Characterization of Liquid Rocket Engine Pumps with Waterflow Testing
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Brandon Riley Williams↗
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Shock and vibration tests of a SNAP 8 mercury pump
Shock and vibration tests of SNAP 8 centrifugal mercury pump
Foley, R. S.↗
Reactor Simulator Testing
As part of the Nuclear Systems Office Fission Surface Power Technology Demonstration Unit (TDU) project, a reactor simulator test loop (RxSim) was design & built to perform integrated testing of the TDU components. In particular, the objectives of RxSim testing was to verify the operation of the core simulator, the instrumentation and control system, and the ground support gas and vacuum test equipment. In addition, it was decided to include a thermal test of a cold trap purification design and a pump performance test at pump voltages up to 150 V since the targeted mass flow rate of 1.75 kg/s was not obtained in the RxSim at the originally constrained voltage of 120 V. This paper summarizes RxSim testing. The gas and vacuum ground support test equipment performed effectively in NaK fill, loop pressurization, and NaK drain operations. The instrumentation and control system effectively controlled loop temperature and flow rates or pump voltage to targeted settings. The cold trap design was able to obtain the targeted cold temperature of 480 K. An outlet temperature of 636 K was obtained which was lower than the predicted 750 K but 156 K higher than the cold temperature indicating the design provided some heat regeneration. The annular linear induction pump (ALIP) tested was able to produce a maximum flow rate of 1.53 kg/s at 800 K when operated at 150 V and 53 Hz. Keywords: fission, space power, nuclear, liquid metal, NaK.
Schoenfeld, Michael P.↗
Reactor Simulator Testing
As part of the Nuclear Systems Office Fission Surface Power Technology Demonstration Unit (TDU) project, a reactor simulator test loop (RxSim) was design & built to perform integrated testing of the TDU components. In particular, the objectives of RxSim testing was to verify the operation of the core simulator, the instrumentation and control system, and the ground support gas and vacuum test equipment. In addition, it was decided to include a thermal test of a cold trap purification design and a pump performance test at pump voltages up to 150 V since the targeted mass flow rate of 1.75 kg/s was not obtained in the RxSim at the originally constrained voltage of 120 V. This paper summarizes RxSim testing. The gas and vacuum ground support test equipment performed effectively in NaK fill, loop pressurization, and NaK drain operations. The instrumentation and control system effectively controlled loop temperature and flow rates or pump voltage to targeted settings. The cold trap design was able to obtain the targeted cold temperature of 480 K. An outlet temperature of 636 K was obtained which was lower than the predicted 750 K but 156 K higher than the cold temperature indicating the design provided some heat regeneration. The annular linear induction pump (ALIP) tested was able to produce a maximum flow rate of 1.53 kg/s at 800 K when operated at 150 V and 53 Hz.
Schoenfeld, Michael P.↗
Reactor Simulator Testing
As part of the Nuclear Systems Office Fission Surface Power Technology Demonstration Unit (TDU) project, a reactor simulator test loop (RxSim) was design & built to perform integrated testing of the TDU components. In particular, the objectives of RxSim testing was to verify the operation of the core simulator, the instrumentation and control system, and the ground support gas and vacuum test equipment. In addition, it was decided to include a thermal test of a cold trap purification design and a pump performance test at pump voltages up to 150 V since the targeted mass flow rate of 1.75 kg/s was not obtained in the RxSim at the originally constrained voltage of 120 V. This paper summarizes RxSim testing. The gas and vacuum ground support test equipment performed effectively in NaK fill, loop pressurization, and NaK drain operations. The instrumentation and control system effectively controlled loop temperature and flow rates or pump voltage to targeted settings. The cold trap design was able to obtain the targeted cold temperature of 480 K. An outlet temperature of 636 K was obtained which was lower than the predicted 750 K but 156 K higher than the cold temperature indicating the design provided some heat regeneration. The annular linear induction pump (ALIP) tested was able to produce a maximum flow rate of 1.53 kg/s at 800 K when operated at 150 V and 53 Hz.
