Engineering topics

Hastings, L. J.

Publications and source records attributed to Hastings, L. J..

At least 19 records

NASA NTRS2017

Tank System Integrated Model: A Cryogenic Tank Performance Prediction Program

Accurate predictions of the thermodynamic state of the cryogenic propellants, pressurization rate, and performance of pressure control techniques in cryogenic tanks are required for development of cryogenic fluid long-duration storage technology and planning for future space exploration missions. This Technical Memorandum (TM) presents the analytical tool, Tank System Integrated Model (TankSIM), which can be used for modeling pressure control and predicting the behavior of cryogenic propellant for long-term storage for future space missions. Utilizing TankSIM, the following processes can be modeled: tank self-pressurization, boiloff, ullage venting, mixing, and condensation on the tank wall. This TM also includes comparisons of TankSIM program predictions with the test data andexamples of multiphase mission calculations.

Bolshinskiy, L. G.↗

NASA NTRS2015

Solar Thermal Upper Stage Liquid Hydrogen Pressure Control Testing

High-energy cryogenic propellant is an essential element in future space exploration programs. Therefore, NASA and its industrial partners are committed to an advanced development/technology program that will broaden the experience base for the entire cryogenic fluid management community. Furthermore, the high cost of microgravity experiments has motivated NASA to establish government/aerospace industry teams to aggressively explore combinations of ground testing and analytical modeling to the greatest extent possible, thereby benefitting both industry and government entities. One such team consisting of ManTech SRS, Inc., Edwards Air Force Base, and Marshall Space Flight Center (MSFC) was formed to pursue a technology project designed to demonstrate technology readiness for an SRS liquid hydrogen (LH2) in-space propellant management concept. The subject testing was cooperatively performed June 21-30, 2000, through a partially reimbursable Space Act Agreement between SRS, MSFC, and the Air Force Research Laboratory. The joint statement of work used to guide the technical activity is presented in appendix A. The key elements of the SRS concept consisted of an LH2 storage and supply system that used all of the vented H2 for solar engine thrusting, accommodated pressure control without a thermodynamic vent system (TVS), and minimized or eliminated the need for a capillary liquid acquisition device (LAD). The strategy was to balance the LH2 storage tank pressure control requirements with the engine thrusting requirements to selectively provide either liquid or vapor H2 at a controlled rate to a solar thermal engine in the low-gravity environment of space operations. The overall test objective was to verify that the proposed concept could enable simultaneous control of LH2 tank pressure and feed system flow to the thruster without necessitating a TVS and a capillary LAD. The primary program objectives were designed to demonstrate technology readiness of the SRS concept at a system level as a first step toward actual flight vehicle demonstrations. More specific objectives included testing the pressure and feed control system concept hardware for functionality, operability, and performance. Valuable LH2 thermodynamic and fluid dynamics data were obtained for application to both the SRS concept and to future missions requiring space-based cryogen propellant management.

Moore, J. D.↗

NASA NTRS2015

TankSIM: A Cryogenic Tank Performance Prediction Program

Accurate prediction of the thermodynamic state of the cryogenic propellants in launch vehicle tanks is necessary for mission planning and successful execution. Cryogenic propellant storage and transfer in space environments requires that tank pressure be controlled. The pressure rise rate is determined by the complex interaction of external heat leak, fluid temperature stratification, and interfacial heat and mass transfer. If the required storage duration of a space mission is longer than the period in which the tank pressure reaches its allowable maximum, an appropriate pressure control method must be applied. Therefore, predictions of the pressurization rate and performance of pressure control techniques in cryogenic tanks are required for development of cryogenic fluid long-duration storage technology and planning of future space exploration missions. This paper describes an analytical tool, Tank System Integrated Model (TankSIM), which can be used for modeling pressure control and predicting the behavior of cryogenic propellant for long-term storage for future space missions. It is written in the FORTRAN 90 language and can be compiled with any Visual FORTRAN compiler. A thermodynamic vent system (TVS) is used to achieve tank pressure control. Utilizing TankSIM, the following processes can be modeled: tank self-pressurization, boiloff, ullage venting, and mixing. Details of the TankSIM program and comparisons of its predictions with test data for liquid hydrogen and liquid methane will be presented in the final paper.

