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At least 433 records · Page 24

Investigative techniques used to locate the liquid hydrogen leakage on the Space Shuttle Main Propulsion System

Standard leak detection methods at ambient temperature have been developed in order to prevent excessive leakage from the Space Shuttle liquid oxygen and liquid hydrogen Main Propulsion System. Unacceptable hydrogen leakage was encountered on the Columbia and Atlantis flight vehicles in the summer of 1990 after the standard leak check requirements had been satisfied. The leakage was only detectable when the fuel system was exposed to subcooled liquid hydrogen during External Tank loading operations. Special instrumentation and analytical tools were utilized during a series of propellant tanking tests in order to identify the sources of the hydrogen leakage. After the leaks were located and corrected, the physical characteristics of the leak sources were analyzed in an effort to understand how the discrepancies were introduced and why the leakage had evaded the standard leak detection methods. As a result of the post-leak analysis, corrective actions and leak detection improvements have been implemented in order to preclude a similar incident.

Hammock, William R., Jr.↗

Performance Gains of Propellant Management Devices for Liquid Hydrogen Depots

This paper presents background, experimental design, and preliminary experimental results for the liquid hydrogen bubble point tests conducted at the Cryogenic Components Cell 7 facility at the NASA Glenn Research Center in Cleveland, Ohio. The purpose of the test series was to investigate the parameters that affect liquid acquisition device (LAD) performance in a liquid hydrogen (LH2) propellant tank, to mitigate risk in the final design of the LAD for the Cryogenic Propellant Storage and Transfer Technology Demonstration Mission, and to provide insight into optimal LAD operation for future LH2 depots. Preliminary test results show an increase in performance and screen retention over the low reference LH2 bubble point value for a 325 2300 screen in three separate ways, thus improving fundamental LH2 LAD performance. By using a finer mesh screen, operating at a colder liquid temperature, and pressurizing with a noncondensible pressurant gas, a significant increase in margin is achieved in bubble point pressure for LH2 screen channel LADs.

Hartwig, Jason W.↗

Commonality Study of the Pressure-Volume-Temperature Based Propellant Gaging Software Modules for the Auxiliary Power Unit, Reaction Control System, and Orbital Maneuvering System

Computer storage requirements can be reduced if areas of commonality exist in two or more programs placed in the same computer and identical code can be used by more than one program. The pressure-volume-temperature (P-V-T) relationship for the propellant tank pressurant agent is utilized as the basis for either a primary of a backup propellant gaging program for the auxiliary power unit (APU), the reaction control system (RCS), and the orbital maneuvering system (OMS). These three propellant gaging programs were investigated. It was revealed that a very limited degree of software commonality exits among them. An examination of this common software indicated that only the computation of the helium compressibility factor in an external function subprogram accessible to both the RCS and OMS propellant gaging programs appears to offer a savings in computer storage requirements.

Duhon, D. D.↗

Generic propellant transfer unit: A project update

Currently, most satellite programs use dedicated hypergolic propellant ground servicing equipment. These 'carts' are typically program specific (non-interchangeable), costly, and non-Department of Transportation (DOT) compliant. They require safety waivers when used on government property and must be emptied before off-site transport. The emptying process usually generates large amounts of Hazardous Wastes. Fuel carts are usually loaded from multiple 208-liter (55 gallon) drums and oxidizer carts from 909-kg (2000 lb) cylinders. This further increases operating costs due to additional container samples and cart-filling transfers. NASA, Kennedy Space Center has developed reusable, generic, DOT compliant propellant delivery containers as possible replacements for the propellant-tank portion of servicing carts. Our ultimate goal is to reduce operating expenses by minimizing propellant transfers, samples, and waste generation through use of bulk propellant operations, minimizing drum or cylinder operations. This has the added benefit of increasing operating safety by decreasing overall propellant operations.

Davis, C. L.↗

Velocity control propulsion subsystem of the Radio Astronomy Explorer satellite for Goddard Space Flight Center

The Velocity Control Propulsion Subsystem (VCPS) was designed the propulsion required for trajectory and lunar orbit corrections of the spacecraft. A GFE clamp assembly physically attaches the VCPS to the spacecraft and the unit is ejected after completing the required corrections. The VCPS is physically and functionally separated from the spacecraft except for the electrical and telemetry interfaces. A GFE transtage provides the superstructure on which the VCPS is assembled. The subsystem consists of two 5 foot pound rocket engine assemblies, 4 propellant tanks, 2 latching valves, 2 fill and drain valves, a system filter, pressure transducer, gas and propellant manifolds and electrical heaters and thermostats. The RAE-B VCPS program covered the design, manufacture and qualification of one subsystem. This subsystem was to be manufactured, subjected to qualification tests; and refurbished, if necessary, prior to flight. The VCPS design and test program precluded the need for refurbishing the subsystem and the unit was delivered to GSFC at the conclusion of the program.

