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At least 433 records · Page 24

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NASA NTRS2008

Calibrating the Helium Pressurization System for the Space Shuttle Liquid-Hydrogen Tank

Analysis of the results from the STS-114 tanking tests and subsequent launch called into question existing thermal and mass models of helium pressurization of the liquid hydrogen tank. This hydrogen tank, which makes up the bottom two-thirds of the External Tank, is pressurized prior to launch to avoid cavitation in the Shuttle Main Engine pumps. At about 2 minutes prior to launch, the main vent valve is closed, and pressurized helium flows into the tank ullage space to achieve set point pressure. As the helium gas cools, its pressure drops, calling for additional helium. Subsequent helium flows are provided in short, timed pulses. The number of pulses is taken as a rough leak indicator. An analysis of thermal models by Marshall Space Flight Center showed considerable uncertainty in the pressure-versus-time behavior of the helium ullage space and the ability to predict the number of pulses normally expected. Kennedy Space Center proposed to calibrate the dime-sized orifice, which together with valves, controls the helium flow quantity (Figure 1). Pressure and temperature sensors were installed to provide upstream and downstream measurements necessary to compute flow rate based on the orifice discharge coefficient. An assessment of flow testing with helium indicated an extremely costly use of this critical resource. In order to reduce costs, we proposed removing the orifices from each Mobile Launcher Platform (MLP) and asking Colorado Engineering Experiment Station Inc. (CEESI) to calibrate the flow. CEESI has a high-pressure air flow system with traceable flow meters capable of handling the large flow rates. However, literature research indicated that square-edged orifices of small diameters often exhibit significant hysteresis and nonrepeatability in the vicinity of choked or sonic flow. Fortunately, the MLP orifices behaved relatively well in testing (Figure 2). Using curve fitting of the air-flow data, in conjunction with ASME orifice modeling equations, a method of relating the helium mass flow to measured air flow data was obtained. This analysis showed that the highest uncertainty in flow occurred in the vicinity of the choking pressure ratio, as would be expected. In addition, analysis of typical flow pulses showed that most of the helium flow occurred either well below or well above this uncertain area. The final result is the ability to provide postlaunch estimates of helium mass flows that are within 1.5 percent of the actual value.

Source record↗

NASA NTRS2010

Seal Analysis for the Ares-I Upper Stage Fuel Tank Manhole Cover

Techniques for studying the performance of Naflex pressure-assisted seals in the Ares-I Upper Stage liquid hydrogen tank manhole cover seal joint are explored. To assess the feasibility of using the identical seal design for the Upper Stage as was used for the Space Shuttle External Tank manhole covers, a preliminary seal deflection analysis using the ABAQUS commercial finite element software is employed. The ABAQUS analyses are performed using three-dimensional symmetric wedge finite element models. This analysis technique is validated by first modeling a heritage External Tank liquid hydrogen tank manhole cover joint and correlating the results to heritage test data. Once the technique is validated, the Upper Stage configuration is modeled. The Upper Stage analyses are performed at 1.4 times the expected pressure to comply with the Constellation Program factor of safety requirement on joint separation. Results from the analyses performed with the External Tank and Upper Stage models demonstrate the effects of several modeling assumptions on the seal deflection. The analyses for Upper Stage show that the integrity of the seal is successfully maintained.

Phillips, Dawn R.↗

NASA NTRS2010

A History of Collapse Factor Modeling and Empirical Data for Cryogenic Propellant Tanks

One of the major technical problems associated with cryogenic liquid propellant systems used to supply rocket engines and their subassemblies and components is the phenomenon of propellant tank pressurant and ullage gas collapse. This collapse is mainly caused by heat transfer from ullage gas to tank walls and interfacing propellant, which are both at temperatures well below those of this gas. Mass transfer between ullage gas and cryogenic propellant can also occur and have minor to significant secondary effects that can increase or decrease ullage gas collapse. Pressurant gas is supplied into cryogenic propellant tanks in order to initially pressurize these tanks and then maintain required pressures as propellant is expelled from these tanks. The net effect of pressurant and ullage gas collapse is increased total mass and mass flow rate requirements of pressurant gases. For flight vehicles this leads to significant and undesirable weight penalties. For rocket engine component and subassembly ground test facilities this results in significantly increased facility hardware, construction, and operational costs. "Collapse Factor" is a parameter used to quantify the pressurant and ullage gas collapse. Accurate prediction of collapse factors, through analytical methods and modeling tools, and collection and evaluation of collapse factor data has evolved over the years since the start of space exploration programs in the 1950 s. Through the years, numerous documents have been published to preserve results of studies associated with the collapse factor phenomenon. This paper presents a summary and selected details of prior literature that document the aforementioned studies. Additionally other literature that present studies and results of heat and mass transfer processes, related to or providing important insights or analytical methods for the studies of collapse factor, are presented.

