Engineering topics

Hedayat, A.

Publications and source records attributed to Hedayat, A..

At least 19 records

NASA NTRS2017

Numerical Modeling of an Integrated Vehicle Fluids System Loop for Pressurizing a Cryogenic Tank

This paper presents a numerical model of the pressurization loop of the Integrated Vehicle Fluids (IVF) system using the Generalized Fluid System Simulation Program (GFSSP). The IVF propulsion system, being developed by United Launch Alliance to reduce system weight and enhance reliability, uses boiloff propellants to drive thrusters for the reaction control system as well as to run internal combustion engines to develop power and drive compressors to pressurize propellant tanks. NASA Marshall Space Flight Center (MSFC) conducted tests to verify the functioning of the IVF system using a flight-like tank. GFSSP, a finite volume based flow network analysis software developed at MSFC, has been used to support the test program. This paper presents the simulation of three different test series, comparison of numerical prediction and test data and a novel method of presenting data in a dimensionless form. The paper also presents a methodology of implementing a compressor map in a system level code.

LeClair, A. C.↗

NASA NTRS2017

Modeling of Liquefaction of Cryogenic Propellant in a Tank

Over the past decades NASA has been focusing to develop technology that would to allow for production of cryogenic propellants on the surface of Mars. The in-situ propellant production reduces the amount of propellants needed to be taken to Mars and ultimately to reduce mission cost. Utilizing Martian resources, the produced gaseous propellants (i.e., oxygen and methane) are liquefied and stored prior to use on the Mars ascent vehicle. In this paper, a model for the liquefaction process of gaseous propellants in a cryogenically refrigerated tank is presented. The tank is considered to be cylindrical with elliptical top and bottom domes. A multi-node transient model is developed based on the mass and energy conservation equations and wall-gas and liquid-gas interface mass and heat transfer correlations. Description of the model and predicted results will be presented in the final paper.

Hedayat, A.↗

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 NTRS2017

An Overview of Recent Cryogenic Fluid Management Developments

Long-term storage, supply, and transfer of cryogenic fluids are critical capabilities needed to advance the human exploration of space. Technologies and advanced development programs have been pursued to address issues likely to confront the designers and developers of future cryogenic fluid management (CFM) subsystems and propulsion systems. NASA and aerospace industries have continued to conduct research and development for the propulsion applications of cryogenic fluids. From the well known in-space applications, to new applications involving superconducting motors within multiple different aircraft, and a renewed interest in production of oxygen on Mars, NASA continues to probe cryogenic applications within propulsion. This article presents brief reviews of several of the current CFM efforts to support future space missions. NASA GRC is currently focusing on understanding some of the finer points in the application of multilayer insulation. GRC recently finished the activation of a new calorimeter that operates at 20 K with a warm boundary that can operate either around 90 K or at 300 K. Current testing is focused on investigating multiple different seam concepts, initially between temperatures of 300 K and 20 K, and between 20 K and 90 K. One of the larger recent NASA investments has been on the Structural Heat Intercept, Insulation, and Vibration Experiment Rig (SHIIVER). SHIIVER is a 4 m diameter tank that is approximately 1/2 scale of the planned upper stage of the new Space Launch System (SLS) rocket. SHIIVER is focused on demonstrating the thermal benefits of multilayer insulation on the tank domes and boil-off vapor cooling on structural cylinders that hold the tank in-line on the rocket. It will also quantify any damage that may incur during the acoustic environment of over 160 decibels that SLS will experience on its trip to Earth orbit. In support of the possible production of oxygen out of the Mars' atmosphere, a team comprised of four NASA centers (GRC, MSFC, JSC, and KSC) collaborated to investigate multiple different hardware combinations, refrigeration cycles, and integration techniques to minimize power and mass of the storage and liquefaction system. Moreover, high efficiency, high capacity cryocoolers are an element of CFM which is essential for achieving NASA's future long duration missions. Currently in development is a 20W at 20K unit for use with liquid hydrogen. It is scheduled for delivery to NASA in the summer of 2017. Two Phase I SBIRS have recently concluded resulting in the preliminary design of two different 90K units, each having a refrigeration capacity of approximately 150W. Once the development efforts are complete, these high capacity 90K units will be integrated into the design of NASA's Liquid Oxygen (LOX)/Methane applications such as the Lander and Ascent Vehicles, or possibly an in-space stage. CFM technology is critical to the success of missions to Mars, Planetary Exploration, and In-Situ Resource Utilization (ISRU) for cryogenic propellant production. NASA is focusing on the development of CFM technologies needed to provide necessary data and relevant experience to support informed decisions on implementation of design of cryogenic systems for long term space missions. Lessons learned from the described CFM developments would lead to enhanced safety and reliability and enabling technologies which could allow NASA to meet future space exploration goals.