Braught, W.↗

An Analysis of Green Propulsion Applied to NASA Missions

The advantages of green propulsion for five mission classes are examined, including a Low Earth Orbit (LEO) mission (GPM), a Geosynchronous Earth Orbit (GEO) mission (SDO), a High Earth Orbit (HEO) mission (MMS), a lunar mission (LRO), and a planetary mission (MAVEN). The propellant mass benefits are considered for all five missions, as well as the effects on the tanks, propellant loading, thruster throughput, thermal considerations, and range requirements for both the AF-M315E and LMP-103S propellants.

Pocket Propulsion↗

Internal Architecture of the Common Habitat

The core stage liquid oxygen tank of the Space Launch System can be manufactured as a habitat instead of as a propellant tank, with a common design such that it is equally suitable for use in 0g, 1/6g, 3/8g, 1g, or variable artificial gravity. This Common Habitat can be the central element of a human spaceflight architecture that encompasses the Moon, Mars, and other destinations within the inner solar system. The Common Habitat is specifically used within an alternative architecture study (that is not part of the current NASA baseline) as the core habitation element within a Lunar Basecamp, Mars Basecamp, and the Deep Space Exploration Vehicle. The Common Habitat internal architecture applies a design philosophy to separate crew functions according to deck. The lower deck is reserved for private functions. It includes eight private crew quarters and four waste and hygiene clusters – each with a private waste management compartment, private full body hygiene compartment, and foyer/clothes changing area. The mid deck is primarily allocated to mission-related working functions. It includes an exercise facility, fabrication / maintenance / repair facility, physical science laboratory (physics, geology, and astronomy), and life science laboratory (biology and human research). The mid deck also has four external hatches, clocked one every 90 degrees, centered on the vehicle vertical centerline. Each hatch has a 60-inch tall by 40-inch wide opening with the mid deck floor 16 inches below the bottom lip of the hatch opening. The upper deck is primarily allocated to group or social functions. It includes a large galley, wardroom with projector and display screen, plant growth chambers, bulk stowage, command and control station, medical facility, hygiene compartment, and vehicle subsystems. A Vertical Translation System, based in part on results from a GrabCAD public challenge, enables crew and equipment traverse between habitat decks in 0g, 1/6g, 3/8g, and 1g. A 40-inch by 60-inch vertical translation corridor ensures that anything that can fit through the external hatches can also be moved from deck to deck. The system includes three component systems: a deploying floor to safety barrier system that folds down to become a traversable floor when vertical translation is not in use and deploys to become a safety barrier during vertical translations; a folding ladder that stows in the ceiling when not in use; and an elevator platform that can attach to the ladder for cargo or incapacitated crew member transport. This system is complemented by a Horizontal Translation System, also based in part on the same GrabCAD challenge, provides for horizontal crew translation in microgravity but requires no vehicle reconfiguration for fractional or whole gravity operation. It relies primarily on gecko-inspired grippers, originally developed at Stanford and NASA JPL, attached to footwear to enable crew to emulate walking. Some handrails are also strategically placed throughout the Common Habitat to aid translation in both gravity and microgravity environments.

Common Habitat↗

Internal Architecture of the Common Habitat

The core stage liquid oxygen tank of the Space Launch System can be manufactured as a habitat instead of as a propellant tank, with a common design such that it is equally suitable for use in 0g, 1/6g, 3/8g, 1g, or variable artificial gravity. It is capable of sustaining a crew size of eight for missions up to 1200 days in duration. This Common Habitat can be the central element of a human spaceflight architecture that encompasses the Moon, Mars, and other destinations within the inner solar system. Within this archtiecture, the Common Habitat is specifically used as the core habitation element within a Lunar Base Camp, Mars Base Camp, and the Deep Space Exploration Vehicle. The Common Habitat internal architecture applies a design philosophy to separate crew functions according to deck. The lower deck is reserved for private functions. It includes eight private crew quarters and four waste and hygiene clusters – each with a private waste management compartment, private full body hygiene compartment, and private foyer/clothes changing area. The mid deck is primarily allocated to mission-related functions. It includes an exercise facility, fabrication / maintenance / repair facility, physical science laboratory (physics, geology, and remote sensing: astronomy, heliophysics, planetary science, and Earth science), and life science laboratory (biology and human research). The mid deck also has four external hatches, clocked one every 90 degrees, centered on the vehicle vertical centerline. Each hatch has a 60-inch tall by 40-inch wide opening with the mid deck floor 16 inches below the bottom lip of the hatch opening. The upper deck also includes some mission functions, but is primarily allocated to social functions. It includes a large galley, wardroom with projector and display screen, plant growth chambers, bulk stowage, command and control station, medical facility, hygiene compartment, and vehicle subsystems.