deQuay, Laurence↗

NASA NTRS2010

Thermographic Methods of Detecting Insulation Voids in Large Cryogenic Tanks

Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. As the Shuttle Program comes to an end we now have the time to perform limited refurbishment. Thermography has been used to monitor the state of insulation as one of the four tanks was drained of cryogen and warmed to ambient temperatures. An anomalous region of insulation detected previously with thermography was confirmed by visual inspections during this period. Thermal models and a comparison of images from the cold and warm tanks suggests that the anomalous region can be detected even without cryogen in the tank. The ability to detect and correct probable insulation voids prior to filling with cryogenic fluid can provide significant cost savings by reducing commodity boil-off over many years of use.

Arens, Ellen↗

NASA NTRS2010

CFD Fuel Slosh Modeling of Fluid-Structure Interaction in Spacecraft Propellant Tanks with Diaphragms

Liquid sloshing within spacecraft propellant tanks causes rapid energy dissipation at resonant modes, which can result in attitude destabilization of the vehicle. Identifying resonant slosh modes currently requires experimental testing and mechanical pendulum analogs to characterize the slosh dynamics. Computational Fluid Dynamics (CFD) techniques have recently been validated as an effective tool for simulating fuel slosh within free-surface propellant tanks. Propellant tanks often incorporate an internal flexible diaphragm to separate ullage and propellant which increases modeling complexity. A coupled fluid-structure CFD model is required to capture the damping effects of a flexible diaphragm on the propellant. ANSYS multidisciplinary engineering software employs a coupled solver for analyzing two-way Fluid Structure Interaction (FSI) cases such as the diaphragm propellant tank system. Slosh models generated by ANSYS software are validated by experimental lateral slosh test results. Accurate data correlation would produce an innovative technique for modeling fuel slosh within diaphragm tanks and provide an accurate and efficient tool for identifying resonant modes and the slosh dynamic response.

Sances, Dillon J.↗

NASA NTRS2011

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗

NASA NTRS2010

A Study of Fluid Interface Configurations in Exploration Vehicle Propellant Tanks

The equilibrium shape and location of fluid interfaces in spacecraft propellant tanks while in low-gravity is of interest to system designers, but can be challenging to predict. The propellant position can affect many aspects of the spacecraft such as the spacecraft center of mass, response to thruster firing due to sloshing, liquid acquisition, propellant mass gauging, and thermal control systems. We use Surface Evolver, a fluid interface energy minimizing algorithm, to investigate theoretical equilibrium liquid-vapor interfaces for spacecraft propellant tanks similar to those that have been considered for NASA's new class of Exploration vehicles. The choice of tank design parameters we consider are derived from the NASA Exploration Systems Architecture Study report. The local acceleration vector employed in the computations is determined by estimating low-Earth orbit (LEO) atmospheric drag effects and centrifugal forces due to a fixed spacecraft orientation with respect to the Earth or Moon, and rotisserie-type spacecraft rotation. Propellant/vapor interface positions are computed for the Earth Departure Stage and Altair lunar lander descent and ascent stage tanks for propellant loads applicable to LEO and low-lunar orbit. In some of the cases investigated the vapor ullage bubble is located at the drain end of the tank, where propellant management device hardware is often located.