Hedayat, A.↗

NASA NTRS2015

Use of Generalized Fluid System Simulation Program (GFSSP) for Teaching and Performing Senior Design Projects at the Educational Institutions

This paper describes the experience of the authors in using the Generalized Fluid System Simulation Program (GFSSP) in teaching Design of Thermal Systems class at University of Alabama in Huntsville. GFSSP is a finite volume based thermo-fluid system network analysis code, developed at NASA/Marshall Space Flight Center, and is extensively used in NASA, Department of Defense, and aerospace industries for propulsion system design, analysis, and performance evaluation. The educational version of GFSSP is freely available to all US higher education institutions. The main purpose of the paper is to illustrate the utilization of this user-friendly code for the thermal systems design and fluid engineering courses and to encourage the instructors to utilize the code for the class assignments as well as senior design projects. The need for a generalized computer program for thermofluid analysis in a flow network has been felt for a long time in aerospace industries. Designers of thermofluid systems often need to know pressures, temperatures, flow rates, concentrations, and heat transfer rates at different parts of a flow circuit for steady state or transient conditions. Such applications occur in propulsion systems for tank pressurization, internal flow analysis of rocket engine turbopumps, chilldown of cryogenic tanks and transfer lines, and many other applications of gas-liquid systems involving fluid transients and conjugate heat and mass transfer. Computer resource requirements to perform time-dependent, three-dimensional Navier-Stokes computational fluid dynamic (CFD) analysis of such systems are prohibitive and therefore are not practical. Available commercial codes are generally suitable for steady state, single-phase incompressible flow. Because of the proprietary nature of such codes, it is not possible to extend their capability to satisfy the above-mentioned needs. Therefore, the Generalized Fluid System Simulation Program (GFSSP1) has been developed at NASA Marshall Space Flight Center (MSFC) as a general fluid flow system solver capable of handling phase changes, compressibility, mixture thermodynamics and transient operations. It also includes the capability to model external body forces such as gravity and centrifugal effects in a complex flow network. The objectives of GFSSP development are: a) to develop a robust and efficient numerical algorithm to solve a system of equations describing a flow network containing phase changes, mixing, and rotation; and b) to implement the algorithm in a structured, easy-to-use computer program. The analysis of thermofluid dynamics in a complex network requires resolution of the system into fluid nodes and branches, and solid nodes and conductors as shown in Figure 1. Figure 1 shows a schematic and GFSSP flow circuit of a counter-flow heat exchanger. Hot nitrogen gas is flowing through a pipe, colder nitrogen is flowing counter to the hot stream in the annulus pipe and heat transfer occurs through metal tubes. The problem considered is to calculate flowrates and temperature distributions in both streams. GFSSP has a unique data structure, as shown in Figure 2, that allows constructing all possible arrangements of a flow network with no limit on the number of elements. The elements of a flow network are boundary nodes where pressure and temperature are specified, internal nodes where pressure and temperature are calculated, and branches where flowrates are calculated. For conjugate heat transfer problems, there are three additional elements: solid node, ambient node, and conductor. The solid and fluid nodes are connected with solid-fluid conductors. GFSSP solves the conservation equations of mass and energy, and equation of state in internal nodes to calculate pressure, temperature and resident mass. The momentum conservation equation is solved in branches to calculate flowrate. It also solves for energy conservation equations to calculate temperatures of solid nodes. The equations are coupled and nonlinear; therefore, they are solved by an iterative numerical scheme. GFSSP employs a unique numerical scheme known as simultaneous adjustment with successive substitution (SASS), which is a combination of Newton-Raphson and successive substitution methods. The mass and momentum conservation equations and the equation of state are solved by the Newton-Raphson method while the conservation of energy and species are solved by the successive substitution method. GFSSP is linked with two thermodynamic property programs, GASP2 and WASP3 and GASPAK4, that provide thermodynamic and thermophysical properties of selected fluids. Both programs cover a range of pressure and temperature that allows fluid properties to be evaluated for liquid, liquid-vapor (saturation), and vapor region. GASP and WASP provide properties of 12 fluids. GASPAK includes a library of 36 fluids. GFSSP has three major parts. The first part is the graphical user interface (GUI), visual thermofluid analyzer of systems and components (VTASC). VTASC allows users to create a flow circuit by a 'point and click' paradigm. It creates the GFSSP input file after the completion of the model building process. GFSSP's GUI provides the users a platform to build and run their models. It also allows post-processing of results. The network flow circuit is first built using three basic elements: boundary node, internal node, and branch.