Bolshinskiy, L. G.↗

NASA NTRS2015

TankSIM: A Cryogenic Tank Performance Prediction Program

Developed for predicting the behavior of cryogenic liquids inside propellant tanks under various environmental and operating conditions. Provides a multi-node analysis of pressurization, ullage venting and thermodynamic venting systems (TVS) pressure control using axial jet or spray bar TVS. Allows user to combine several different phases for predicting the liquid behavior for the entire flight mission timeline or part of it. Is a NASA in-house code, based on FORTRAN 90-95 and Intel Visual FORTRAN compiler, but can be used on any other platform (Unix-Linux, Compaq Visual FORTRAN, etc.). The last Version 7, released on December 2014, included detailed User's Manual. Includes the use of several RefPROP subroutines for calculating fluid properties.

Bolshinskiy, L. G.↗

NASA NTRS2014

Liquid Methane Testing With a Large-Scale Spray Bar Thermodynamic Vent System

NASA's Marshall Space Flight Center conducted liquid methane testing in November 2006 using the multipurpose hydrogen test bed outfitted with a spray bar thermodynamic vent system (TVS). The basic objective was to identify any unusual or unique thermodynamic characteristics associated with densified methane that should be considered in the design of space-based TVSs. Thirteen days of testing were performed with total tank heat loads ranging from 720 to 420 W at a fill level of approximately 90%. It was noted that as the fluid passed through the Joule-Thompson expansion, thermodynamic conditions consistent with the pervasive presence of metastability were indicated. This Technical Publication describes conditions that correspond with metastability and its detrimental effects on TVS performance. The observed conditions were primarily functions of methane densification and helium pressurization; therefore, assurance must be provided that metastable conditions have been circumvented in future applications of thermodynamic venting to in-space methane storage.

Hastings, L. J.↗

NASA NTRS2013

Large-Scale Liquid Hydrogen Tank Rapid Chill and Fill Testing for the Advanced Shuttle Upper Stage Concept

Cryogenic upper stages in the Space Shuttle program were prohibited primarily due to a safety risk of a 'return to launch site' abort. An upper stage concept addressed this concern by proposing that the stage be launched empty and filled using shuttle external tank residuals after the atmospheric pressure could no longer sustain an explosion. However, only about 5 minutes was allowed for tank fill. Liquid hydrogen testing was conducted within a near-ambient environment using the multipurpose hydrogen test bed 638.5 ft3 (18m3) cylindrical tank with a spray bar mounted longitudinally inside. Although the tank was filled within 5 minutes, chilldown of the tank structure was incomplete, and excessive tank pressures occurred upon vent valve closure. Elevated tank wall temperatures below the liquid level were clearly characteristic of film boiling. The test results have substantial implications for on-orbit cryogen transfer since the formation of a vapor film would be much less inhibited due to the reduced gravity. However, the heavy tank walls could become an asset in normal gravity testing for on-orbit transfer, i.e., if film boiling in a nonflight weight tank can be inhibited in normal gravity, then analytical modeling anchored with the data could be applied to reduced gravity environments with increased confidence.

Flachbart, R. H.↗

NASA NTRS2012

Liquid Acquisition Device Design Sensitivity Study

In-space propulsion often necessitates the use of a capillary liquid acquisition device (LAD) to assure that gas-free liquid propellant is available to support engine restarts in microgravity. If a capillary screen-channel device is chosen, then the designer must determine the appropriate combination screen mesh and channel geometry. A screen mesh selection which results in the smallest LAD width when compared to any other screen candidate (for a constant length) is desirable; however, no best screen exists for all LAD design requirements. Flow rate, percent fill, and acceleration are the most influential drivers for determining screen widths. Increased flow rates and reduced percent fills increase the through-the-screen flow pressure losses, which drive the LAD to increased widths regardless of screen choice. Similarly, increased acceleration levels and corresponding liquid head pressures drive the screen mesh selection toward a higher bubble point (liquid retention capability). After ruling out some screens on the basis of acceleration requirements alone, candidates can be identified by examining screens with small flow-loss-to-bubble point ratios for a given condition (i.e., comparing screens at certain flow rates and fill levels). Within the same flow rate and fill level, the screen constants inertia resistance coefficient, void fraction, screen pore or opening diameter, and bubble point can become the driving forces in identifying the smaller flow-loss-to-bubble point ratios.

