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At least 1,333 records · Page 74

Modeling Xenon Tank Pressurization using One-Dimensional Thermodynamic and Heat Transfer Equations

As a first step in understanding what ground support equipment (GSE) is required to provide external cooling during the loading of 5,000 kg of xenon into 4 aluminum lined composite overwrapped pressure vessels (COPVs), a modeling analysis was performed using Microsoft Excel. The goals of the analysis were to predict xenon temperature and pressure throughout loading at the launch facility, estimate the time required to load one tank, and to get an early estimate of what provisions for cooling xenon might be needed while the tanks are being filled. The model uses the governing thermodynamic and heat transfer equations to achieve these goals. Results indicate that a single tank can be loaded in about 15 hours with reasonable external coolant requirements. The model developed in this study was successfully validated against flight and test data. The first data set is from the Dawn mission which also utilizes solar electric propulsion with xenon propellant, and the second is test data from the rapid loading of a hydrogen cylindrical COPV. The main benefit of this type of model is that the governing physical equations using bulk fluid solid temperatures can provide a quick and accurate estimate of the state of the propellant throughout loading which is much cheaper in terms of computational time and licensing costs than a Computation Fluid Dynamics (CFD) analysis while capturing the majority of the thermodynamics and heat transfer.

Thermodynamic tank modeling↗

Study of propellant dynamics in a shuttle type launch vehicle

A method and an associated digital computer program for evaluating the vibrational characteristics of large liquid-filled rigid wall tanks of general shape are presented. A solution procedure was developed in which slosh modes and frequencies are computed for systems mathematically modeled as assemblages of liquid finite elements. To retain sparsity in the assembled system mass and stiffness matrices, a compressible liquid element formulation was incorporated in the program. The approach taken in the liquid finite element formulation is compatible with triangular and quadrilateral structural finite elements so that the analysis of liquid motion can be coupled with flexible tank wall motion at some future time. The liquid element repertoire developed during the course of this study consists of a two-dimensional triangular element and a three-dimensional tetrahedral element.

Jones, C. E.↗

Ground testing on the nonvented fill method of orbital propellant transfer: Results of initial test series

The results are presented of a series of no-vent fill experiments conducted on a 175 cu ft flightweight hydrogen tank. The experiments consisted of the nonvented fill of the tankage with liquid hydrogen using two different inlet systems (top spray, and bottom spray) at different tank initial conditions and inflow rates. Nine tests were completed of which six filled in excess of 94 percent. The experiments demonstrated a consistent and repeatable ability to fill the tank in excess of 94 percent using the nonvented fill technique. Ninety-four percent was established as the high level cutoff due to requirements for some tank ullage to prevent rapid tank pressure rise which occurs in a tank filled entirely with liquid. The best fill was terminated at 94 percent full with a tank internal pressure less than 26 psia. Although the baseline initial tank wall temperature criteria was that all portions of the tank wall be less than 40 R, fills were achieved with initial wall temperatures as high as 227 R.

Chato, David J.↗

Ground testing of the nonvented fill method of orbital propellant transfer - Results of initial test series

The results are presented of a series of no-vent fill experiments conducted on a 175 cu ft flightweight hydrogen tank. The experiments consisted of the nonvented fill of the tankage with liquid hydrogen using two different inlet systems (top spray, and bottom spray) at different tank initial conditions and inflow rates. Nine tests were completed of which six filled in exceess of 94 percent. The experiments demonstrated a consistent and repeatable ability to fill the tank in excess of 94 percent using the nonvented fill technique. Ninety-four percent was established as the high level cutoff due to requirements for some tank ullage to prevent rapid tank pressure rise which occurs in a tank filled entirely with liquid. The best fill was terminated at 94 percent full with a tank internal pressure less than 26 psia. Although the baseline initial tank wall temperature criteria was that all portions of the tank wall be less than 40 R, fills were achieved with initial wall temperatures as high as 227R.