Zimmerli, Gregory A.↗

NASA NTRS2012

Model of the Radio Frequency (RF) Excitation Response from Monopole and Dipole Antennas in a Large Scale Tank

Good antenna-mode coupling is needed for determining the amount of propellant in a tank through the method of radio frequency mass gauging (RFMG). The antenna configuration and position in a tank are important factors in coupling the antenna to the natural electromagnetic modes. In this study, different monopole and dipole antenna mounting configurations and positions were modeled and responses simulated in a full-scale tank model with the transient solver of CST Microwave Studio (CST Computer Simulation Technology of America, Inc.). The study was undertaken to qualitatively understand the effect of antenna design and placement within a tank on the resulting radio frequency (RF) tank spectrum.

Wilson, Jeffrey D.↗

NASA NTRS2012

STS-133/ET-137 Tanking Test Photogrammetry Assessment

Following the launch scrub of Space Shuttle mission STS-133 on November 5, 2010, an anomalous condition of cracked and raised thermal protection system (TPS) foam was observed on the External Tank (ET). Subsequent dissection of the affected TPS region revealed cracks in the feet of two Intertank (IT) metallic stringers. An extensive investigation into the cause(s) and corrective action(s) for the cracked stringers was initiated, involving a wide array of material and structural tests and nondestructive evaluations, with the intent to culminate into the development of flight rational. One such structural test was the instrumented tanking test performed on December 17, 2010. The tanking test incorporated two three-dimensional optical displacement measurement systems to measure full-field outer surface displacements of the TPS surrounding the affected region that contained the stringer cracks. The results showed that the radial displacement and rotation of the liquid oxygen (LO2) tank flange changed significantly as the fluid level of the LO2 approached and passed the LO2 tank flange.

Oliver, Stanley T.↗

NASA NTRS2013

Effect of Residual Noncondensables on Pressurization and Pressure Control of a Zero-Boil-Off Tank in Microgravity

The Zero-Boil-Off Tank (ZBOT) Experiment is a small-scale experiment that uses a transparent ventless Dewar and a transparent simulant phase-change fluid to study sealed tank pressurization and pressure control with applications to on-surface and in-orbit storage of propellant cryogens. The experiment will be carried out under microgravity conditions aboard the International Space Station in the 2014 timeframe. This paper presents preliminary results from ZBOT's ground-based research that focuses on the effects of residual noncondensable gases in the ullage on both pressurization and pressure reduction trends in the sealed Dewar. Tank pressurization is accomplished through heating of the test cell wall in the wetted and un-wetted regions simultaneously or separately. Pressure control is established through mixing and destratification of the bulk liquid using a temperature controlled forced jet flow with different degrees of liquid jet subcooling. A Two-Dimensional axisymmetric two-phase CFD model for tank pressurization and pressure control is also presented. Numerical prediction of the model are compared to experimental 1g results to both validate the model and also indicate the effect of the noncondensable gas on evolution of pressure and temperature distributions in the ullage during pressurization and pressure control. Microgravity simulations case studies are also performed using the validated model to underscore and delineate the profound effect of the noncondensables on condensation rates and interfacial temperature distributions with serious implications for tank pressure control in reduced gravity.

Marangoni and Natural Convection↗

NASA NTRS2015

Simscape Modeling of a Custom Closed-Volume Tank

The library for Mathworks Simscape does not currently contain a model for a closed volume fluid tank where the ullage pressure is variable. In order to model a closed-volume variable ullage pressure tank, it was necessary to consider at least two separate cases: a vertical cylinder, and a sphere. Using library components, it was possible to construct a rough model for the cylindrical tank. It was not possible to construct a model for a spherical tank, using library components, due to the variable area. It was decided that, for these cases, it would be preferable to create a custom library component to represent each case, using the Simscape language. Once completed, the components were added to models, where filling and draining the tanks could be simulated. When the models were performing as expected, it was necessary to generate code from the models and run them in Trick (a real-time simulation program). The data output from Trick was then compared to the output from Simscape and found to be within acceptable limits.

Simscape↗

NASA NTRS2015

Computational Fluid Dynamics Based Extraction of Heat Transfer Coefficient in Cryogenic Propellant Tanks

Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from: inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. The work presented under this task uses the first-principles based Computational Fluid Dynamics (CFD) technique to compute heat transfer from tank wall to the cryogenic fluids, and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between tank wall and cryogenic propellant, and that between tank wall and ullage gas were then simulated. The results showed that commonly used heat transfer correlations for either vertical or horizontal plate over predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis.

