid waste system. An in-tank process to remove (or decompose) TPB safely would be of great value. Previous testing at Savannah River National Laboratory (SRNL) demonstrated the destruction of glycolate via chemical oxidation using sodium permanganate with simulated and radioactive waste. Scoping tests were performed to study the destruction of TPB to determine if the contents of Tank 48H would be amenable to the same type of destruction. Partial destruction of TPB was observed in Tank 48H simulants under mild conditions (e g., pH 11, room temperature) with no definitive indication of benzene generation. To build upon the success of the scoping tests, an additional study was requested to provide a better understanding of the underlying chemistry for Tank 48H content destruction using sodium permanganate. Three experiments were performed with Tank 48H simulants at 40 °C to determine the efficacy of using sodium permanganate for TPB destruction. Three starting pH values were selected: 1) pH 11 for comparison with the previous work at room temperature, 2) pH 10 as the minimum pH recommended by the Corrosion Control Program (CCP) for in-tank processing, and 3) pH 8 to determine the effectiveness of TPB destruction at near neutral pH. While below the allowable pH for the CCP, the experiment at pH 8 was performed to study the TPB-Permanganate reaction under more extreme conditions and further verify the potential for out-of-tank processing.

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DOE OSTI2024

Sludge Batch 11 Assembly: Tank 51

Savannah River Mission Completion (SRMC) Nuclear Safety and Engineering Integration has requested that Savannah River National Laboratory (SRNL) perform Tank 51 characterization analyses in support of Sludge Batch 11 (SB11) assembly. This report provides important characterization of the slurry in Tank 51 after transfers from Tank 22, Tank 35, and Tank 13 (post Tank 15 to Tank 13 transfer) to Tank 51 that demonstrates the sludge concurs with the estimated transfer mass for the SB11 recipe. A total of 3 sets of Tank 51 samples were delivered to SRNL from March 2023 to February 2024. The composite sample was analyzed for the following: density, weight percent solids, chemical composition, radionuclides, and supernate corrosion control analyses. The results of the Tank 51 samples are consistent with and representative of expected sludge projections for Sludge Batch 11.

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NASA NTRS1990

Design considerations for honeycomb double-bubble tanks utilized in aerospace vehicles

Future earth-to-orbit vehicles will utilize reusable internal fuel tanks requiring most of the vehicle volume. Because weight reduction and volumetric efficiency are essential, these tanks will be integral to the vehicle structure, and the vehicle cross section will dictate the size and shape of the tank. For a fuselage with a noncircular cross section, a multibubble tank configuration may be employed. Multibubble tanks offer a reduction in tank weight over a single-lobe tank or several cylindrical tanks in a noncircular cross section but sacrifice the efficiency of utilizing the entire fuselage cross section. This paper includes a general configuration analysis of a double-bubble tank, a materials and efficiency study, and a complete mission design analysis centers on sizing the tank to withstand ascent and reentry loads while minimizing the structural weight.

Lentz, Christopher A.↗
NASA NTRS1994

Experimental Investigation of Jet-Induced Mixing of a Large Liquid Hydrogen Storage Tank

Experiments have been conducted to investigate the effect of fluid mixing on the depressurization of a large liquid hydrogen storage tank. The test tank is approximately ellipsoidal, having a volume of 4.89 m(exp 3) and an average wall heat flux of 4.2 W/m(exp 2) due to external heat input. A mixer unit was installed near the bottom of the tank to generate an upward directed axial jet flow normal to the liquid-vapor interface. Mixing tests were initiated after achieving thermally stratified conditions in the tank either by the introduction of hydrogen gas into the tank or by self-pressurization due to ambient heat leak through the tank wall. The subcooled liquid jet directed towards the liquid-vapor interface by the mixer induced vapor condensation and caused a reduction in tank pressure. Tests were conducted at two jet submergence depths for jet Reynolds numbers from 80,000 to 495,000 and Richardson numbers from 0.014 to 0.52. Results show that the rate of tank pressure change is controlled by the competing effects of subcooled jet flow and the free convection boundary layer flow due to external tank wall heating. It is shown that existing correlations for mixing time and vapor condensation rate based on small scale tanks may not be applicable to large scale liquid hydrogen systems.

Lin, C. S.↗
NASA NTRS2010

Water Tank with Capillary Air/Liquid Separation

A bladderless water tank (see figure) has been developed that contains capillary devices that allow it to be filled and emptied, as needed, in microgravity. When filled with water, the tank shields human occupants of a spacecraft against cosmic radiation. A membrane that is permeable by air but is hydrophobic (neither wettable nor permeable by liquid water) covers one inside surface of the tank. Grooves between the surface and the membrane allow air to flow through vent holes in the surface as the tank is filled or drained. A margin of wettable surface surrounds the edges of the membrane, and all the other inside tank surfaces are also wettable. A fill/drain port is located in one corner of the tank and is covered with a hydrophilic membrane. As filling begins, water runs from the hydrophilic membrane into the corner fillets of the tank walls. Continued filling in the absence of gravity will result in a single contiguous air bubble that will be vented through the hydrophobic membrane. The bubble will be reduced in size until it becomes spherical and smaller than the tank thickness. Draining the tank reverses the process. Air is introduced through the hydrophobic membrane, and liquid continuity is maintained with the fill/drain port through the corner fillets. Even after the tank is emptied, as long as the suction pressure on the hydrophilic membrane does not exceed its bubble point, no air will be drawn into the liquid line.