Schoenfeld, Michael P.↗
Study and development of an air conditioning system operating on a magnetic heat pump cycle (design and testing of flow directors)
This report describes the fabrication, design of flow director, fluid flow direction analysis and testing of flow director of a magnetic heat pump. The objectives of the project are: (1) to fabricate a demonstration magnetic heat pump prototype with flow directors installed; and (2) analysis and testing of flow director and to make sure working fluid loops flow through correct directions with minor mixing. The prototype was fabricated and tested at the Development Testing Laboratory of Kennedy Space Center. The magnetic heat pump uses rear earth metal plates rotate in and out of a magnetic field in a clear plastic housing with water flowing through the rotor plates to provide temperature lift. Obtaining the proper water flow direction has been a problem. Flow directors were installed as flow barriers between separating point of two parallel loops. Function of flow directors were proven to be excellent both analytically and experimentally.
Wang, Pao-Lien↗
Functional and performance tests of two capillary pumped loop engineering models
This paper presents the results of the functional and performance tests for two capillary pumped loop (CPL) engineering models. Both CPL systems are aluminum/ammonia transport systems which contain eight parallel evaporators and six parallel condensers in a single loop. Tests conducted include the transport limit, heat load shearing between evaporators, liquid inventory/temperature control by the reservoir, pressure priming under heat load, diode function of condensers, and isolation of a single deprimed evaporator. Consistent performance results were obtained for both systems. Transport capabilities of up to 70 kw-m with individual evaporators managing up to 1.7 kw, with a corresponding input heat flux of 15w/sq cm, were demonstrated. These tests demonstrated the ability of a CPL system to operate over a wide range of conditions and thus established the viability of these systems for high power thermal management of large spacecraft, such as the NASA Space Station.
Ku, J.↗
Design, manufacture, and test of coolant pump-motor assembly for Brayton power conversion system
The design, development, fabrication, and testing of seven coolant circulating pump-motor assemblies are discussed. The pump-motor assembly is driven by the nominal 44.4-volt, 400-Hz, 3-phase output of a nominal 56-volt dc input inverter. The pump-motor assembly will be used to circulate Dow Corning 200 liquid coolant for use in a Brayton cycle space power system. The pump-motor assembly develops a nominal head of 70 psi at 3.7 gpm with an over-all efficiency of 26 percent. The design description, drawings, photographs, reliability results, and developmental and acceptance test results are included.
Gabacz, L. E.↗
Test results of a pumped two-phase mounting plate with ammonia
The design, fabrication, and testing of full-scale prototype units of a two-phase mounting plate (TPMP), which will be used in a two-phase ammonia-based thermal control system for a large spacecraft, are described. The mounting plate uses an evaporator design in which liquid is mechanically pumped through porous feed tubes within the plate. The prototype TPMPs were tested with ammonia at heat loads over 3000 W (3.2 W/sq cm) and local heat fluxes of up to 4 W/sq cm. Calculated total heat transfer coefficients from these tests were between 0.8 and 1.0 W/sq cm per C. This represents a better than twenty-fold improvement over comparable single-phase heat transfer coefficients. Design diagrams are included.
Swanson, T. D.↗
Analysis and Modeling of a Two-Phase Jet Pump of a Flow Boiling Test Facility for Aerospace Applications
Jet pumps are devices capable of pumping fluids to a higher pressure employing a nozzle/diffuser/mixing chamber combination. A primary fluid is usually allowed to pass through a converging-diverging nozzle where it can accelerate to supersonic speeds at the nozzle exit. The relatively high kinetic energy that the primary fluid possesses at the nozzle exit is accompanied by a low pressure region in order to satisfy Bernoulli's equation. The low pressure region downstream of the nozzle exit permits a secondary fluid to be entrained into and mixed with the primary fluid in a mixing chamber located downstream of the nozzle. Several combinations may exist in terms of the nature of the primary and secondary fluids in so far as whether they are single or two-phase fluids. Depending on this, the jet pump may be classified as gas/gas, gas/liquid, liquid/liquid, two-phase/liquid, or similar combinations. The mixing chamber serves to create a homogeneous single-phase or two-phase mixture which enters a diffuser where the high kinetic energy of the fluid is converted into pressure energy. If the fluid mixture entering the diffuser is in the supersonic flow regime, a normal shock wave usually develops inside the diffuser. If the fluid mixture is one that can easily change phase, a condensation shock would normally develop. Because of the overall rise in pressure