SEARCH · Search NASA
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Battery case, equipped with relief valve, connector, and two covers, separates the explosive mixture from all potential spark sources. Bottom ends of vent tubes are cemented into cell vents and upper ends fit through the gas barrier cover. This arrangement isolates generated gases from the electric power.
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.
This study implemented validated literature models to predict audible noise due to pressurized gaseous hydrogen releases through a thermally-activated pressure relief device (TPRD) and attached vent stack. A literature survey discovered limited hydrogen-specific noise prediction models validated by experiments. However, empirical noise prediction models for air flowing through pipes and valves were identified. These empirical models were used to predict noise levels and compared against hydrogen noise data reported in two studies: one experimental study of noise from hydrogen leaking through a pipe and another which modeled hydrogen flowing through a solenoid valve during a fuel cell vehicle refueling. The valve flow model was then applied to predict noise for hydrogen releases through a TPRD. Results show that hydrogen releases through a TPRD can produce harmful noise levels varying from 134 to 150 dB. However, further model validation and additional experimental data are needed to improve prediction confidence and accuracy.
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.
Transient thermodynamic analyses were made of the LOX loading system proposed for the space shuttle main propulsion test article (MPTA). This system is made up of a LOX replenish system and a main LOX line which include the barge tank, the lines, pumps, and valves between the barge and the orbiter (ORB) ground service equipment (GSE) interface, the MPTA fill system, the space shuttle main engine (SSME) chilldown bleed system, and the GSE vent system. System analyses include predictions of system performance sensitivity to operating sequence and LOX flowrate, temperature, and quality at the ORB/GSE interface. The transient thermodynamic conditions at the SSME feed line entrance, ET entrance (tank bottom), and the SSME bleed/GSE vent TEE are also included. The analyses are based on continuous SSME bleed flow during GSE facility chilldown.
During zero-gravity orbital cryogenic propulsion operations, a thermodynamic vent system (TVS) concept is expected to maintain tank pressure control without propellant resettling. In this case, a longitudinal spray bar mixer system, coupled with a Joule-Thompson (J-T) valve and heat exchanger, was evaluated in a series of TVS tests using the 18 cu m multipurpose hydrogen test bed. Tests performed at fill levels of 90, 50, and 25 percent, coupled with heat tank leaks of about 20 and 50 W, successfully demonstrated tank pressure control within a 7-kPa band. Based on limited testing, the presence of helium constrained the energy exchange between the gaseous and liquid hydrogen (LH2) during the mixing cycles. A transient analytical model, formulated to characterize TVS performance, was used to correlate the test data. During self-pressurization cycles following tank lockup, the model predicted faster pressure rise rates than were measured; however, once the system entered the cyclic self-pressurization/mixing/venting operational mode, the modeled and measured data were quite similar. During a special test at the 25-percent fill level, the J-T valve was allowed to remain open and successfully reduced the bulk LH2 saturation pressure from 133 to 70 kPa in 188 min.
The Main Propulsion System (MPS) uses three Flow Control Valves (FCV) to modulate the flow of pressurant hydrogen gas from the Space Shuttle Main Engines (SSME) to the hydrogen External Tank (ET). This maintains pressure in the ullage volume as the liquid level drops, preserving ET structural integrity and assuring the engines receive a sufficient amount of head pressure. On Space Transportation System (STS)-126 (2009), with only a handful of International Space Station (ISS) assembly flights from the end of the Shuttle program, a portion of a single FCV?s poppet head broke off at about a minute and a half after liftoff. The risk of the poppet head failure is that the increased flow area through the FCV could result in excessive gaseous hydrogen flow back to the external tank, which could result in overboard venting of hydrogen ullage pressure. If the hydrogen venting were to occur in first stage (i.e., lower atmosphere), a flammability hazard exists that could lead to catastrophic loss of crew and vehicle. Other failure risks included particle impact damage to MPS downstream hardware. Although the FCV design had been plagued by contamination-related sluggish valve response problems prior to a redesign at STS-80 (1996), contamination was ruled out as the cause of the STS-126 failure. Employing a combination of enhanced hardware inspection and a better understanding of the consequences of a poppet failure, safe flight rationale for subsequent flights (STS-119 and later) was achieved. This paper deals with the technical lessons learned during the investigation and mitigation of this problem at a time when assembly flights were each in the critical path to Space Station success.