Chato, David J.↗

Pressurization of a Flightweight, Liquid Hydrogen Tank: Evaporation and Condensation at a Liquid Vapor Interface

Evaporation and condensation at a liquid-vapor interface is important for long-term, in-space cryogenic propellant storage. Yet the current understanding of inter-facial physics does not consistently predict behavior of evaporation or condensation rates. The proposed paper will present a physical model, based on the 1-D Heat equation and Schrage's equation, which demonstrates thin thermal layers at the fluid vapor interface.

cryogenic hydrogen↗

Systems and operations - Living with complexity and growth

Since the space station concept currently being developed by NASA calls for system updates and additions over a period of at least ten years following launch, attention must be given to the interfaces between station elements. Efforts have begun to develop generic fault detection, isolation, and correction techniques that could simplify on-orbit operations, maintenance and repair. An integrated hydrogen-oxygen system has been identified as the feature promising the greatest reduction in resupply costs. Scavenging excess fuel from the Space Shuttle's internal and external tanks, and using leftover Shuttle payload for fluid tankage, could supply hydrogen and oxygen for consumption in the form of propellants, fuel cell electricity, and life support gases. Advancements in cryogenic fluid management and storage technology are the keys to the design of this integrated system. Attention is given to the Interactive Design and Evaluation of Advanced Spacecraft computer-aided design and analysis system, which allows system engineers to study the integration problems presented by 40 technical modules.

Hook, W. R.↗

Propellant transfer: Attached depot

Propellant transfer at an attached depot involves: (1) resupply tankers (dedicated launch from the ground or scavenging from the external tank) to resupply the depot; (2) depot storage and supply tanks (attached, free-flyer, or tethered) from which liquid hydrogen and liquid oxygen are transferred to fill the space-based OTV; and (3) the space-based OTV which is resupplied with cryogens from the depot. Liquid storage and supply, thermal control, and transfer/resupply requirements for an attached depot are listed, and technologies defined. The specific fluid management elements and approaches for an attached depot are enumerated. The cryogenic fluid management facility (CFMF) shuttle attached-payload test bed, scheduled for a mid-1988 first launch, is expected to provide much of the needed technology.

Eberhardt, R. N.↗

Computational prediction of propellant reorientation

Viewgraphs from a presentation on computational prediction of propellant reorientation are given. Information is given on code verification, test conditions, predictions for a one-quarter scale cryogenic tank, pulsed settling, and preliminary results.

Hochstein, John I.↗

Preliminary System Analysis of In Situ Resource Utilization for Mars Human Exploration

We carried out a system analysis of processes for utilization of Mars resources to support human exploration of Mars by production of propellants from indigenous resources. Seven ISRU processes were analyzed to determine mass. power and propellant storage volume requirements. The major elements of each process include C02 acquisition, chemical conversion, and storage of propellants. Based on a figure of merit (the ratio of the mass of propellants that must be brought from Earth in a non-ISRU mission to the mass of the ISRU system. tanks and feedstocks that must be brought from Earth for a ISRU mission) the most attractive process (by far); is one where indigenous Mars water is accessible and this is processed via Sabatier/Electrolysis to methane and oxygen. These processes are technically relatively mature. Other processes with positive leverage involve reverse water gas shift and solid oxide electrolysis.

Mars↗

Analytical Investigation of Propellant Slosh Stability Boundary on a Space Vehicle

The effect of propellant sloshing upon the stability of a liquid-propelled space vehicle has been studied extensively. For a typical space vehicle with thrust vector control and a single slosh tank, the slosh danger zone is located between the vehicle center of mass and the center of percussion. If the slosh mass is located between these two locations, baffles may be required to provide additional damping for stability. In this work, the methodology behind the classic single tank solution analytical is extended to a tandem tank configuration where the tanks are located along the vehicle centerline or symmetrically offset from the centerline. Secondly, the slosh stability boundary for a vehicle with pairs of outboard reaction jets, rather than thrust vectoring, for attitude control is studied. Finally, the impact of aerodynamics and vehicle axial acceleration on the classic danger zone solution are analyzed.