VanDyke, M. K.↗

NASA NTRS2012

Solar Thermal Upper Stage Liquid Hydrogen Pressure Control Testing and Analytical Modeling

The demonstration of a unique liquid hydrogen (LH2) storage and feed system concept for solar thermal upper stage was cooperatively accomplished by a Boeing/NASA Marshall Space Flight Center team. The strategy was to balance thermodynamic venting with the engine thrusting timeline during a representative 30-day mission, thereby, assuring no vent losses. Using a 2 cubic m (71 cubic ft) LH2 tank, proof-of-concept testing consisted of an engineering checkout followed by a 30-day mission simulation. The data were used to anchor a combination of standard analyses and computational fluid dynamics (CFD) modeling. Dependence on orbital testing has been incrementally reduced as CFD codes, combined with standard modeling, continue to be challenged with test data such as this.

Olsen, A. D.↗

NASA NTRS2011

Thermal Integration of a Liquid Acquisition Device into a Cryogenic Feed System

Primary objectives of this effort were to define the following: (1) Approaches for quantification of the accumulation of thermal energy within a capillary screen liquid acquisition device (LAD) for a lunar lander upper stage during periods of up to 210 days on the lunar surface, (2) techniques for mitigating heat entrapment, and (3) perform initial testing, data evaluation. The technical effort was divided into the following categories: (1) Detailed thermal modeling of the LAD/feed system interactions using both COMSOL computational fluid device and standard codes, (2) FLOW-3D modeling of bulk liquid to provide interfacing conditions for the LAD thermal modeling, (3) condensation conditioning of capillary screens to stabilize surface tension retention capability, and (4) subscale testing of an integrated LAD/feed system. Substantial progress was achieved in the following technical areas: (1) Thermal modeling and experimental approaches for evaluating integrated cryogen LAD/feed systems, at both the system and component levels, (2) reduced gravity pressure control analyses, (3) analytical modeling and testing for capillary screen conditioning using condensation and wicking, and (4) development of rapid turnaround testing techniques for evaluating LAD/feed system thermal and fluid integration. A comprehensive effort, participants included a diverse cross section of representatives from academia, contractors, and multiple Marshall Space Flight Center organizations.

Hastings, L. J.↗

NASA NTRS2011

Characteristics of Subcooled Liquid Methane During Passage Through a Spray-Bar Joule-Thompson Thermodynamic Vent System

NASA s Marshall Space Flight Center (MSFC) conducted liquid methane (LCH4) testing in November 2006 using the multipurpose hydrogen test bed (MHTB) outfitted with a spray-bar thermodynamic vent system (TVS). The basic objective was to identify any unusual or unique thermodynamic characteristics associated with subcooled LCH4 that should be considered in the design of space-based TVSs. Thirteen days of testing were performed with total tank heat loads ranging from 720 W to 420 W at a fill level of approximately 90%. During an updated evaluation of the data, it was noted that as the fluid passed through the Joule Thompson expansion, thermodynamic conditions consistent with the pervasive presence of metastability were indicated. This paper describes the observed thermodynamic conditions that correspond with metastability and effects on TVS performance.

Hastings, L. J.↗

NASA NTRS2010

Large-Scale Demonstration of Liquid Hydrogen Storage with Zero Boiloff for In-Space Applications

Cryocooler and passive insulation technology advances have substantially improved prospects for zero-boiloff cryogenic storage. Therefore, a cooperative effort by NASA s Ames Research Center, Glenn Research Center, and Marshall Space Flight Center (MSFC) was implemented to develop zero-boiloff concepts for in-space cryogenic storage. Described herein is one program element - a large-scale, zero-boiloff demonstration using the MSFC multipurpose hydrogen test bed (MHTB). A commercial cryocooler was interfaced with an existing MHTB spray bar mixer and insulation system in a manner that enabled a balance between incoming and extracted thermal energy.

Hastings, L. J.↗

NASA NTRS2007

Capillary Liquid Acquisition Device Heat Entrapment

Cryogenic liquid acquisition devices (LADs) for space-based propulsion interface directly with the feed system, which can be a significant heat leak source. Further, the accumulation of thermal energy within LAD channels can lead to the loss of subcooled propellant conditions and result in feed system cavitation during propellant outflow. Therefore, the fundamental question addressed by this program was: To what degree is natural convection in a cryogenic liquid constrained by the capillary screen meshes envisioned for LADs? Testing was first conducted with water as the test fluid, followed by LN2 tests. In either case, the basic experimental approach was to heat the bottom of a cylindrical column of test fluid to establish stratification patterns measured by temperature sensors located above and below a horizontal screen barrier position. Experimentation was performed without barriers, with screens, and with a solid barrier. The two screen meshes tested were those typically used by LAD designers, 200x1400 and 325x2300, both with Twill Dutch Weave. Upon consideration of both the water and LN2 data, it was concluded that heat transfer across the screen meshes was dependent upon barrier thermal conductivity and that the capillary screen meshes were impervious to natural convection currents.

