Bearings and seals for cryogenic fluids
Lubricating mechanism, cage design, and heat generation of ball bearings for liquid hydrogen turbopumps, and design factors of contact seals for liquid fluorine pumps
Scibbe, H. W.↗
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Comparison of SPIRALG Performance Predictions with a Spread Sheet Solution
The aero design of an inward pumping spiral groove face seal using an in-house spread sheet was compared with predictions from the NASA code SPIRALG. The high pressure compressor exit of an aero gas turbine was chosen as the location for the candidate seal. This is a challenging environment as rotational velocity, pressure drop, and temperature are high. This presentation compares the resulting lift forces, leakages, and friction loss for various ride heights. Within practical ranges of ride height, the lift force predictions agreed well. However, both leakage and friction loss predictions were significantly different.
Roberts, Martyn G.↗
A finite-element-based perturbation model for the rotordynamic analysis of shrouded pump impellers: Part 2: User's guide
This report describes the computational steps involved in executing a finite-element-based perturbation model for computing the rotor dynamic coefficients of a shrouded pump impeller or a simple seal. These arise from the fluid/rotor interaction in the clearance gap. In addition to the sample cases, the computational procedure also applies to a separate category of problems referred to as the 'seal-like' category. The problem, in this case, concerns a shrouded impeller, with the exception that the secondary, or leakage, passage is totally isolated from the primary-flow passage. The difference between this and the pump problem is that the former is analytically of the simple 'seal-like' configuration, with two (inlet and exit) flow-permeable stations, while the latter constitutes a double-entry / double-discharge flow problem. In all cases, the problem is that of a rotor clearance gap. The problem here is that of a rotor excitation in the form of a cylindrical whirl around the housing centerline for a smooth annular seal. In its centered operation mode, the rotor is assumed to give rise to an axisymmetric flow field in the clearance gap. As a result, problems involving longitudinal or helical grooves, in the rotor or housing surfaces, go beyond the code capabilities. Discarding, for the moment, the pre- and post-processing phases, the bulk of the computational procedure consists of two main steps. The first is aimed at producing the axisymmetric 'zeroth-order' flow solution in the given flow domain. Detailed description of this problem, including the flow-governing equations, turbulence closure, boundary conditions, and the finite-element formulation, was covered by Baskharone and Hensel. The second main step is where the perturbation model is implemented, with the input being the centered-rotor 'zeroth-order' flow solution and a prescribed whirl frequency ratio (whirl frequency divided by the impeller speed). The computational domain, in the latter case, is treated as three dimensional, with the number of computational planes in the circumferential direction being specified a priori. The reader is reminded that the deformations in the finite elements are all infinitesimally small because the rotor eccentricity itself is a virtual displacement. This explains why we have generically termed the perturbation model the 'virtually' deformable finite-element category. The primary outcome of implementing the perturbation model is the tangential and radial components, F(sub theta)(sup *) and F(sub r)(sup *) of the fluid-exerted force on the rotor surface due to the whirling motion. Repetitive execution of the perturbation model subprogram over a sufficient range of whirl frequency ratios, and subsequent interpolation of these fluid forces, using the least-square method, finally enable the user to compute the impeller rotor dynamic coefficients of the fluid/rotor interaction. These are the direct and cross-coupled stiffness, damping, and inertia effects of the fluid/rotor interaction.
Baskharone, Erian A.↗
Development of gas-to-gas lift pad dynamic seals, volumes 1 and 2
Dynamic tests were performed on self acting (hydrodynamic) carbon face rotary shaft seals to assess their potential, relative to presently used labyrinth seals, for improving performance of aircraft gas turbine engines by reducing air leakage flow rate at compressor end seal locations. Three self acting bearing configurations, designed to supply load support at the interface of the stationary carbon seal and rotating seal race, were tested. Two configurations, the shrouded taper and shrouded flat step, were incorporated on the face of the stationary carbon seal element. The third configuration, inward pumping spiral grooves, was incorporated on the hard faced surface of the rotating seal race. Test results demonstrated seal leakage air flow rates from 75 to 95% lower that can be achieved with best state-of-the-art labyrinth designs and led to identification of the need for a more geometrically stable seal design configuration which is presently being manufactured for subsequent test evaluation.