Jing Pei↗

Technology Development for Hydrogen Propellant Storage and Transfer at the Kennedy Space Center (KSC)

The National Aeronautics and Space Administration (NASA) is a major user of liquid hydrogen. In particular, NASA's John F. Kennedy (KSC) Space Center has operated facilities for handling and storing very large quantities of liquid hydrogen (LH2) since the early 1960s. Safe operations pose unique challenges and as a result NASA has invested in technology development to improve operational efficiency and safety. This paper reviews recent innovations including methods of leak and fire detection and aspects of large storage tank health and integrity. We also discuss the use of liquid hydrogen in space and issues we are addressing to ensure safe and efficient operations should hydrogen be used as a propellant derived from in-situ volatiles.

cryogenics↗

Modeling and Simulation of Tank Pressure Control using Zero-Boiloff Active Thermal Control for LOXSAT Technology Demonstration Mission

To-date, research and modeling of cryogenic fluid management technologies (CFM) for spaceflight has been limited to ground tests, short-duration zero-g simulations (e.g. drop towers), and small-scale experiments on-orbit. There has not been a large-scale flight demonstration of a flight-like system. As future NASA missions to take humans further from Earth will require large, in-space cryogenic propulsion vehicles, it is imperative to begin collecting flight data for these systems to accurately model and design future vehicles. To meet this goal, NASA awarded tipping point technology demonstration awards to Eta Space, Lockheed Martin, Space Exploration Technologies (SpaceX), and United Launch Alliance (ULA) to demonstrate on-orbit storage and transfer of cryogenic propellant. For its award, Eta Space is developing LOXSAT-1. It is a small satellite that will be launched on a Rocket Lab Electron rocket. The spacecraft consists of a Rocket Lab Photon spacecraft bus with a primary payload of a spherical liquid oxygen (LOX) storage tank with thermodynamic control systems. The primary objective of the mission is to demonstrate zero-boil-off storage of liquid oxygen. To accomplish this objective, the payload is equipped with an active thermal control system fluid loop that consists of propellant management device (PMD), positive-displacement pump, heat exchanger connected to a cryocooler, and a spray bar mixing injector. When the fluid loop is operating, fluid is drawn from the tank by the PMD and pumped through the heat exchanger, lowering the fluid temperature below the fluid temperature in the tank. This subcooled liquid is then injected back into the tank through the spray bar. The subcooled injected liquid has two effects. If it is sprayed into the ullage space, the injected liquid will form into jets or droplets and exchange heat with the ullage gas. This will cool and condense the gas, reducing the pressure in the tank. Additionally, the liquid that is not sprayed through the ullage, as well as any remaining liquid spray from the ullage, will rejoin the liquid mass of the tank, lowering the bulk temperature of the liquid. These combines effects provide for zero-boil off pressure control by lowering the tank pressure and the liquid saturation pressure simultaneously, ensuring the liquid stays subcooled. To model these complex mechanics and predict the performance of the active thermal control system, NASA is providing Eta Space with 3 parallel models of the tank. The approach of providing 3 different models allows for cross-checking and comparisons between the three to better understand how different modeling assumptions and selection semi-empirical factors affects the modeling result. Additionally, developing 3 models provides three different schemes for numerical simulation, providing confidence that results depict real physical phenomenon and not numerical quirks of the program. Within the tank thermodynamics, there are two primary areas of heat transfer we concern ourselves with: the heat transfer between the ullage space and the droplet spray, and between the ullage space and bulk liquid. For the droplet heat transfer, there are multiple sets of assumptions that can be made and correlations that can be used. Currently, two working models - the TankSIM model and Easy5 model – provide for an overview of the different approaches available. The TankSIM model and Easy5 model use two different models for droplet heating and evaporation that illustrate how the models use different types of mechanisms to arrive at the same answer. For the TankSIM model, droplets are treated as spheres of constant radius. Heat is transferred from the ullage to the droplet and warms the droplet until it reaches saturation, then the droplet begins evaporating and reducing its radius and mass. To calculate the heat transfer coefficient between the droplet and ullage, the Ranz-Marshall correlation is used. To determine the number of droplets in the ullage, a resident mass approach is used. This approach averages the number of droplets such that residuals at the start-up and shut-off of the spray bar cancel out. This same approach is used in the Easy5 model. The GFSSP model implements a linked list to track individual droplet “nodes” within the model. For the Easy5 model, the droplet is assumed to have an interface at a temperature equal to the saturation temperature corresponding to the pressure of the gas phase. The heat transfer from the gas to the interface and the interface to the droplet bulk is then calculated, and the net mass transfer between the droplet and interface is determined by performing an energy balance across the interface. For the gas side of the interface, the Ranz-Marshall correlation is used. For the liquid side of the interface, a variety of correlations were tried, including Kronig and Brink (1950) and effective conductivity models. As a result of these assumptions, the Easy5 model currently predicts faster depressurization, as at saturated vapor conditions, the heat transfer coeffect on the liquid side for the Easy5 model is greater than the heat transfer coefficient predicted by Ranz-Marshall used in the TankSIM code. This greater heat flux translates into faster condensation of the saturated ullage gas. At the bulk liquid to ullage interface, the models are in much closer agreement. Both models model the ullage as a sphere centered within the bulk liquid in the tank, and both use the energy-jumping boundary condition to model heat and mass transfer across the interface. There are slight differences in how the interface temperature is calculated, however. The Easy5 model assumes the temperature of the interface is equal to the saturation temperature associated with the pressure of the gas phase. The TankSIM model calculates this temperature with Alabovskii’s equation, which provides a correction factor for interface temperatures. Analysis tasks are focused on determining rates of depressurization within the tank during active cooling operation. To maintain net positive suction head at the pump inlet, the tank pressure cannot fall faster than the saturation pressure associated with the temperature of the bulk liquid. Additionally, there is interest in analyzing the performance of the loop at different pump speeds and cryocooler input powers. Adjusting the flowrate affects both the performance of the heat exchanger between the cryocooler and pumped liquid, and the heat transfer between the droplet spray and the ullage. Ideally, a pump speed and cryocooler power can be selected that will allow the tank to operate in zero-boil-off mode with a very narrow range of storage pressure.