Yang, H. Q.↗

NASA NTRS2015

CFD Extraction of Heat Transfer Coefficient in Cryogenic Propellant Tanks

Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. This study uses first-principles based CFD methodology to compute heat transfer from the tank wall to the cryogenic fluids and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between the tank wall and cryogenic propellant, and that between the tank wall and ullage gas were then simulated. The results showed that the commonly used heat transfer correlations for either vertical or horizontal plate over-predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis.

Yang, H. Q.↗

NASA NTRS2015

CFD Modeling of the Multipurpose Hydrogen Test Bed (MHTB) Self-Pressurization and Spray Bar Mixing Experiments in Normal Gravity: Effect of the Accommodation Coefficient on the Tank Pressure

A CFD model for simulating the self-pressurization of a large scale liquid hydrogen storage tank is utilized in this paper to model the MHTB self-pressurization experiment. The kinetics-based Schrage equation is used to account for the evaporative and condensi ng interfacial mass flows in this model. The effect of the accommodation coefficient for calculating the interfacial mass transfer rate on the tank pressure during tank selfpressurization is studied. The values of the accommodation coefficient which were considered in this study vary from 1.0e-3 to 1.0e-1 for the explicit VOF model and from 1.0e-4 to 1.0e-3 for the implicit VOF model. The ullage pressure evolutions are compared against experimental data. A CFD model for controlling pressure in cryogenic storage tanks by spraying cold liquid into the ullage is also presented. The Euler-Lagrange approach is utilized for tracking the spray droplets and for modeling the interaction between the droplets and the continuous phase (ullage). The spray model is coupled with the VOF model by performing particle tracking in the ullage, removing particles from the ullage when they reach the interface, and then adding their contributions to the liquid. Droplet-ullage heat and mass transfer are modeled. The flow, temperature, and interfacial mass flux, as well as droplets trajectories, size distribution and temperatures predicted by the model are presented. The ul lage pressure and vapor temperature evolutions are compared with experimental data obtained from the MHTB spray bar mixing experiment. The effect of the accommodation coefficient for calculating the interfacial and droplet mass transfer rates on the tank pressure during mixing of the vapor using spray is studied. The values used for the accommodation coefficient at the interface vary from 1.0e-5 to 1.0e-2. The droplet accommodation coefficient values vary from 2.0e-6 to 1.0e-4.

cryogenic fluid storage↗

NASA NTRS2015

Numerical Investigation of Microgravity Tank Pressure Rise Due to Boiling

The ability to control self-pressurization in cryogenic storage tanks is essential for NASAs long-term space exploration missions. Predictions of the tank pressure rise in Space are needed in order to inform the microgravity design and optimization process. Due to the fact that natural convection is very weak in microgravity, heat leaks into the tank can create superheated regions in the liquid. The superheated regions can instigate microgravity boiling, giving rise to pressure spikes during self-pressurization. In this work, a CFD model is developed to predict the magnitude and duration of the microgravity pressure spikes. The model uses the Schrage equation to calculate the mass transfer, with a different accommodation coefficient for evaporation at the interface, condensation at the interface, and boiling in the bulk liquid. The implicit VOF model was used to account for the moving interface, with bounded second order time discretization. Validation of the models predictions was carried out using microgravity data from the Tank Pressure Control Experiment, which flew aboard the Space Shuttle Mission STS-52. Although this experiment was meant to study pressurization and pressure control, it underwent boiling during several tests. The pressure rise predicted by the CFD model compared well with the experimental data. The ZBOT microgravity experiment is scheduled to fly on February 2016 aboard the ISS. The CFD model was also used to perform simulations for setting parametric limits for the Zero-Boil-Off Tank (ZBOT) Experiments Test Matrix in an attempt to avoid boiling in the majority of the test runs that are aimed to study pressure increase rates during self-pressurization. *Supported in part by NASA ISS Physical Sciences Research Program, NASA HQ, USA

pressure rise↗

NASA NTRS2016

Validation of High-Resolution CFD Method for Slosh Damping Extraction of Baffled Tanks