Pope, A. N.↗
An experimental investigation of rubbing interaction in labyrinth seals at cryogenic temperature
An experimental program was carried out to address issues related to the observed cracking of the titanium knife edges on the labyrinth seals of the high pressure fuel pump (HPFP) in the Space Shuttle main engine (SSME). Thermal shock experiments were carried out using a jet specimen with geometry similar to the knife edge geometry. These tests demonstrate that cracking of the titanium alloy is possible in a situation involving repeated thermal cycles over a wide temperature range, as might be realized during a rub in the liquid hydrogen fuel pump. High speed rub interaction tests were conducted using a representative knife edge and seal geometry over a broad range of interaction rates. Alternative materials were also experimentally evaluated. These tests provide information which can be used to design improved labyrinth seals for the HPFP of the SSME. In particular, plasma-sprayed aluminum-graphite was found to be significantly better than aluminum alloy seals used at present from the standpoint of rub performance. Ion nitriding of the titanium alloy knife edges was also found to improve rub performance compared with the untreated baseline knife edge material.
Dolan, F. X.↗
Compact Microwave Mercury Ion Clock for Deep-Space Applications
We have recently completed a breadboard ion-dock physics package based on Kg ions shuttled between a quadrupole and a 16-pole rf trap. With this architecture we have demonstrated short-term stability -1-2xl0-13 at 1 second, averaging to 10-15 at 1 day. This development shows that 8- maser quality stabilities can be produced in a small clock package, comparable in size to an oItra-stable quartz oscillator required for holding 1-2xl0-13 at 1 second. This performance was obtained in a sealed vacuum configuration where only agetter pump was used to maintain vacuum. The vacuum tube containing the traps has now been onder sealed vacuum conditions for nearly two years with no measurable degradation of ion trapping lifetimes or clock short-term performance. We have fabricated the vacuum tube, ion trap and UV windows from materials that will allow a - 400 C tube bake-out to prepare for tube sealoff. This approach to the vacuum follows the methods used in mght vacuum tube electronics, such as flight TWTA's where tube operation lifetime and shelf life of up to 15 years is achieved. We use neon as a buffer gas with 2-3 times less pressure induced frequency pulling than helium and, being heavier, negligable diffusion losses will occur over the operation lifetime.
space clock↗
Dynamic analysis of turbulent annular seals based on Hirs' lubrication equation
Expressions are derived which define dynamic coefficients for high-pressure annular seals typical of neck-ring and interstage seals employed in multistage centrifugal pumps. Completely developed turbulent flow is assumed in both the circumferential and axial directions, and is modeled in this analysis by Hirs' turbulent lubrication equations. Linear zeroth and first-order 'short-bearing' perturbation solutions are developed by an expansion in the eccentricity ratio. The influence of inlet swirl is accounted for in the development of the circumferential flow field. Comparisons are made between the stiffness, damping, and inertia coefficients derived herein based on Hirs' model and previously published results based on other models. Finally, numerical results are presented for interstage seals in the Space Shuttle Main Engine High Pressure Fuel Turbopump and a water pump.