Bolshinskiy, L. G.↗

NASA NTRS2007

Thermodynamic Vent System Performance Testing with Subcooled Liquid Methane and Gaseous Helium Pressurant

Due to its high specific impulse and favorable thermal properties for storage, liquid methane (LCH4) is being considered as a candidate propellant for exploration architectures. In order to gain an -understanding of any unique considerations involving micro-gravity pressure control with LCH4, testing was conducted at the Marshall Space Flight Center using the Multipurpose Hydrogen Test Bed (MHTB) to evaluate the performance of a spray-bar thermodynamic vent system (TVS) with subcooled LCH4 and gaseous helium (GHe) pressurant. Thirteen days of testing were performed in November 2006, with total tank heat leak conditions of about 715 W and 420 W at a fill level of approximately 90%. The TVS system was used to subcool the LCH4 to a liquid saturation pressure of approximately 55.2 kPa before the tank was pressurized with GHe to a total pressure of 165.5 kPa. A total of 23 TVS cycles were completed. The TVS successfully controlled the ullage pressure within a prescribed control band but did not maintain a stable liquid saturation pressure. This was likely. due to a TVS design not optimized for this particular propellant and test conditions, and possibly due to a large artificially induced heat input directly into the liquid. The capability to reduce liquid saturation pressure as well as maintain it within a prescribed control band, demonstrated that the TVS could be used to seek and maintain a desired liquid inlet temperature for an engine (at a cost of propellant lost through the TVS vent). One special test was conducted at the conclusion of the planned test activities. Reduction of the tank ullage pressure by opening the Joule-Thomson valve (JT) without operating the pump was attempted. The JT remained open for over 9300 seconds, resulting in an ullage pressure reduction of 30 kPa. The special test demonstrated the feasibility of using the JT valve for limited ullage pressure reduction in the event of a pump failure.

Flachbart, R. H.↗

NASA NTRS2006

Testing the Effects of Helium Pressurant on Thermodynamic Vent System Performance with Liquid Hydrogen

In support of the development of a zero gravity pressure control capability for liquid hydrogen, testing was conducted at the Marshall Space Flight Center using the Multipurpose Hydrogen Test Bed (MHTB) to evaluate the effects of helium pressurant on the performance of a spray bar thermodynamic vent system (TVS). Fourteen days of testing was performed in August - September 2005, with an ambient heat leak of about 70-80 watts and tank fill levels of 90%, 50%, and 25%. The TVS successfully controlled the tank pressure within a +/- 3.45 kPa (+/- 0.5 psi) band with various helium concentration levels in the ullage. Relative to pressure control with an "all hydrogen" ullage, the helium presence resulted in 10 to 30 per cent longer pressure reduction durations, depending on the fill level, during the mixing/venting phase of the control cycle. Additionally, the automated control cycle was based on mixing alone for pressure reduction until the pressure versus time slope became positive, at which time the Joule-Thomson vent was opened. Testing was also conducted to evaluate thermodynamic venting without the mixer operating, first with liquid then with vapor at the recirculation line inlet. Although ullage stratification was present, the ullage pressure was successfully controlled without the mixer operating. Thus, if vapor surrounded the pump inlet in a reduced gravity situation, the ullage pressure can still be controlled by venting through the TVS Joule Thomson valve and heat exchanger. It was evident that the spray bar configuration, which extends almost the entire length of the tank, enabled significant thermal energy removal from the ullage even without the mixer operating. Details regarding the test setup and procedures are presented in the paper. 1

Flachbart, R. H.↗

NASA NTRS2005

Liquid Nitrogen (Oxygen Simulent) Thermodynamic Venting System Test Data Analysis