Majumdar, A. K.↗

NASA NTRS2015

Use of Generalized Fluid System Simulation Program (GFSSP) for Teaching and Performing Senior Design Projects at the Educational Institutions

Majumdar, A. K.↗

NASA NTRS2015

Cryogenic Fluid Management Technology Development for Nuclear Thermal Propulsion

Cryogenic fluid management technology is critical to the success of future nuclear thermal propulsion powered vehicles and long duration missions. This paper discusses current capabilities in key technologies and their development path. The thermal environment, complicated from the radiation escaping a reactor of a nuclear thermal propulsion system, is examined and analysis presented. The technology development path required for maintaining cryogenic propellants in this environment is reviewed. This paper is intended to encourage and bring attention to the cryogenic fluid management technologies needed to enable nuclear thermal propulsion powered deep space missions.

Taylor, B. D.↗

NASA NTRS2015

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

To gain confidence in developing analytical models of the purging process for the cryogenic main propulsion systems of upper stage, two test series were conducted. The test article, a 3.35 m long with the diameter of 20 cm incline line, was filled with liquid or gaseous hydrogen and then purged with gaseous helium (GHe). Total of 10 tests were conducted. The influences of GHe flow rates and initial temperatures were evaluated. The Generalized Fluid System Simulation Program (GFSSP), an in-house general-purpose fluid system analyzer computer program, was utilized to model and simulate selective tests. The test procedures, modeling descriptions, and the results are presented in the following sections.

Hedayat, A.↗

NASA NTRS2015

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

The purging operations for cryogenic main propulsion systems of upper stage are usually carried out for the following cases: 1) Purging of the Fill/Drain line after completion of propellant loading. This operation allows the removal of residual propellant mass; and 2) Purging of the Feed/Drain line if the mission is scrubbed. The lines would be purged by connections to a ground high-pressure gas storage source. The flow-rate of purge gas should be regulated such that the pressure in the line will not exceed the required maximum allowable value. Exceeding the maximum allowable pressure may lead to structural damage in the line. To gain confidence in analytical models of the purge process, a test series was conducted. The test article, a 20-cm incline line, was filled with liquid hydrogen and then purged with gaseous helium (GHe). The influences of GHe flow-rates and initial temperatures were evaluated. The Generalized Fluid System Simulation Program, an in-house general-purpose computer program for flow network analysis, was utilized to model and simulate the testing. The test procedures, modeling descriptions, and the results will be presented in the final paper.

Hedayat, A.↗

NASA NTRS2015

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

To gain confidence in developing analytical models of the purging process for the cryogenic main propulsion systems of upper stage, two test series were conducted. Test article, a 3.35m long with the diameter of 20 cm incline line, was filled with liquid (LH2)or gaseous hydrogen (GH2) and then purged with gaseous helium (GHe). Total of 10 tests were conducted. Influences of GHe flow rates and initial temperatures were evaluated. Generalized Fluid System Simulation Program (GFSSP), an in-house general-purpose fluid system analyzer, was utilized to model and simulate selective tests.