Childs, D. W.↗
Custom Unit Pump Development for the EVA PLSS
This paper describes the effort by the Texas Engineering Experiment Station (TEES) and Honeywell for NASA to design and test a pre-flight prototype pump for use in the Extra-vehicular activity (EVA) portable life support subsystem (PLSS). Major design decisions were driven by the need to reduce the pump s mass, power, and volume compared to the existing PLSS pump. In addition, the pump must accommodate a much wider range of abnormal conditions than the existing pump, including vapor/gas bubbles and increased pressure drop when employed to cool two suits simultaneously. A positive displacement, external gear type pump was selected because it offers the most compact and highest efficiency solution over the required range of flow rates and pressure drops. An additional benefit of selecting a gear pump design is that it is self priming and capable of ingesting non-condensable gas without becoming air locked. The chosen pump design consists of a 28 V DC, brushless, seal-less, permanent magnet motor driven, external gear pump that utilizes a Honeywell development that eliminates the need for magnetic coupling. The pump design was based on existing Honeywell designs, but incorporated features specifically for the PLSS application, including all of the key features of the flight pump. Testing at TEES verified that the pump meets the design requirements for range of flow rates, pressure drop, power consumption, working fluid temperature, operating time, gas ingestion, and restart capability under both ambient and vacuum conditions. The pump operated at 40 to 240 lbm/hr flow rate, 35 to 100 oF pump temperature, and 5 to 10 psid pressure rise. Power consumption of the pump controller at the nominal operating point in both ambient and vacuum conditions was 9.5 W, which was less than the 12 W predicted. Gas ingestion capabilities were tested by injecting 100 cc of air into the fluid line; the pump operated normally throughout this test.
Schuller, Michael↗
Prospects for Ultra-Stable Timekeeping with Sealed Vacuum Operation in Multi-Pole Linear Ion Trap Standards
A recent long-term comparison between the compensated multi-pole Linear Ion Trap Standard (LITS) and the laser-cooled primary standards via GPS carrier phase time transfer showed a deviation of less than 2.7x10(exp -17)/day. A subsequent evaluation of potential drift contributors in the LITS showed that the leading candidates are fluctuations in background gases and the neon buffer gas. The current vacuum system employs a "flow-through" turbomolecular pump and a diaphragm fore pump. Here we consider the viability of a "sealed" vacuum system pumped by a non-evaporable getter for long-term ultra-stable clock operation. Initial tests suggests that both further stability improvement and longer mean-time-between-maintenance can be achieved using this approach
timekeeping stability↗
Analysis and design of helium-buffered face seals for the SSME high-pressure oxygen turbopump
One form of a gas-buffered seal consists of two opposed fluid-film face seals, each mating against a single collar. The buffer fluid is introduced at the OD and flows through the radial clearances of each seal to opposite and separate environments at the IDs. This arrangement was investigated for the helium buffer seals applied to the oxidizer pump of the Space Shuttle Main Engine (SSME). A variety of face configurations were considered, and the self-energized-hydrostatic and spiral-groove geometries were selected for detailed evaluation. Fluid-film performance, dynamic response, and thermoelastic distortions were determined. Because of very high temperature gradients, distortions of the turbine-side seal ring were excessive. Otherwise, performance was excellent in all respects.
Shapiro, Wilbur↗
Life Testing of the Vapor Compression Distillation Urine Processing Assembly (VCD/UPA) at the Marshall Space Flight Center
Wastewater and urine generated on the International Space Station will be processed to recover pure water. The method selected is vapor compression distillation (VCD). To verify the long-term reliability and performance of the VCD Urine Processing Assembly (UPA), accelerated life testing was performed at the Marshall Space Flight Center (MSFC) from January 1993 to April 1996. Two UPAS, the VCD-5 and VCD-5A, were tested for 204 days and 665 days, respectively. The compressor gears and the distillation centrifuge drive belt were found to have an operating life of approximately 4800 hours. Precise alignment of the flex-spline of the fluids pump is essential to avoid failure of the pump after about 400 hours of operation. Also, leakage around the seals of the drive shaft of the fluids pump and purge pump must be eliminated for continued good performance. Results indicate that, with some design and procedural modifications and suitable quality control, the required performance and operational life can be met with the VCD/UPA.