zero boil-off↗

Modeling and Simulation of Tank Pressure Control using Zero-Boil Off Active Thermal Control for LOXSAT Technology Demonstration Mission

To-date, research and modeling of cryogenic fluid management technologies (CFM) for spaceflight has been limited to ground tests, short-duration zero-g simulations (e.g. drop towers), and small-scale experiments on-orbit. There has not been a large-scale flight demonstration of a flight-like system. As future NASA missions to take humans further from Earth will require large, in-space cryogenic propulsion vehicles, it is imperative to begin collecting flight data for these systems to accurately model and design future vehicles. To meet this goal, NASA awarded tipping point technology demonstration awards to Eta Space, Lockheed Martin, Space Exploration Technologies (SpaceX), and United Launch Alliance (ULA) to demonstrate on-orbit storage and transfer of cryogenic propellant. For its award, Eta Space is developing LOXSAT-1. It is a small satellite that will be launched on a Rocket Lab Electron rocket. The spacecraft consists of a Rocket Lab Photon spacecraft bus with a primary payload of a spherical liquid oxygen (LOX) storage tank with thermodynamic control systems. The primary objective of the mission is to demonstrate zero-boil-off storage of liquid oxygen. To accomplish this objective, the payload is equipped with an active thermal control system fluid loop that consists of propellant management device (PMD), positive-displacement pump, heat exchanger connected to a cryocooler, and a spray bar mixing injector. When the fluid loop is operating, fluid is drawn from the tank by the PMD and pumped through the heat exchanger, lowering the fluid temperature below the fluid temperature in the tank. This subcooled liquid is then injected back into the tank through the spray bar. The subcooled injected liquid has two effects. If it is sprayed into the ullage space, the injected liquid will form into jets or droplets and exchange heat with the ullage gas. This will cool and condense the gas, reducing the pressure in the tank. Additionally, the liquid that is not sprayed through the ullage, as well as any remaining liquid spray from the ullage, will rejoin the liquid mass of the tank, lowering the bulk temperature of the liquid. These combines effects provide for zero-boil off pressure control by lowering the tank pressure and the liquid saturation pressure simultaneously, ensuring the liquid stays subcooled. To model these complex mechanics and predict the performance of the active thermal control system, NASA is providing Eta Space with 3 parallel models of the tank. The approach of providing 3 different models allows for cross-checking and comparisons between the three to better understand how different modeling assumptions and selection semi-empirical factors affects the modeling result. Additionally, developing 3 models provides three different schemes for numerical simulation, providing confidence that results depict real physical phenomenon and not numerical quirks of the program. Within the tank thermodynamics, there are two primary areas of heat transfer we concern ourselves with: the heat transfer between the ullage space and the droplet spray, and between the ullage space and bulk liquid. For the droplet heat transfer, there are multiple sets of assumptions that can be made and correlations that can be used. Currently, two working models - the TankSIM model and Easy5 model – provide for an overview of the different approaches available. The TankSIM model and Easy5 model use two different models for droplet heating and evaporation that illustrate how the models use different types of mechanisms to arrive at the same answer. For the TankSIM model, droplets are treated as spheres of constant radius. Heat is transferred from the ullage to the droplet and warms the droplet until it reaches saturation, then the droplet begins evaporating and reducing its radius and mass. To calculate the heat transfer coefficient between the droplet and ullage, the