Facility capabilities have been expanded at Test Cell 23, Research Combustor Lab (RCL23) at the NASA Glenn Research Center, with a new gaseous hydrogen fuel system. The purpose of this facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Previously, this facility only had jet fuel available to perform these various combustor flametube tests. The new hydrogen fuel system will support the testing and development of aircraft combustors with zero carbon dioxide (CO2) emissions. Research information generated from this test rig includes combustor emissions and performance data via gas sampling probes and emissions measuring equipment. The new gaseous hydrogen system is being supplied from a 70 000-standard-ft3 tube trailer at flow rates up to 0.05 lb/s (maximum). The hydrogen supply pressure is regulated, and the flow is controlled with a -in. remotely operated globe valve. Both a calibrated subsonic venturi and a coriolis mass flowmeter are used to measure flow. Safety concerns required the placement of all hydrogen connections within purge boxes, each of which contains a small nitrogen flow that is vented past a hydrogen detector. If any hydrogen leaks occur, the hydrogen detectors alert the operators and automatically safe the facility. Facility upgrades and modifications were also performed on other fluids systems, including the nitrogen gas, cooling water, and air systems. RCL23 can provide nonvitiated heated air to the research combustor, up to 350 psig at 1200 F and 3.0 lb/s. Significant modernization of the facility control systems and the data acquisition systems was completed. A flexible control architecture was installed that allows quick changes of research configurations. The labor-intensive hardware interface has been removed and changed to a software-based system. In addition, the operation of this facility has been greatly enhanced with new software programming and graphic operator interface stations. Glenn s RCL23 facility systems were successfully checked out in the spring of 2002, and hydrogen combustor research testing began in the summer of 2002.
The Amine Swingbed is an amine-based, vacuum-regenerated adsorption technology for removing carbon dioxide and humidity from a habitable spacecraft environment, and is the baseline technology for the Orion Program’s Multi-Purpose Crew Vehicle (MPCV). It uses a pair of interleaved-layer beds filled with SA9T, the amine sorbent, and a linear multiball valve rotates 270° back and forth to control the flow of air and vacuum to adsorbing and desorbing beds. One bed adsorbs CO2 and H2O from cabin air while the other bed is exposed to vacuum for regeneration by venting the CO2 and H2O. The two beds are thermally linked, so no additional heating or cooling is required. The technology can be applied to habitable environments where recycling CO2 and H2O is not required such as short duration missions.
An igniter is described mounted on a vent stack with an upper, flame cage near the top of the stack to ignite emissions from the stack. The igniter is a tube with a lower, open, flared end having a spark plug near the lower end and a solenoid-controlled valve which supplies propane fuel from a supply tank. Propane from the tank is supplied at the top under control of a second, solenoid-controlled valve. The valve controlling the lower supply is closed after ignition at the flame cage. The igniter is economical, practical, and highly reliable.
The Spallation Neutron Source at Oak Ridge National Laboratory operates the Cryogenic Moderator System (CMS) which provides hydrogen cooling at 20K to three neutron moderators. Each hydrogen loop is protected by multiple burst discs and reclosing relief valves. As a result of the Proton Power Upgrade project, the CMS moderator loops will hold more hydrogen and thus require piping modifications. Operational experience has demonstrated that transient pressure increases in these hydrogen loops occasionally result in the rupture of the burst discs. The causes for pressure transients in the system that might lead to hydrogen venting are varied and complex, for example loss of vacuum or cooling. Dynamic simulation and analysis of the parameters considered as the worst-case relief venting scenario were performed and will be presented.