Wieland, Paul O.↗
The Summer of Hydrogen
Ground crew veterans at Kennedy Space Center still talk about what they call "the summer of hydrogen"-the long, frustrating months in 1990 when the shuttle fleet was grounded by an elusive hydrogen leak that foiled our efforts to fill the orbiter's external fuel tank. Columbia (STS-35) was on Launch Pad A for a scheduled May 30 launch when we discovered the hydrogen leak during - tanking. The external fuel tank is loaded through the orbiter. Liquid hydrogen flows through a 17-inch umbilical between the orbiter and the tank. During fueling, we purge the aft fuselage with gaseous nitrogen to reduce the risk of fire, and we have a leak-detection system in the mobile launch platform, which samples (via tygon tubing) the atmosphere in and around the vehicle, drawing it down to a mass spectrometer that analyzes its composition. When we progressed to the stage of tanking where liquid hydrogen flows through the vehicle, the concentration of hydrogen approached four percent-the limit above which it would be dangerously flammable. We had a leak. We did everything we could think of to find it, and the contractor who supplied the flight hardware was there every day, working alongside us. We did tanking tests, which involved instrumenting the suspected leak sources, and cryo-loaded the external tank to try to isolate precisely where the leak originated. We switched out umbilicals; we replaced the seals between the umbilical and the orbiter. We inspected the seals microscopically and found no flaws. We replaced the recirculation pumps, and we found and replaced a damaged teflon seal in a main propulsion system detent cover, which holds the prevalve-the main valve supplying hydrogen to Space Shuttle Main Engine 3 -in the open position. The seal passed leak tests at ambient temperature but leaked when cryogenic temperatures were applied. We added new leak sensors-up to twenty at a time and tried to be methodical in our placements to narrow down the possible sources of the problem. We even switched orbiters, sending Columbia back to the Vehicle Assembly Building and bringing out Atlantis, scheduled to fly as STS-38. Two shuttles on their mobile launchers passing in the night was a majestic sight, but not one you want to see if you're trying to get an orbiter launched. None of this told us where the leak was, or if we were dealing with more than one leak source.
Weber, Philip↗
Aerodynamic performance of conventional and advanced design labyrinth seals with solid-smooth abradable, and honeycomb lands
Labyrinth air seal static and dynamic performance was evaluated using solid, abradable, and honeycomb lands with standard and advanced seal designs. The effects on leakage of land surface roughness, abradable land porosity, rub grooves in abradable lands, and honeycomb land cell size and depth were studied using a standard labyrinth seal. The effects of rotation on the optimum seal knife pitch were also investigated. Selected geometric and aerodynamic parameters for an advanced seal design were evaluated to derive an optimized performance configuration. The rotational energy requirements were also measured to determine the inherent friction and pumping energy absorbed by the various seal knife and land configurations tested in order to properly assess the net seal system performance level. Results indicate that: (1) seal leakage can be significantly affected with honeycomb or abradable lands; (2) rotational energy absorption does not vary significantly with the use of a solid-smooth, an abradable, or a honeycomb land; and (3) optimization of an advanced lab seal design produced a configuration that had leakage 25% below a conventional stepped seal.
Stocker, H. L.↗
Analysis of the SSME HPOTP bearing inlet cavity
Analysis of the flow in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) bearing no. 1 inlet cavity was completed in support of return-to-flight. With the incorporation of several design changes in the Phase 2 turbopump, rotordynamic stability of the pumps was enhanced, but the durability and life of the LOX-cooled bearings has decreased. During the post-Challenger SSME recertification, the causes of limited bearing durability were investigated. One topic addressed was the flow environment upstream of the pump-end bearing and the effect of seal exit swirl and a cavity anti-vortex rib on the bearing environment and life. The objective is to define the hydrodynamic environment upstream of the pump-end bearing and determine the effect of seal exit swirl and the anti-vortex rib on bearing inlet swirl. The problem was posed as an axisymmetric cavity flow with the computational domain extending from the seal exit to the bearing inlet. This domain was discretized with 22800 grid points. Boundary conditions were obtained from a 1-D model of the SSME coolant path. The inlet Mach number was 0.19 and the problem was solved with the CMINT code utilizing the Briley-McDonald/Beam-Warming algorithm with preconditioning to speed convergence at low Mach numbers. Three parametric cases with inlet swirl of 50 percent shaft speed (labyrinth seal), 20 percent shaft speed (damping seal), and no inlet swirl were considered. Computational results indicate large vortical flow structures in the cavity, with the labyrinth, damping, and no-swirl cases yielding bearing inlet swirl rates of 14, 10, and 9 percent of shaft speed, respectively. When these results were used as input to the SHABRETH bearing model, limited durability could not be explained by these small differences in swirl. Also, based on these results, a proposed design change for the cavity anti-vortex rib was not implemented by the SSME chief engineer.