Habitability↗

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗

Purging of a tank-mounted multilayer insulation system by gas diffusion

The investigation was conducted on a multilayer insulation (MLI) system mounted on a spherical liquid hydrogen propellant tank. The MLI consisted of two blankets of insulation each containing 15 double-aluminized Mylar radiation shields separated by double silk net spacers. The gaseous nitrogen initially contained within the MLI system and vacuum chamber was purged with gaseous helium introduced both underneath the MLI and into the vacuum chamber. The MLI panels were assumed to be purged primarily by means of gas diffusion. Overall, test results indicated that nitrogen concentrations well below 1 percent could be achieved everywhere within the MLI system. Typical times to achieve 1 percent nitrogen concentration within the MLI panels ranged from 69 minutes at the top of the tank to 158 minutes at the bottom of the tank. Four space-hold thermal performance tests indicated no significant thermal degradation of the MLI system had occurred due to the purge tests conducted. The final measured heat input attributed to the MLI was 7.23 watts as compared to 7.18 watts for the initial baseline thermal performance test.

Sumner, I. E.↗

Numerical Modeling of the Transient Chilldown Process of a Cryogenic Propellant Transfer Line

Before cryogenic fuel depots can be fully realized, efficient methods with which to chill down the spacecraft transfer line and receiver tank are required. This paper presents numerical modeling of the chilldown of a liquid hydrogen tank-to-tank propellant transfer line using the Generalized Fluid System Simulation Program (GFSSP). To compare with data from recently concluded turbulent LH2 chill down experiments, seven different cases were run across a range of inlet liquid temperatures and mass flow rates. Both trickle and pulse chill down methods were simulated. The GFSSP model qualitatively matches external skin mounted temperature readings, but large differences are shown between measured and predicted internal stream temperatures. Discrepancies are attributed to the simplified model correlation used to compute two-phase flow boiling heat transfer. Flow visualization from testing shows that the initial bottoming out of skin mounted sensors corresponds to annular flow, but that considerable time is required for the stream sensor to achieve steady state as the system moves through annular, churn, and bubbly flow. The GFSSP model does adequately well in tracking trends in the data but further work is needed to refine the two-phase flow modeling to better match observed test data.

Chilldown↗

Unibody Composite Pressurized Structure

An integrated, generic unibody composite pressurized structure (UCPS) combined with a positive expulsion device (PED), consisting of an elastomeric bladder for monopropellant hydrazine, has been quasi-standardized for spacecraft use. The combination functions as an all-composite, non-metallic, propellant tank with bladder. The integrated UCPS combines several previous innovations - specifically, the linerless, all-composite cryogenic tank technology; all-composite boss; resin formulation; and integrated stringer system. The innovation combines the UCPS with an integrated propellant management device (PMD), the PED or bladder, to create an entirely unique system for in-space use. The UCPS is a pressure vessel that incorporates skirts, stringers, and other structures so that it is both an in-space hydrazine tank, and also a structural support system for a spacecraft in a single, all-composite unit. This innovation builds on the progress in the development of a previous SBIR (Small Business Innovation Research) Phase I with Glenn Research Center and an SBIR III with Johnson Space Center that included the fabrication of two 42-in. (≈107-cm) diameter all-composite cryogenic (LOX and liquid methane) UCPS test tanks for a lunar lander. This Phase II provides hydra zine compatibility testing of the elastomeric bladder, a see-through PED to validate the expulsion process and model, and a complete UCPS-based PED with stringers and skirts that will be used to conduct initial qualification and expulsion tests. This extends the UCPS technology to include hydrazine-based, in-space pro - pulsion applications and can also be used for electric propulsion. This innovation creates a system that, in comparison to the traditional approach, is lower in weight, cost, volume, and production time; is stronger; and is capable of much higher pressures. It also has fewer failure modes, and is applicable to both chemical and electric propulsion systems.

Rufer, Markus↗

Characterization of an Integral Thermal Protection and Cryogenic Insulation Material for Advanced Space Transportation Vehicles

NASA's planned advanced space transportation vehicles will benefit from the use of integral/conformal cryogenic propellant tanks which will reduce the launch weight and lower the earth-to-orbit costs considerably. To implement the novel concept of integral/conformal tanks requires developing an equally novel concept in thermal protection materials. Providing insulation against reentry heating and preserving propellant mass can no longer be considered separate problems to be handled by separate materials. A new family of materials, Superthermal Insulation (STI), has been conceiving and investigated by NASA's Ames Research Center to simultaneously provide both thermal protection and cryogenic insulation in a single, integral material.

