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Cryogenic Propellant Storage and Transfer (CPST) Engineering Development Unit (EDU) Multilayer Insulation (MLI) Installation Overview
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The Pursuit of In-Space Cryogenic Propellant Storage and Transfer
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Study of cryogenic container thermodynamics during propellant transfer
Study of thermodynamic phenomena occurring during transfer of cryogenic liquids from dewar to receiver tank reveals that the basic cause of tank implosion is evaporation rate of droplets entering the tank in the early transfer phase. Analyses of the thermodynamics involved and implosion prevention techniques are included.
OTV orbital tanking systems
Orbital transfer of cryogenic propellants could benefit spacecraft and Orbital Transfer Vehicle (OTV) missions in the 1980s by supplying main propulsion, attitude control, or other fluid systems. The Space Shuttle can operate as a tanker when equipped with cryogenic propellant storage and orbital transfer systems. The key technologies are multilayer insulation, capillary propellant acquisition, zero-g gaging, orbital chilldown, and possibly large flight weight dewars. The technologies and operations could be realistically demonstrated using a Centaur that has been integrated with the Shuttle. Orbital refueling capability can enhance the usefulness of the whole Shuttle program
Investigation of Transient Gas Phase Column Density Due to Droplet Evaporation
A NASA robotic refueling mission experiment on board the International Space Station (ISS) was designed to repeatedly transfer simulated cryogenic propellant between two dewars. After each metered transfer, the cryogen was to be vented overboard via sublimation or evaporation. ISS payload providers must conduct analyses to demonstrate that any planned gaseous venting generate no more than a certain level of material that may interfere with optical measurements from other payloads that may be located nearby. This requirement is expressed in terms of a maximum column number density (CND). For the experiment under consideration, fluid droplets likely would accompany any such vapor. Earlier related studies led to development of analytical expressions for column density along general paths for a number of practical cases under steady conditions, including droplet evaporation. These expressions are not appropriate for rapid evaporation of small droplets however, since the droplets cannot sustain mass flow rates consistent with steady conditions. In this work, analytical expressions are developed for estimating column density near a rapidly evaporating droplet along general paths. The influence for instantaneous evaporation is created first as a limiting case, where it is found the peak value occurs at the time it takes a wave of vapor to reach the closest point along the optical path traveling at its most probable thermal speed. Next, the case for finite-period evaporation is evaluated for constant conditions. Compared to the instantaneous case, peak column density occurs shortly after droplet extinction, but at a lower intensity. A new mathematical function is discovered that solves the integrals associated with this case. Finally, ways to account for droplet motion and changes in evaporation rate with size and temperature are discussed in this framework.
Space Station Freedom/lunar transfer vehicle propellant operation hazard analysis
Space Station Freedom (SSF), as a transportation node for Space Exploration Initiative missions, would involve the assembly and refurbishing of lunar and Mars transfer vehicles. This includes operations involving cryogenic propellants (LH2 7 LO2) such as storing and handling of loaded propellant tanks, assembly onto the vehicle, and propellant transfer. Cryogenic propellants dictate rigorous safety precautions and impose unique requirements to ensure flight safety to both personnel and SSF elements. The objective of this study is to identify potential hazards and risks associated with cryogenic propellants. This involves identification of pertinent system design features and operational procedures. Criticality of identified risks/hazards shall be assessed and those that fall in the catastrophic and critical categories shall include mitigating solutions.
Integrated System for Health Management and Autonomous Control (ISHM-AC) for Cryogenic Operations on the Simulated Propellant Loading System
Autonomous control systems represent a technological barrier from manual and automated operated control systems in an industry wide application. An increase in energy-efficient storage, transfer and use of cryogens and cryogenic propellants on Earth and in space has been observed in space related industries between NASA, government and commercial programs. An increase in efficiency of cryogenic systems demands an increase in the capabilities of the control and monitoring system that manages them. As new technologies are developed for cryogenic systems, complexity and capability increases. The increase in complexities are a natural drive to develop better and more capable health monitoring and control system management. Current research and development efforts lead the Cryogenics Test Laboratory at the Kennedy Space Center to improve its automated control and health monitoring system from a Programmable Logic Control (PLC) based-only system to a fully Integrated System for Health Management (ISHM) - Autonomous Control (AC) capable of performing autonomous operations on a cryogenic propellant transfer system. This ISHM-AC system has been developed and tested by controlling a complete simulated propellant transfer operation. The capabilities and test results of this fully integrated autonomous system for cryogenics propellant transfer operation will be presented in this paper.
CFD Modeling of a Cryogenic Methane Drain Test with and without Induced Sloshing
Current planned NASA missions to the Moon and Mars involve the transfer of cryogenic propellants in orbit. These activities require large amounts of cryogenic propellant and the ability to transfer these fluids from one tank to another in an efficient manner. Predicting the pressurant required for the supply tank pressurization during the initial pressurization and expulsion process will be important to understand priori to reduce propellant margin.
Thermal Desktop Modeling of the 2016 CRYOTE-2 Tank Chill and Fill Tests
The storing and transfer of cryogenic propellants is an enabling technology for NASA as it moves to expand future missions into low Earth orbit (LEO) and beyond. The transfer of cryogenic propellants is of particular interest because it has never been successfully demonstrated in microgravity. Several ground tests have been conducted in past decades examining various tank chilldown and fill methods. Creating accurate models using these historical datasets is a vital step toward developing appropriate modeling tools to form pre-test predictions for eventual flight and ground tests of various novel injector concepts. The goal of this work was to create a working model in Thermal Desktop using data from the CRYOTE-2 experiments whose purpose was to demonstrate the chill and fill process in a spherical receiver tank parametrically examining the effect of injection method, receiver tank initial wall temperature and initial state, supply pressure, and mass flow rate on the NVF process. These tests were conducting using liquid nitrogen with different injectors with different injection patterns. The focus of the current work is on one particular spray nozzle. The pressure rise inside the tank, the fill level, and the change in the outside wall temperature were all tracked and compared with test data. The Thermal Desktop model was able to accurately predict each of these metrics for this nozzle within 11.0%, 22.0%, and 7.0%, respectively.