Tension in Microgravity Modeled Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, jets must be contained by surface tension forces. Recent NASA experiments in microgravity (Tank Pressure Control Experiment, TPCE, and Vented Tank Pressure Experiment, VTRE) resulted in a wealth of data about jet behavior in microgravity. VTRE was surprising in that, although it contained a complex geometry of baffles and vanes, the limit on liquid inflow was the emergence of a liquid jet from the top of the vane structure. Clearly understanding the restraint of liquid jets by surface tension is key to managing fluids in low gravity. To model this phenomenon, we need a numerical method that can track the fluid motion and the surface tension forces. The fluid motion is modeled with the Navier-Stokes equation formulated for low-speed incompressible flows. The quantities of velocity and pressure are placed on a staggered grid, with velocity being tracked at cell faces and pressure at cell centers. The free surface is tracked via the introduction of a color function that tracks liquid as 1/2 and gas as -1/2. A phase model developed by Jacqmin is used. This model converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly. Previous attempts at this formulation have been criticized for smearing the interface. However, by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function, interface smearing is avoided. These equations can be rewritten as two coupled Poisson equations that also include the velocity. The method of solution is as follows: first, the phase equations are solved from this solution, a velocity field is generated, then a successive overrelaxation scheme is used to solve for a pressure field consistent with the velocity solution. After the code was implemented in axisymmetric form and verified by several test cases, the drop tower runs of Aydelott were modeled. The model handed the free-surface deformation quite nicely, even to the point of modeling geyser growth in the regime where the free surface was no longer restrained. A representative run is shown.
The Multipurpose Hydrogen Test Bed (MHTB) Test Readiness Review (TRR), in preparation for upcoming thermodynamic vent system testing with LN2 (an LO2 simulant), was conducted on Aug 10 with no significant concerns or open action items. The 21 day test series, designed to evaluate the spray bar mixer/vent system concept suitability for zero-g operation began on August 19. The testing is progressing very well and results indicate that the Moog latching valve is more effective than the Castor solenoid valve in reducing pressure during the vent/mixing cycles. Testing with self-pressurization is expected to be completed on September 3 and testing with helium pressurization will be initiated on September 4 or 5. Additional activities during first half of August included coordination of Notification of Intent (NOI) to propose letters involving CFM in response to the HR&T BAA for Extramural Proposals.
In pressurization systems, regulators and orifices are use to control the flow of the pressurant. For the X-34 Main Propulsion System, three pressurization subsystem design configuration options were considered. In the first option, regulators were used while in the other options, orifices were considered. In each design option, the vent/relief system must be capable of relieving the pressurant flow without allowing the tank pressure to rise above proof, therefore, impacts on the propellant tank vent system were investigated and a trade study of the pressurization system was conducted. The analysis indicated that design option using regulators poses least risk. Then, a detailed transient thermal/fluid analysis of the recommended pressurization system was performed. Helium usage, thermodynamic conditions, and overpressurization of each propellant tank were evaluated. The pneumatic and purge subsystem is used for pneumatic valve actuation, Inter-Propellant Seal purges, Engine Spin Start, and engine purges at the required interface pressures, A transient analysis of the pneumatic and purge subsystem provided helium usage and flow rates to Inter-Propellant Seal and engine interfaces. Fill analysis of the helium bottles of pressurization and pneumatic subsystems during ground operation was performed. The required fill time and the stored
A portable pressure-application device has been designed and built for use in testing and calibrating piezoelectric pressure transducers in the field. The device generates pressure pulses of known amplitude. A pressure pulse (in contradistinction to a steady pressure) is needed because in the presence of a steady pressure, the electrical output of a piezoelectric pressure transducer decays rapidly with time. The device includes a stainless- steel compressed-air-storage cylinder of 500 cu cm volume. A manual hand pump with check valves and a pressure gauge are located at one end of the cylinder. A three-way solenoid valve that controls the release of pressurized air is located at the other end of the cylinder. Power for the device is provided by a 3.7-V cordless-telephone battery. The valve is controlled by means of a pushbutton switch, which activates a 5 V to +/-15 V DC-to-DC converter that powers the solenoid. The outlet of the solenoid valve is connected to the pressure transducer to be tested. Before the solenoid is energized, the transducer to be tested is at atmospheric pressure. When the solenoid is actuated by the push button, pressurized air from inside the cylinder is applied to the transducer. Once the pushbutton is released, the cylinder pressure is removed from the transducer and the pressurized air applied to the transducer is vented, bringing the transducer back to atmospheric pressure. Before this device was used for actual calibration, its accuracy was checked with a NIST (National Institute of Standards and Technology) traceable calibrator and commercially calibrated pressure transducers. This work was done by Wanda Solano of Stennis Space Center and Greg Richardson of Lockheed Martin Corp.