Mcconnaughey, P. K.↗
Miniaturized Mercury Ion Clock for Ultrastable Deep Space Applications
We have recently completed a prototype ion-clock physics package based on Hg ions shuttled between a quadrupole and a 16-pole rf trap. With this architecture we have demonstrated short-term stability ~2-3x10-13 at 1 second, averaging to 10-15 at 1 day. This development shows that H-maser quality stabilities can be produced in a small clock package, comparable in size to an ultra-stable quartz oscillator required for holding 1-2x10-13 at 1 second. This performance was obtained in a sealed vacuum configuration where only a getter pump was used to maintain vacuum. The vacuum tube containing the traps has now been under sealed vacuum conditions for nearly 1.5 years with no measurable degradation of ion trapping lifetimes or clock short-term performance. Because the tube is sealed, the Hg source and Neon buffer gas are held indefinitely, for the life of the tube. There is no consumption of Hg in this system unlike in a Cs beam tube where lifetime is often limited by Cs depletion.
mercury ion clocks↗
Progress on Small Mercury Ion Clock for Space Applications
We have recently completed a breadboard ion-clock physics package based on Hg ions shuttled between a quadrupole and a 16-pole rf trap. With this architecture we have demonstrated short-term stability approx.1-2x10-(sup 1)(sup 3) at 1 second, averaging to 10-(sup 1)? at 1 day. This development shows that H-maser quality stabilities can be produced in a small clock package, comparable in size to an ultra-stable quartz oscillator required for holding 1-2x10-(sup 1)(sup 3) at 1 second. This performance was obtained in a sealed vacuum configuration where only a getter pump was used to maintain vacuum. The vacuum tube containing the traps has now been under sealed vacuum conditions for over three years with no measurable degradation of ion trapping lifetimes or clock short-term performance. We have fabricated the vacuum tube, ion trap and UV windows from materials that will allow approx. 400 deg C bake-out to prepare for tube seal-off. This approach to the vacuum follows the methods used in flight vacuum tube electronics, such as flight TWTA's where tube operation lifetime and shelf life of up to 15 years is achieved.
positioning↗
Compact Microwave Mercury Ion Clock for Space Applications
We have recently completed a breadboard ion-clock physics package based on Hg ions shuttled between a quadrupole and a 16-pole rf trap. With this architecture we have demonstrated short-term stability approximately 1 - 2 x 10(exp -13) at 1 second, averaging to 10(exp -15) at 1 day. This development shows that H-maser quality stabilities can be produced in a small clock package, comparable in size to an ultra-stable quartz oscillator required for holding 1 - 2 x 10(exp -13) at 1 second. This performance was obtained in a sealed vacuum configuration where only a getter pump was used to maintain vacuum. The vacuum tube containing the traps has now been under sealed vacuum conditions for nearly three years with no measurable degradation of ion trapping lifetimes or clock short-term performance. We have fabricated the vacuum tube, ion trap and UV windows from materials that will allow an approximately 400 C bake-out to prepare for tube seal-off. This approach to the vacuum follows the methods used in flight vacuum tube electronics, such as flight TWTA's where tube operation lifetime and shelf life of up to 15 years is achieved.
Atomic Clock↗
Noncontacting devices to indicate deflection and vibration of turbopump internal rotating parts
The research is reported which was conducted to develop devices for measuring vibrations and deflections of parts, such as impellers, shafts, turbine wheels, and inducers in operating turbopumps. Three devices were developed to the breadboard stage: ultrasonic Doppler transducer, flash X-rays, and light-pipe reflectance. It was found that the X-ray technique is applicable to the shaft assembly and the turbine seal of the J-2 pump, and the light-pipe-reflectance device appears to be ideal for cryogenic pump sections.
Hamilton, D. B.↗