Ranz-Marshall correlation is used. To determine the number of droplets in the ullage, a resident mass approach is used. This approach averages the number of droplets such that residuals at the start-up and shut-off of the spray bar cancel out. This same approach is used in the Easy5 model. The GFSSP model implements a linked list to track individual droplet “nodes” within the model. For the Easy5 model, the droplet is assumed to have an interface at a temperature equal to the saturation temperature corresponding to the pressure of the gas phase. The heat transfer from the gas to the interface and the interface to the droplet bulk is then calculated, and the net mass transfer between the droplet and interface is determined by performing an energy balance across the interface. For the gas side of the interface, the Ranz-Marshall correlation is used. For the liquid side of the interface, a variety of correlations were tried, including Kronig and Brink (1950) and effective conductivity models. As a result of these assumptions, the Easy5 model currently predicts faster depressurization, as at saturated vapor conditions, the heat transfer coeffect on the liquid side for the Easy5 model is greater than the heat transfer coefficient predicted by Ranz-Marshall used in the TankSIM code. This greater heat flux translates into faster condensation of the saturated ullage gas. At the bulk liquid to ullage interface, the models are in much closer agreement. Both models model the ullage as a sphere centered within the bulk liquid in the tank, and both use the energy-jumping boundary condition to model heat and mass transfer across the interface. There are slight differences in how the interface temperature is calculated, however. The Easy5 model assumes the temperature of the interface is equal to the saturation temperature associated with the pressure of the gas phase. The TankSIM model calculates this temperature with Alabovskii’s equation, which provides a correction factor for interface temperatures. Analysis tasks are focused on determining rates of depressurization within the tank during active cooling operation. To maintain net positive suction head at the pump inlet, the tank pressure cannot fall faster than the saturation pressure associated with the temperature of the bulk liquid. Additionally, there is interest in analyzing the performance of the loop at different pump speeds and cryocooler input powers. Adjusting the flowrate affects both the performance of the heat exchanger between the cryocooler and pumped liquid, and the heat transfer between the droplet spray and the ullage. Ideally, a pump speed and cryocooler power can be selected that will allow the tank to operate in zero-boil-off mode with a very narrow range of storage pressure.

zero boil-off↗

Low-thrust chemical propulsion system propellant expulsion and thermal conditioning study

Thermal conditioning systems for satisfying engine net positive suction pressure (NPSP) requirements, and propellant expulsion systems for achieving propellant dump during a return-to-launch site (RTLS) abort were studied for LH2/LO2 and LCH4/LO2 upper stage propellant combinations. A state-of-the-art thermal conditioning system employing helium injection beneath the liquid surface shows the lowest weight penalty for LO2 and LCH4. A technology system incorporating a thermal subcooler (heat exchanger) for engine NPSP results in the lowest weight penalty for the LH2 tank. A preliminary design of two state-of-the-art and two new technology systems indicates a weight penalty difference too small to warrant development of a LH2 thermal subcooler. Analysis results showed that the LH2/LO2 propellant expulsion system is optimized for maximum dump line diameters, whereas the LCH4/LO2 system is optimized for minimum dump line diameter (LCH4) and maximum dump line diameter (LO2). The primary uncertainty is the accurate determination of two-phase flow rates through the dump system; experimentation is not recommended because this uncertainty is not considered significant.