Modeling of A Large-Scale Liquid Oxygen Propellant Transfer Test
Current planned NASA missions to the Moon and Mars involve the transfer of cryogenic propellants in orbit. Correctly predicting the flow rate during the propellant transfer operation could help with planning these operations. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these propellant transfer processes can be used to predict the propellant transfer flow rate. To gain confidence in these computational models, appropriate anchoring and validation to experimental data can be performed. Ground tests conducted at SpaceX involving the transfer of liquid oxygen were carried out to investigate the effect of the thermodynamic conditions including inlet pressure and temperature and downstream pressure on the flow rate. The results from the test were compared against flow rate predictions from a commercially available two-phase flow software. On average the model predicted the flow rates within 10% of the experimentally observed flow rates for the full range of thermodynamic inlet and outlet conditions.
An analytical and experimental evaluation of shadow shields and their support members.
Review of the major results of an analytical and experimental program aimed at determining the potential effectiveness of shadow shields in minimizing radiant heat transfer into cryogenic propellant tanks on long-duration interplanetary missions, taking into account the thermal interaction between shields and their support structures. Analytical procedures are developed and applied that include the strut-shield interaction in predicting shadow shield performance. The results of experimental studies of the effects of configuration variables on the performance of a scale model of a shadow shield system are presented. The experimental results are used to verify the validity of analytical predictions. The results obtained show that: (1) shadow shields can be effective in reducing the heat transfer into cryogenic propellant tanks, and (2) the conductive heat transfer through supports can be reduced by selective surface coatings.
Cryogenic Spray Quenching of A Simulated Propellant Storage Tank Wall With Heat Transfer Enhancement By A Thin-Film Coating and Flow Pulsing in Microgravity
Human space exploration to the Moon, Mars, and possibly asteroids is NASA’s biggest challenge for the new millennium. One of the critical elements to this mission is the effective, sufficient, and reliable supply of cryogenic propellant fluids. Future lower-earth-orbiting (LEO) propellant fuel depots and human-carrying orbital transfer spacecraft flying to the moon and Mars will have to utilize the high thrust and high efficiency of liquid cryogenic chemical propulsion or nuclear thermal propulsion. Efficient in-space tank-to-tank propellant transfer (propellant fuel depot to orbital transfer spacecraft) of cryogenic propellants is an enabling technology for the planned Crewed Mars Surface Mission. The transfer of cryogenic propellants in space, however, has yet to be accomplished, solely due to the unavailability of cryogenic quenching heat transfer data during chilldown (quenching) and filling of the propellant receiver tank in reduced gravity and microgravity as liquid propellant cannot be stored in a required liquid state until the tank is quenched down to the liquid temperature. Therefore, highly energy efficient thermal-fluid management breakthrough concepts to conserve and minimize the cryogen consumption during propellant transfer have become the focus of research and engineering development, especially for the deep-space mission to Mars. In this paper, we introduce such concepts and demonstrate their feasibility for cryogenic storage tank chilldown in parabolic flights under a simulated space microgravity condition. In order to maximize the storage tank chilldown efficiency for the least amount of cryogen consumption, the technology adopted included cryogenic spray cooling, Teflon thin-film coating of the simulated tank surface, and spray flow pulsing. The completed flight experiments successfully demonstrated that spray cooling is the most efficient cooling method for the tank chilldown in microgravity. In microgravity, Teflon coating alone can improve the efficiency up to 72% and the efficiency can be improved up to 59% by flow pulsing alone. However, Teflon coating together with flow pulsing was found to substantially enhance the chilldown efficiency in microgravity for up to 113%.
An analytical and experimental evaluation of shadow shields and their support members
Experimental tests were performed on a model shadow shield thermal protection system to examine the effect of certain configuration variables. The experimental results were used to verify the ability of an analytical program to predict the shadow shield performance including the shield-support interaction. In general, the analysis (assuming diffuse surfaces) agreed well with the experimental support temperature profiles. The agreement for the shield profiles was not as good. The results demonstrated: (1) shadow shields can be effective in reducing the heat transfer into cryogenic propellant tanks, and (2) the conductive heat transfer through supports can be reduced by selective surface coatings.
Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen
Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.
Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen
Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.
Study of low gravity propellant transfer Quarterly progress report, 23 Sep. - 22 Dec. 1970
Modular transfer of cryogenic propellants for orbiting space stations using shuttle system
Velocity Vector Field Visualization of Flow in Liquid Acquisition Device Channel
A capillary flow liquid acquisition device (LAD) for cryogenic propellants has been developed and tested in NASA Glenn Research Center to meet the requirements of transferring cryogenic liquid propellants from storage tanks to an engine in reduced gravity environments. The prototypical mesh screen channel LAD was fabricated with a mesh screen, covering a rectangular flow channel with a cylindrical outlet tube, and was tested with liquid oxygen (LOX). In order to better understand the performance in various gravity environments and orientations at different liquid submersion depths of the screen channel LAD, a series of computational fluid dynamics (CFD) simulations of LOX flow through the LAD screen channel was undertaken. The resulting velocity vector field visualization for the flow in the channel has been used to reveal the gravity effects on the flow in the screen channel.