in the diffuser as well as the additional rise in pressure across the shock layer, condensation becomes more likely. Associated with the pressure rise across the shock is a velocity reduction from the supersonic to the subsonic range. If the two-phase flow entering the diffuser is predominantly gaseous with liquid droplets suspended in it, it will transform into a predominantly liquid flow containing gaseous bubbles (bubbly flow) somewhere in the diffuser. While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the authors apart from that of Anand (1992) which accounted for condensation shocks. One of the objectives of this research effort is to develop a comprehensive model in which the effects of phase slip and inter-phase heat transfer as well as the wall friction and shock waves are accounted for. While this modeling effort is predominantly analytical in nature and is primarily intended to provide a parametric understanding of the jet pump performance under different operating scenarios, another parallel effort employing a commercial CFD code is also implemented. The latter effort is primarily intended to model an axisymmetric counterpart of the problem in question. The viability of using the CFD code to model a two-phase flow jet pump will be assessed by attempting to recreate some of the existing performance data of similar jet pumps. The code will eventually be used to generate the jet pump performance characteristics of several scenarios involving jet pump geometries as well as flow regimes in order to be able to determine an optimum design which would be suitable for a two-phase flow boiling test facility at NASA-Marshall. Because of the extensive nature of the analytical model developed, the following section will only provide very brief highlights of it, while leaving the details to a more complete report submitted to the NASA colleague. This report will also contain some of the simulation results obtained using the CFD code.
Sherif, S. A.↗
Flight Testing of a Cryogenic Capillary Pumped Loop
This paper describes the flight test results of the fifth generation cryogenic capillary pumped loop (CCPL-5) which flew on the Space Shuttle STS-95 in October of 1998 as part of the CRYOTSU Flight Experiment. This flight was the first in-space demonstration of the CCPL, a lightweight heat transport and thermal switching device for future integrated cryogenic bus systems. The CCPL-5 utilized nitrogen as the working fluid and operated between 80K and 110K. Flight results indicated excellent performance of the CCPL-5 under zero-G environment. The CCPL could start from a supercritical condition in all tests, and the loop operating temperature could be tightly controlled regardless of changes in the heat load and/or the sink temperature. In addition, the loop demonstrated successful operation with a heat load of 0.5 W as well as with parasitic heat loads alone.
Ku, Jentung↗
Design, development and test of a capillary pump loop heat pipe
The development of a capillary pump loop (CPL) heat pipe, including computer modeling and breadboard testing, is presented. The computer model is a SINDA-type thermal analyzer, combined with a pressure analyzer, which predicts the transients of the CPL heat pipe during operation. The breadboard is an aluminum/ammonia transport system which contains multiple parallel evaporator and condenser zones within a single loop. Test results have demonstrated the practicality and reliability of such a design, including heat load sharing among evaporators, liquid inventory/temperature control feature, and priming under load. Transport capability for this system is 65 KW-M with individual evaporator pumps managing up to 1.7 KW at a heat flux of 15 W/sq cm. The prediction of the computer model for heat transport capabilities is in good agreement with experimental results.
Kroliczek, E. J.↗
Titanium pump impeller fabrication and testing
Design, fabrication, and testing of improved titanium impeller for high pressure liquid hydrogen pumps
Wolf, J. E.↗
Reactor Simulator Testing Overview
OBJECTIVE: Integrated testing of the TDU components TESTING SUMMARY: a) Verify the operation of the core simulator, the instrumentation and control system, and the ground support gas and vacuum test equipment. b) Thermal test heat regeneration design aspect of a cold trap purification filter. c) Pump performance test at pump voltages up to 150 V (targeted mass flow rate of 1.75 kg/s was not obtained in the RxSim at the originally constrained voltage of 120 V). TESTING HIGHLIGHTS: a) Gas and vacuum ground support test equipment performed effectively for NaK fill, loop pressurization, and NaK drain operations. b) Instrumentation and control system effectively controlled loop temperature and flow rates or pump voltage to targeted settings. c) Cold trap design was able to obtain the targeted cold temperature of 480 K. An outlet temperature of 636 K was obtained which was lower than the predicted 750 K but 156 K higher than the cold temperature indicating the design provided some heat regeneration. d) ALIP produce a maximum flow rate of 1.53 kg/s at 800 K when operated at 150 V and 53 Hz.