In designing systems for the long-term storage of cryogens in low gravity space environments, one must consider the effects of thermal stratification on excessive tank pressure that will occur due to environmental heat leakage. During low gravity operations, a Thermodynamic Venting System (TVS) concept is expected to maintain tank pressure without propellant resettling. The TVS consists of a recirculation pump, Joule-Thomson (J-T) expansion valve, and a parallel flow concentric tube heat exchanger combined with a longitudinal spray bar. Using a small amount of liquid extracted by the pump and passing it though the J-T valve, then through the heat exchanger, the bulk liquid and ullage are cooled, resulting in lower tank pressure. A series of TVS tests were conducted at the Marshall Space Flight Center using liquid nitrogen as a liquid oxygen simulant. The tests were performed at fill levels of 90%, 50%, and 25% with gaseous nitrogen and helium pressurants, and with a tank pressure control band of 7 kPa. A transient one-dimensional model of the TVS is used to analyze the data. The code is comprised of four models for the heat exchanger, the spray manifold and injector tubes, the recirculation pump, and the tank. The TVS model predicted ullage pressure and temperature and bulk liquid saturation pressure and temperature are compared with data. Details of predictions and comparisons with test data regarding pressure rise and collapse rates will be presented in the final paper.

Hedayat, A.↗

NASA NTRS2005

Testing of a Spray-bar Thermodynamic Vent System in Liquid Nitrogen

To support development of a microgravity pressure control capability for liquid oxygen, thermodynamic vent system (TVS) testing was conducted at Marshall Space Flight Center (MSFC) using liquid nitrogen (LN2) as a LOX simulant. The spray bar TVS hardware used was originally designed by the Boeing Company for testing in liquid hydrogen (LH2). With this concept, a small portion of the tank fluid is passed through a Joule-Thomson (J-T) device, and then through a longitudinal spray bar mixed-heat exchanger in order to cool the bulk fluid. To accommodate the larger mass flow rates associated with LN2, the TVS hardware was modified by replacing the recirculation pump with an LN2 compatible pump and replacing the J-T valve. The primary advantage of the spray-bar configuration is that tank pressure control can be achieved independent of liquid and vapor location, enhancing the applicability of ground test data to microgravity conditions. Performance testing revealed that the spray-bar TVS was effective in controlling tank pressure within a 6.89 kPa band for fill levels of 90%, 50%, and 25%. Tests were also conducted with gaseous helium (GHe) in the ullage. The TVS operated nominally with GHe in the ullage, with performance similar to the tests with gaseous nitrogen (GN2). Testing demonstrated that the spray-bar TVS design was flexible enough for use in two different propellants with minimal hardware modifications.

Flachbart, R. H.↗

NASA NTRS2005

Liquid Nitrogen (Oxygen Simulant) Thermodynamic Vent System Test Data Analysis

In designing systems for the long-term storage of cryogens in low-gravity (space) environments, one must consider the effects of thermal stratification on tank pressure that will occur due to environmental heat leaks. During low-gravity operations, a Thermodynamic Vent System (TVS) concept is expected to maintain tank pressure without propellant resettling. A series of TVS tests was conducted at NASA Marshall Space Flight Center (MSFC) using liquid nitrogen (LN2) as a liquid oxygen (LO2) simulant. The tests were performed at tank til1 levels of 90%, 50%, and 25%, and with a specified tank pressure control band. A transient one-dimensional TVS performance program is used to analyze and correlate the test data for all three fill levels. Predictions and comparisons of ullage pressure and temperature and bulk liquid saturation pressure and temperature with test data are presented.

Hedayat, A.↗

NASA NTRS2004

Analytical Modeling and Test Correlation of Variable Density Multilayer Insulation for Cryogenic Storage

A unique foam/multilayer insulation (MLI) combination concept for orbital cryogenic storage was experimentally evaluated using a large-scale hydrogen tank. The foam substrate insulates for ground-hold periods and enables a gaseous nitrogen purge as opposed to helium. The MLI, designed for an on-orbit storage period for 45 days, includes several unique features including a variable layer density and larger but fewer perforations for venting during ascent to orbit. Test results with liquid hydrogen indicated that the MLI weight or tank heat leak is reduced by about half in comparison with standard MLI. The focus of this effort is on analytical modeling of the variable density MLI (VD-MLI) on-orbit performance. The foam/VD-MLI model is considered to have five segments. The first segment represents the optional foam layer. The second, third, and fourth segments represent three different MLI layer densities. The last segment is an environmental boundary or shroud that surrounds the last MLI layer. Two approaches are considered: a variable density MLI modeled layer by layer and a semiempirical model or "modified Lockheed equation." Results from the two models were very comparable and were within 5-8 percent of the measured data at the 300 K boundary condition.

Hastings, L. J.↗