Salerno, L. J.↗

Experimental Studies of Liquefaction and Densification of Liquid Oxygen

The propellant combination that offers optimum performance is very reactive with a low average molecular weight of the resulting combustion products. Propellant combinations such as oxygen and hydrogen meet the above criteria, however, the propellants in gaseous form require large propellant tanks due to the low density of gas. Thus, rocketry employs cryogenic refrigeration to provide a more dense propellant stored as a liquid. In addition to propellant liquefaction, cryogenic refrigeration can also conserve propellant and provide propellant subcooling and propellant densification. Previous studies analyzed vapor conditioning of a cryogenic propellant, with the vapor conditioning by either a heat exchanger position in the vapor or by using the vapor in a refrigeration cycle as the working fluid. This study analyzes the effects of refrigeration heat exchanger located in the liquid of the common propellant oxidizer, liquid oxygen. This study predicted and determined the mass condensation rate and heat transfer coefficient for liquid oxygen.

Partridge, Jonathan Koert↗

Study of liquid slosh in the tracking and data relay satellite hydrazine tanks

An experimental study was conducted to provide data for evaluation of the parameters for an analytical mechanical model representation of liquid/interface dynamics in the TDRSS propellant tanks. Models were developed for two liquid-under ullage (forward tank) configurations and for one liquid-over-ullage (aft tank) configuration. However, additional test runs were conducted with liquids of different densities in both cases to allow separation of bladder stiffness and gravity effects under various simulated steady acceleration conditions. Both static and dynamic parameters are evaluated to provide a good prediction of observed results.

Kana, D. D.↗

Quarter Scale RLV Multi-Lobe LH2 Tank Test Program

Thirty cryogenic pressure cycles have been completed on the Lockheed Martin Michoud Space Systems quarter scale RLV composite multi-lobe liquid hydrogen propellant tank assembly, completing the initial phases of testing and demonstrating technologies key to the success of large scale composite cryogenic tankage for X33, RLV, and other future launch vehicles.

Blum, Celia↗

Passive propellant system

A passive propellant acquisition and feed system is disclosed which acquires and feeds gas-free propellant in low or zero-g environments during orbital maneuvers and retains this propellant under high axially directed acceleration such as may be experienced during launch of a space vehicle and orbit-to-orbit transfer is described. The propellant system includes a dual compartment propellant tank with independent surface tension acquisition channels in each compartment to provide gas-free flow of pressurized liquid propellant from one compartment to the other in one direction only.

Hess, D. A.↗

Liquid Methane Conditioning Capabilities Developed at the NASA Glenn Research Center's Small Multi- Purpose Research Facility (SMiRF) for Accelerated Lunar Surface Storage Thermal Testing

Glenn Research Center s Creek Road Cryogenic Complex, Small Multi-Purpose Research Facility (SMiRF) recently completed validation / checkout testing of a new liquid methane delivery system and liquid methane (LCH4) conditioning system. Facility checkout validation was conducted in preparation for a series of passive thermal control technology tests planned at SMiRF in FY10 using a flight-like propellant tank at simulated thermal environments from 140 to 350K. These tests will validate models and provide high quality data to support consideration of LCH4/LO2 propellant combination option for a lunar or planetary ascent stage.An infrastructure has been put in place which will support testing of large amounts of liquid methane at SMiRF. Extensive modifications were made to the test facility s existing liquid hydrogen system for compatibility with liquid methane. Also, a new liquid methane fluid conditioning system will enable liquid methane to be quickly densified (sub-cooled below normal boiling point) and to be quickly reheated to saturation conditions between 92 and 140 K. Fluid temperatures can be quickly adjusted to compress the overall test duration. A detailed trade study was conducted to determine an appropriate technique to liquid conditioning with regard to the SMiRF facility s existing infrastructure. In addition, a completely new roadable dewar has been procured for transportation and temporary storage of liquid methane. A new spherical, flight-representative tank has also been fabricated for integration into the vacuum chamber at SMiRF. The addition of this system to SMiRF marks the first time a large-scale liquid methane propellant test capability has been realized at Glenn.This work supports the Cryogenic Fluid Management Project being conducted under the auspices of the Exploration Technology Development Program, providing focused cryogenic fluid management technology efforts to support NASA s future robotic or human exploration missions.

Bamberger, Helmut H.↗