Schoenfeld, Michael P.↗
Solid Rocket Booster Hydraulic Pump Port Cap Joint Load Testing
The solid rocket booster uses hydraulic pumps fabricated from cast C355 aluminum alloy, with 17-4 PH stainless steel pump port caps. Corrosion-resistant steel, MS51830 CA204L self-locking screw thread inserts are installed into C355 pump housings, with A286 stainless steel fasteners installed into the insert to secure the pump port cap to the housing. In the past, pump port cap fasteners were installed to a torque of 33 Nm (300 in-lb). However, the structural analyses used a significantly higher nut factor than indicated during tests conducted by Boeing Space Systems. When the torque values were reassessed using Boeing's nut factor, the fastener preload had a factor of safety of less than 1, with potential for overloading the joint. This paper describes how behavior was determined for a preloaded joint with a steel bolt threaded into steel inserts in aluminum parts. Finite element models were compared with test results. For all initial bolt preloads, bolt loads increased as external applied loads increased. For higher initial bolt preloads, less load was transferred into the bolt, due to external applied loading. Lower torque limits were established for pump port cap fasteners and additional limits were placed on insert axial deformation under operating conditions after seating the insert with an initial preload.
Gamwell, W. R.↗
SNAP-8 NaK-pump-motor-assembly 400 hertz start tests
SNAP 8 sodium potassium pump-motor assembly start tests
Boecker, F.↗
BASG thermomechanical pump helium 2 transfer tests
The purpose of the effort described was to perform experiments and calculations related to using a thermomechanical pump in the space-based resupply of the Space Infrared Telescope Facility (SIRTF) with Helium 2. Thermomechanical (fountain effect) pumps have long been suggested as a means for pumping large quantities of Helium 2. The unique properties of Helium 2 have made it useful for cooling space instruments. Several space science missions, including SIRTF, are now being planned which would benefit greatly from on-orbit resupply of Helium 2. A series of experiments were performed to demonstrate that large volumes of Helium 2 can be transferred with a thermomechanical pump at high flow rates and at high efficiency from one dewar to another through valves and lines that are similar to the plumbing arrangement that would be necessary to accomplish such a transfer on-orbit. In addition, temperature, pressure, and flow rate data taken during the tests were used to verify and refine a computer model which was developed.
Mills, G. L.↗
Development of a water source heat pump hardware-in-the-loop (HIL) testing facility for smart building applications
Over the last decade, the global fight against climate change through electrification has led to an increase in research on building heating, ventilation, and air conditioning (HVAC) systems that utilize intelligent control algorithms to provide demand-side grid service while maintaining the thermal comfort of building occupants. As the pivotalpoint between building electricity consumption and indoor thermal comfort, high-efficiency electrical heatpumps are at the center of these emerging studies, and various grid-interactive and occupant-comfort control algorithms have been developed for them. The impact of these algorithms on the heatpump operation andperformance under different weather, building load, and grid requests calls for investigation and verification via experimental tests with actual heat pumps integrated with real-time building and grid responses. This study presents a Water-Source Heat Pump Hardware-in-The-Loop (HIL) Test Facility developed with the capability to perform such tests. The hardware configuration for this testfacility introduces a hydronic system that emulates the conditions for the heat pump water-side, and a duct system that emulates conditions for the heat pump airside. Both data acquisition and emulator control are implemented through the National Instruments (NI) LabVIEW software running on an NI PXIplatform. The HIL mechanism based on the hardware-software integration that allows the testbed to communicate with a generic simulation environment is also discussed. Currently, the test facility setup includes a single heatpump and virtual building model in EnergyPlus coupled with an occupant behavioral model in MATLAB. Preliminary test results of the current setup demonstrate the building load emulator's ability to track the simulated gone temperature with a Root Mean Square Deviation (RSME) below 0.12°C (0.216°F). An uncertainty analysis based on sensor accuracies shows that the heat pump coefficient of performance (COP) can be measured with a relative uncertainty of 10.4% in cooling and 3.7% in heating. Apartfrom the current testing on a single heat pump, the test facility also provides the flexibility to include additional heat pumps to form a heat pump cluster, as well as coupling the heat pump with active thermal storage to provide enhanced demandflexibility.
Calfa, Caleb↗