This report documents the Zero-g Thermodynamic Venting System (TVS) performance prediction computer program. The zero-g TVS is a device that destratifies and rejects environmentally induced zero-g thermal gradients in the LH2 storage transfer system. A recirculation pump and spray injection manifold recirculates liquid throughout the length of the tank thereby destratifying both the ullage gas and liquid bulk. Heat rejection is accomplished by the opening of the TVS control valve which allows a small flow rate to expand to a low pressure thereby producing a low temperature heat sink which is used to absorb heat from the recirculating liquid flow. The program was written in FORTRAN 77 language on the HP-9000 and IBM PC computers. It can be run on various platforms with a FORTRAN compiler.
Fluid Systems involves different projects that require parametric modeling, which is a model that maintains consistent relationships between elements as is manipulated. One of these projects is the Neo Liquid Propellant Testbed, which is part of Rocket U. As part of Rocket U (Rocket University), engineers at NASA's Kennedy Space Center in Florida have the opportunity to develop critical flight skills as they design, build and launch high-powered rockets. To build the Neo testbed; hardware from the Space Shuttle Program was repurposed. Modeling for Neo, included: fittings, valves, frames and tubing, between others. These models help in the review process, to make sure regulations are being followed. Another fluid systems project that required modeling is Plant Habitat's TCUI test project. Plant Habitat is a plan to develop a large growth chamber to learn the effects of long-duration microgravity exposure to plants in space. Work for this project included the design and modeling of a duct vent for flow test. Parametric Modeling for these projects was done using Creo Parametric 2.0.
The goal of the salt sampling program at Argonne is to develop and deploy automated molten salt sampling approaches for interfacing relevant unit operations with salt analysis to improve the timeliness and accuracy of sampling-based accountancy measurements. One technology under development is a vacuum sampler loop module. In this system, molten salt is drawn from a process vessel through a heated sampling line and into a charge vessel. Next, one or more samples are split from the volume in the charge vessel and the remaining salt is returned to the process. The vacuum sampler loop module is being developed to interface with other sample processing and analysis modules to enable rapid at-line sample characterization. The main purpose of the vacuum sampling loop module is to enable the collection of samples that are more representative of the bulk salt by replacing traditional point samplers (i.e., dip probes) with a sampling approach that captures a larger cross section of salt. Additionally, the vacuum sampling approach eliminates the risk of dross contamination of samples and avoids the use of moving parts in the salt. Two methods of interfacing the vacuum sampling loop with a precision pneumatic sample generator were investigated in FY21. This report covers the testing of fluidic coupling between the two modules. Two iterations of the fluidically coupled modules were tested. The first iteration system coupled the two modules using a freeze valve to seal the vacuum sampler during filling and to control flow into the pneumatic sample generator. While this integrated system functioned as intended, some changes were implemented to make the system more robust and better suited to remote deployment. Specifically, the system was made to be more modular and active control of the vacuum filling operation was replaced with a passive control mechanism. For passive filling, the salt charge vessel was vented to a small gas tank that was at negative pressure, causing salt to be drawn into the vessel until the force of the fluid head was in equilibrium with the gas pressure. The passive control system performed well and will be used in future iterations. Another change in the second system was a newly configured pneumatic sample generator in which sample ejection occurred through a hole in the reservoir’s stainless-steel side wall instead of through a non-wetted sapphire orifice on the bottom. This alternate configuration may be better suited for near-process deployment because it enables on-line orifice maintenance and an orifice bypass drain back to the process. A third change in the second iteration system was the transition to a two-chamber charge vessel which split off a fraction of the sampled salt as a liquid aliquot. The goal was to create a buffer mechanism that would allow reproducible aliquoting of samples, independently of variability in the charge vessel fill height. While the two-chamber design was functional, the sample size reproducibility was below target values. To improve reproducibility and overcome many of the impediments to remote deployment of the vacuum sampling loop module, separate work was conducted to replace the two-chamber liquid aliquoting mechanism with aliquoting into single-use sample tubes. Solid salt transfer in the sample tubes will replace fluidic coupling for integrating the vacuum sampler with downstream modules. Because the proposed operations can all be executed with simple overhead actuation mechanisms or other existing hot-cell technology, there will be no need for large investments in novel hot cell sample handling technologies using this alternate approach. As such, near-term deployment of the vacuum sampling technology will be achievable. This new approach for automated coupling of sample tubes with down-stream modules is covered in a separate FY21 report, and a remotely operated version of the vacuum sampler loop module with the tube aliquoting feature is planned for FY22.