Ungar, Eugene K.↗
NASA NTRS2006

Multifunctional Tanks for Spacecraft

A document discusses multifunctional tanks as means to integrate additional structural and functional efficiencies into designs of spacecraft. Whereas spacecraft tanks are traditionally designed primarily to store fluids and only secondarily to provide other benefits, multifunctional tanks are designed to simultaneously provide multiple primary benefits. In addition to one or more chamber(s) for storage of fluids, a multifunctional tank could provide any or all of the following: a) Passageways for transferring the fluids; b) Part or all of the primary structure of a spacecraft; c) All or part of an enclosure; d) Mechanical interfaces to components, subsystems, and/or systems; e) Paths and surfaces for transferring heat; f)Shielding against space radiation; j) Shielding against electromagnetic interference; h) Electrically conductive paths and surfaces; and i) Shades and baffles to protect against sunlight and/or other undesired light. Many different multifunctional-tank designs are conceivable. The design of a particular tank can be tailored to the requirements for the spacecraft in which the tank is to be installed. For example, the walls of the tank can be flat or curved or have more complicated shapes, and the tank can include an internal structure for strengthening the tank and/or other uses.

Collins, David H.↗
NASA NTRS2004

Strain-Gauge Measurement of Weight of Fluid in a Tank

A method of determining the amount of fluid in a tank is based on measurement of strains induced in tank supports by the weight of the fluid. Unlike most prior methods, this method is nonintrusive: there is no need to insert instrumentation in the tank and, hence, no need to run wires, cables, or tubes through the tank wall. Also unlike most prior methods, this method is applicable even if the fluid in the tank is at supercritical pressure and temperature, because it does not depend on the presence of a liquid/gas interface (as in liquid-level-measuring methods). The strain gauges used in this method may be of two types: foil and fiber-optic. Four foil gauges (full bridge) are mounted on each of the tank-supporting legs. As the tank is filled or emptied, the deformation in each leg increases or decreases, respectively. Measured deformations of all legs are added to obtain a composite deformation indicative of the change in weight of the tank plus fluid. An initial calibration is performed by recording data at two points (usually, empty and full) for which the mass or weight of fluid is known. It is assumed that the deformations are elastic, so that the line passing through the two points can be used as a calibration curve of mass (or weight) of fluid versus deformation. One or more fiber-optic gauges may be used instead of the foil gauges. The resolution of the fiber-optic and foil gauges is approximately the same, but the fiber-optic gauges are immune to EMI (electromagnetic interference), are linear with respect to temperature over their entire dynamic range (as defined by the behavior of the sample), and measure thermally induced deformations as predictable signals. Conversely, long term testing has demonstrated that the foil gauges exhibit an erratic behavior whenever subjected to direct sun radiation (even if protected with a rubberized cover). Henceforth, for deployment in outdoor conditions, fiber-optic gauges are the only option if one is to rely on the system for an extended period of time when a recalibration procedure may not be acceptable. A set of foil gauges had been tested on the supports of a 500-gallon (1,900-liter) tank. The gauges were found to be capable of measuring the deformations (up to 22 micro-strain) that occurred during filling and emptying of the tank. The fluid masses calculated from the gauge readings were found to be accurate within 4.5 percent. However, the reliability of the foil gauges over a few hours was not acceptable. Therefore, the foil sensor system is acceptable for use only in controlled environments (complete shade, or indoors).

Figueroa, Jorge↗
NASA NTRS2011

External Tank Program - Legacy of Success

The largest single element of Space Shuttle is the External Tank (ET), which serves as the structural backbone of the vehicle during ascent and provides liquid propellants to the Orbiter s three Main Engines. The ET absorbs most of the seven million pounds of thrust exerted by the Solid Rocket Boosters and Main Engines. The design evolved through several block changes, reducing weight each time. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. The initial configuration, the standard weight tank, weighed 76,000 pounds and was an aluminum 2219 structure. The light weight tank weighed 66,000 pounds and flew 86 missions. The super light weight tank weighed 58,500 pounds and was primarily an aluminum-lithium structure. The final configuration and low weight enabled system level performance sufficient for assembly of the International Space Station in a high inclination orbit, vital for international cooperation. Another significant challenge was the minimization of ice formation on the cryogenic tanks. This was essential due to the system configuration and the choice of ceramic thermal protection system materials on the Orbiter. Ice would have been a major debris hazard. Spray on foam insulation materials served multiple functions including thermal insulation, conditioning of cryogenic propellants, and thermal protection for the tank structure during ascent and entry. The tank is large, and unique manufacturing facilities, tooling, and handling, and transportation operations were developed. Weld processes and tooling evolved with the design as it matured through several block changes. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the multi-decade program. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when hurricane Katrina damaged the manufacturing facility. Numerous lessons from these efforts, the manufacturing and material processing issues, the key design features, and evolution of the design will be discussed.