Determination of slosh damping is a very challenging task as there is no analytical solution. The damping physics involve the vorticity dissipation which requires the full solution of the nonlinear Navier-Stokes equations. As a result, previous investigations and knowledge were mainly carried out by extensive experimental studies. A Volume-Of-Fluid (VOF) based CFD program developed at NASA MSFC was applied to extract slosh damping in a baffled tank from the first principle. First, experimental data using water with subscale smooth wall tank were used as the baseline validation. CFD simulation was demonstrated to be capable of accurately predicting natural frequency and very low damping value from the smooth wall tank at different fill levels. The damping due to a ring baffle at different liquid fill levels from barrel section and into the upper dome was then investigated to understand the slosh damping physics due to the presence of a ring baffle. Based on this study, the Root-Mean-Square error of our CFD simulation in estimating slosh damping was less than 4.8%, and the maximum error was less than 8.5%. Scalability of subscale baffled tank test using water was investigated using the validated CFD tool, and it was found that unlike the smooth wall case, slosh damping with baffle is almost independent of the working fluid and it is reasonable to apply water test data to the full scale LOX tank when the damping from baffle is dominant. On the other hand, for the smooth wall, the damping value must be scaled according to the Reynolds number. Comparison of experimental data, CFD, with the classical and modified Miles equations for upper dome was made, and the limitations of these semi-empirical equations were identified.

Yang, H. Q.↗

NASA NTRS2018

Experimental Thermal Performance Testing of Cryogenic Tank Systems and Materials

A comparative study was conducted to collect and analyze thermal conductivity data on a wide variety of low density materials, as well as thermal performance data on a number of vacuum-jacketed cryogenic tank systems. Although a vast number of these types of materials and cryogenic tank systems exist, the thermal conductivity of insulation materials and the thermal performance of cryogenic tank systems is often difficult to compare because many industrial methods and experimental conditions are available and utilized. The availability of a new thermal conductivity measurement device, the Macroflash Cup Cryostat, which is applicable for assessing a variety of materials, is accessible at NASA's Cryogenic Test Laboratory (CTL) at the Kennedy Space Center (KSC). The convenience of this device has resulted in the ability to rapidly measure the thermal conductivity properties of these materials by using a flat-plate liquid nitrogen (LN2) boiloff technique that employs a guarded heat flow test methodology in order to determine the effective thermal conductivity (ke) of a test specimen. As the thermal conductivities are measured at cryogenic temperatures, materials suitable for both future space missions and cryogenic tank systems can be identified and experimentally analyzed. Also recognizable are materials which may help increase energy efficiency by limiting the thermal losses encountered under various environmental conditions. The overall focus of this work consisted of two parts. One part, was to produce and analyze thermal conductivity data on a wide variety of materials with suitable properties conducive to those needed to aid in the production of a calibration curve for the "low end" of the Macroflash instrument. (Low end meaning materials with a thermal conductivity rating below 100 milliwatts per meter-Kelvin). The second part was to collect and analyze heat transfer data for a variety of small vacuum-jacketed vessels (cryogenic tank systems) in order to compare the thermal performance between them.

Myers, Wesley C.↗

NASA NTRS2018

Validation of a CFD Model Predicting the Effect of High Level Lateral Acceleration Sloshing on the Heat Transfer and Pressure Drop in a Small-Scale Tank in Normal Gravity

A two-phase CFD model is developed to study the effects of sloshing with high level lateral acceleration on the heat transfer and pressure drop in a small scale tank. Computational results are compared to the data provided by a non-isothermal sloshing experiment without phase change conducted by T. Himeno et al. at the University of Tokyo and JAXA in 2011. The results of the current model are, also, compared to CFD predictions reported by Himeno et al. A step change in lateral acceleration was applied in the experiment. Different levels of lateral acceleration amplitude, varying between 0G and 0.5G, were considered. CFD results for interface movement and tank pressure are presented and compared in this paper to the experimental data for the case in which the value of lateral acceleration was set to 0.5G. The effects of initial and boundary conditions and turbulence modeling approach on the tank pressure change during sloshing are discussed in detail. The effect of conjugate heat transfer in the tank wall is also studied to show its important role in determining the tank pressure evolution. The results of the Reynolds Averaged Navier Stokes (RANS) models are compared to the results of the Large Eddy Simulation model (LES) to underscore the importance of correctly capturing the effects of turbulence for high fidelity predictions.

multiphase flow↗