Hedayat, A.↗

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

Modeling and Analysis of Chill and Fill Processes for the EDU Tank

NASA's future missions may require long-term storage and transfer of cryogenic propellants. The Engineering Development Unit (EDU), a NASA in-house effort supported by both Marshall Space Flight Center (MSFC) and Glenn Research Center (GRC), is a Cryogenic Fluid Management (CFM) test article that primarily serves as a manufacturing pathfinder and a risk reduction task for a future CFM payload. The EDU test article, comprises a flight like tank, internal components, insulation, and attachment struts. The EDU is designed to perform integrated passive thermal control performance testing with liquid hydrogen in a space-like vacuum environment. A series of tests, with liquid hydrogen as a testing fluid, was conducted at Test Stand 300 at MSFC during summer of 2014. The objective of this effort was to develop a thermal/fluid model for evaluating the thermodynamic behavior of the EDU tank during the chill and fill processes. Generalized Fluid System Simulation Program (GFSSP), an MSFC in-house general-purpose computer program for flow network analysis, was utilized to model and simulate the chill and fill portion of the testing. The model contained the liquid hydrogen supply source, feed system, EDU tank, and vent system. The modeling description and comparison of model predictions with the test data will be presented in the final paper.

Hedayat, A.↗

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

Tri-Gas Pressurization System Testing and Modeling for Cryogenic Applications

The use of Tri‐gas in rocket propulsion systems is somewhat of a new technology. This paper defines Tri‐gas as a mixture of gases composed largely of helium with a small percentage of a stoichiometric mixture of hydrogen and oxygen. When exposed to a catalyst the hydrogen and oxygen in the mixture combusts, significantly raising the temperature of the mixture. The increase in enthalpy resulting from the combustion process significantly decreases the required quantity of gas needed to pressurize the ullage of the vehicle propellant tanks. The objective of this effort was to better understand the operating characteristics of Tri‐gas in a pressurization system with low temperature applications. In conjunction with ongoing programs at NASA Marshall Space Flight Center, an effort has been undertaken to evaluate the operating characteristics of Tri‐gas through modeling and bench testing. Through improved understanding of the operating characteristics, the risk of using this new technology in a launch vehicle propulsion system was reduced. Bench testing of Tri‐gas was a multistep process that targeted gas characteristics and performance aspects that pose a risk to application in a pressurization system. Pressurization systems are vital to propulsion system performance. Keeping a target ullage pressure in propulsions tanks is necessary to supply propellant at the conditions and flow rates required to maintain desired engine functionality. The first component of testing consisted of sampling Tri‐gas sources that had been stagnant for various lengths of time in order to determine the rate at which stratification takes place. Second, a bench test was set up in which Tri‐gas was sent through a catalyst bed. This test was designed to evaluate the performance characteristics of Tri‐gas, under low temperature inlet temperatures, in a flight‐like catalyst bed reactor. The third, most complex, test examined the performance characteristics of Tri‐gas at low temperature temperatures in a test configuration built to more closely resemble a vehicle pressurization system. The results of these bench tests address various risks that all relate to underperformance of Tri‐gas pressurization systems.

Taylor, B.↗

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

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

The purging operations for cryogenic main propulsion systems of upper stage are usually carried out for the following cases: 1) Purging of the Fill/Drain line after completion of propellant loading. This operation allows the removal of residual propellant mass; and 2) Purging of the Feed/Drain line if the mission is scrubbed. The lines would be purged by connections to a ground high-pressure gas storage source. The flowrate of purge gas should be regulated such that the pressure in the line will not exceed the required maximum allowable value. Exceeding the maximum allowable pressure may lead to structural damage in the line. To gain confidence in analytical models of the purge process, a test series was conducted. The test article, a 20-cm incline line, was filled with liquid hydrogen and then purged with gaseous helium (GHe). The influences of GHe flowrates and initial temperatures were evaluated. The Generalized Fluid System Simulation Program, an in-house general-purpose computer program for flow network analysis, was utilized to model and simulate the testing. The test procedures, modeling descriptions, and the results will be presented in the final paper.

Hedayat, A.↗

NASA NTRS2013

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

Hedayat, A.↗

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.↗