Pilet, Jeffery C.↗
NASA NTRS2011

Sloshing in Liquid Hydrogen and LOX Propellant Tanks After Main Engine Cut-off

NASA Marshall Space Flight Center is designing and developing the Main Propulsion System (MPS) for Ares launch vehicles. The objective of this study is to calculate the sloshing forces and moments in the LH2 and LO2 propellant tanks using a CFD/VOF analysis under realistic flight conditions. Propellant sloshing in the liquid hydrogen (LH2) and the liquid oxygen (LO2) propellant tanks after Main Engine Cut Off (MECO) was modeled using the Volume of Fluid (VOF) module of the computational fluid dynamics code, CFD-ACE+. The present simulation shows that there are substantial sloshing side forces acting on the LH2 tank during the deceleration of the vehicle after MECO. The LH2 tank features a side wall drain pipe. The side loads result from the residual propellant mass motion in the LH2 tank which is initiated by the stop of flow into the drain pipe at MECO. The simulations show that radial force on the LH2 tank wall is less than 50 lbf and the radial moment calculated based up the center of gravity of the vehicle is predicted to be as high as 300 lbf-ft. The LO2 tank features a bottom dome drain system and is equipped with sloshing baffles. The remaining LO2 in the tank slowly forms a liquid column along the centerline of tank under the zero gravity environments. The radial force on the LO2 tank wall is predicted less than 100 lbf. The radial moment calculated based on the center of gravity of the vehicle is predicted as high as 4500 lbf-ft just before MECO and dropped down to near zero after propellant draining stopped completely.

Kim, Sura↗
NASA NTRS2016

Wave Amplitude Dependent Engineering Model of Propellant Slosh in Spherical Tanks

Liquid propellant slosh is often a concern for the controllability of flight vehicles. Anti-slosh devices are traditionally included in propellant tank designs to limit the amount of sloshing allowed during flight. These devices and any necessary supports can be quite heavy to meet various structural requirements. Some of the burden on anti-slosh devices can be relieved by exploiting the nonlinear behavior of slosh waves in bare smooth wall tanks. A nonlinear regime slosh model for bare spherical tanks was developed through a joint analytical and experimental effort by NASA/MSFC. The developed slosh model accounts for the large damping inherent in nonlinear slosh waves which is more accurate and drives conservatism from vehicle stability analyses that use traditional bare tank slosh models. A more accurate slosh model will result in more realistic predicted slosh forces during flight reducing or removing the need for active controls during a maneuver or baffles in the tank design. Lower control gains and smaller or fewer tank baffles can reduce cost and system complexity while increasing vehicle performance. Both Computational Fluid Dynamics (CFD) simulation and slosh testing of three different spherical tank geometries were performed to develop the proposed slosh model. Several important findings were made during this effort in addition to determining the parameters to the nonlinear regime slosh model. The linear regime slosh damping trend for spherical tanks reported in NASA SP-106 was shown to be inaccurate for certain regions of a tank. Additionally, transition to the nonlinear regime for spherical tanks was only found to occur at very large wave amplitudes in the lower hemisphere and was a strong function of the propellant fill level in the upper hemisphere. The nonlinear regime damping trend was also found to be a function of the propellant fill level.

Brodnick, Jacob↗
NASA NTRSDate not supplied

Numerical Modeling of No Vent Filling of a Cryogenic Tank with Thermo-dynamic Vent System Assisted Injector

This paper presents a multi-node finite volume model of No Vent Filling (NVF) of a cryogenic tank with Thermo-dynamic Vent System (TVS) assisted injector, using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code. NVF tests were conducted in a CRYOgenic Orbital Testbed (CRYOTE) tank which was filled by liquid nitrogen using a TVS assisted injector with vent valve closed during the entire filling process. In TVS assisted injector, the liquid flow splits into two streams: one stream is routed to a Joule-Thomson (J-T) orifice where the flow immediately flashes from liquid to vapor or two phase mixture because the downstream to J-T leg is maintained at vacuum level.; the other stream is injected into the tank after being cooled by cold vapor of J-T leg in a heat exchanger. The flow through J-T leg is also used to cool the outer metal matrix of the injector which in turn cools the vapor in the tank ullage. The cooling of vapor in the ullage by cold injector surface reduces ullage pressure that allows liquid to enter and fill the tank. An integrated numerical model of the test set up was developed. The model included the dual lines of TVS assisted injector, tank and tank wall. The tank was discretized into multiple fluid nodes and branches to represent the ullage and liquid nitrogen and multiple solid nodes to represent the tank wall and structure. The heat transfer between solid to fluid was calculated from pool boiling correlations which include film, transition, and nucleate boiling, as well as natural convection during pre- and post-boiling. The model also accounts for the condensation of vapor at ullage-injector interface and when it comes in contact with the liquid spray. The predicted pressure, resident mass, wall temperature in the tank were compared with the test data.

Alok Majumdar↗