Merino, F.↗

Extended duration lunar lander

Selenium Technologies has been conducting preliminary design work on a manned lunar lander for use in NASA's First Lunar Outpost (FLO) program. The resulting lander is designed to carry a crew of four astronauts to a prepositioned habitat on the lunar surface, remain on the lunar surface for up to 45 days while the crew is living in the habitat, then return the crew to earth via direct reentry and land recovery. Should the need arise, the crew can manually guide the lander to a safe lunar landing site, and live in the lander for up to ten days on the surface. Also, an abort to earth is available during any segment of the mission. The main propulsion system consists of a cluster of four modified Pratt and Whitney RL10 rocket engines that use liquid methane (LCH4) and liquid oxygen (LOX). Four engines are used to provide redundancy and a satisfactory engine out capability. Differences between the new propulsion system and the original system include slightly smaller engine size and lower thrust per engine, although specific impulse remains the same despite the smaller size. Concerns over nozzle ground clearance and engine reliability, as well as more information from Pratt and Whitney, brought about this change. The power system consists of a combination of regenerative fuel cells and solar arrays. While the lander is in flight to or from the moon, or during the lunar night, fuel cells provide all electrical power. During the lunar day, solar arrays are deployed to provide electrical power for the lander as well as electrolyzers, which separate some water back into hydrogen and oxygen for later use by the fuel cells. Total storage requirements for oxygen, hydrogen, and water are 61 kg, 551 kg, and 360 kg, respectively. The lander is a stage-and-a-half design with descent propellant, cargo, and landing gear contained in the descent stage, and the main propulsion system, ascent propellant, and crew module contained in the ascent stage. The primary structure for both stages is a truss, to which all tanks and components are attached. The crew module is a conical shape similar to that of the Apollo Command Module, but significantly larger with a height and maximum diameter of six meters.

Babic, Nikola↗

Simultaneous Sensor and Process Fault Diagnostics for Propellant Feed System

The main objective of this research is to extract fault features from sensor faults and process faults by using advanced fault detection and isolation (FDI) algorithms. A tank system that has some common characteristics to a NASA testbed at Stennis Space Center was used to verify our proposed algorithms. First, a generic tank system was modeled. Second, a mathematical model suitable for FDI has been derived for the tank system. Third, a new and general FDI procedure has been designed to distinguish process faults and sensor faults. Extensive simulations clearly demonstrated the advantages of the new design.

Cao, J.↗

Structural Analysis of the Redesigned Ice/Frost Ramp Bracket

This paper describes the interim structural analysis of a redesigned Ice/Frost Ramp bracket for the Space Shuttle External Tank (ET). The proposed redesigned bracket consists of mounts for attachment to the ET wall, supports for the electronic/instrument cables and propellant repressurization lines that run along the ET, an upper plate, a lower plate, and complex bolted connections. The eight nominal bolted connections are considered critical in the summarized structural analysis. Each bolted connection contains a bolt, a nut, four washers, and a non-metallic spacer and block that are designed for thermal insulation. A three-dimensional (3D) finite element model of the bracket is developed using solid 10-node tetrahedral elements. The loading provided by the ET Project is used in the analysis. Because of the complexities associated with accurately modeling the bolted connections in the bracket, the analysis is performed using a global/local analysis procedure. The finite element analysis of the bracket identifies one of the eight bolted connections as having high stress concentrations. A local area of the bracket surrounding this bolted connection is extracted from the global model and used as a local model. Within the local model, the various components of the bolted connection are refined, and contact is introduced along the appropriate interfaces determined by the analysts. The deformations from the global model are applied as boundary conditions to the local model. The results from the global/local analysis show that while the stresses in the bolts are well within yield, the spacers fail due to compression. The primary objective of the interim structural analysis is to show concept viability for static thermal testing. The proposed design concept would undergo continued design optimization to address the identified analytical assumptions and concept shortcomings, assuming successful thermal testing.

Phillips, D. R.↗