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NASA NTRS2019

On-Orbit Xenon Refueling Loading Times and Transient Analysis

The Power and Propulsion Element (PPE) of the Lunar Orbital Platform-Gateway will demonstrate the first on-orbit refueling of xenon propellant for a solar electric propulsion system. An analysis was performed in Microsoft Excel to determine what factors influence the overall refueling time of a single 2,000-kilogram capacity xenon propellant tank, as well as provide estimates for overall refueling duration. Due to the high heat of compression of xenon, the propellant tank could exceed its maximum allowable temperature during refueling if the xenon flow rate and temperature are unregulated. In order to prevent overheating, a logic based "bang-bang" operation was used for refueling, shutting off the mass feed when the tank reached a maximum temperature. Heat is removed from the tank via radiation to the surrounding spacecraft bus. The analysis shows that optimizing key parameters such as mass flow rate into the tank, residual propellant in the tank during the onset of refueling, and tank diameter significantly reduces the overall refueling duration. Optimization is not straightforward, however, as the loading time does not trend monotonically with the parameters. Overall, the most significant impact on loading duration comes from altering the residual propellant in the tank. Increasing the mass of residual propellant from 2 percent to 20 percent reduces the overall refueling duration by 56 percent. Future work based on this analysis includes creation of a SINDA/FLUINT model and building a ground-based xenon refueling system emulator.

Xenon↗

NASA NTRSDate not supplied

Thermal Analysis of Refueling Propellant Systems for PPE

To support the sustainability of Gateway, approach the challenge of sustainable presence beyond low earth orbit, and provide proving grounds for future missions beyond the surface of the moon, refueling capabilities must be incorporated into Gateway. The objective is to replenish propellants into the Power and Propulsion Element (PPE) from the European System Providing Refueling, Infrastructure and Telecommunications (ESPIRIT) through the Habitation and logistics outpost (HALO). PPE refueling will consist of a bipropellant transfer system, as well as a main propellant transfer system. Refueling the Power and Propulsion Element in near rectilinear halo orbit can present various issues, and to thermally maintain the refueling system during this event requires diligent planning and thermal design. Presently, a thermal model exists to analyze the components of the refueling system as the development of PPE continues. The analysis from the thermal model will verify the integrity of the all the components during a refueling event throughout the duration of the mission given various environmental differences. To confidently refuel PPE, thermal analysis, and various tests of the refueling components, must be completed to achieve the desired sustainability of Gateway.

Ethan Sparks↗

NASA NTRSDate not supplied

Development Testing of the Gateway Integrated Bipropellant Refueling Subsystem

The Lunar Gateway is a deep space orbiting outpost being developed by the National Aeronautics and Space Administration (NASA) in partnership with the European Space Agency (ESA) and other domestic and international partners. Because Gateway is a vital component of NASA’s Artemis program supporting long-term human exploration of the moon, it is designed for on-orbit refueling to allow for a longer life performance. The reaction control system (RCS) bipropellant refueling system onboard the station will have the capability to transfer propellants, monomethyl hydrazine (MMH) and mixed oxides of nitrogen-3 (MON-3), under controlled conditions and will span across three modules: the European System Providing Refueling Infrastructure and Telecommunication Refueling Module (ESPRIT-RM or ERM), the Habitation and Logistics Outpost (HALO), and the Propulsion and Power Element (PPE). These propellant transfers are complex operations with known hazards, and one of the risk areas is exceeding the flight system’s maximum design pressure (MDP) in priming and refueling pause/stop operations. In priming, liquid propellant is transferred from a pressurized source tank to evacuated transfer lines, which could result in excessive transient surge pressures and potentially damage hardware. In refueling pause/stop operations, fast-acting isolation valves (IV) are closed, which could lead to damaging water hammer. To mitigate these risks and develop the system, a collaborative NASA/ESA/Thales Alenia Space – United Kingdom (TAS-UK) test program was completed at TAS-UK on a simplified refueling breadboard representing ERM, HALO, and PPE bipropellant transfer systems. The objectives of the integrated breadboard testing were to (1) gather performance data to characterize and demonstrate critical refueling operations, (2) help inform flight designs, and (3) to validate numerical models that can be extended to predicting flight system performance. Integrated breadboard test data has shown the architected system performance is closing initial design assumptions. Further testing with propellant on a higher fidelity fluid simulator and analysis are planned.

Adela D Han↗

NASA NTRSDate not supplied

Development Testing of the Gateway Integrated Bipropellant Refueling Subsystem

Adela D Han↗

NASA NTRS1993

Preliminary analysis of the benefits derived to US Air Force spacecraft from on-orbit refueling

This analysis was undertaken during FY-91 as a preliminary step to identify potential benefits from refueling Air Force satellites on orbit. Both economic and operational benefits were included. Operational benefits were related in economic terms to allow evaluation. All economic comparisons were made using FY-91 costs. An additional purpose of the effort was to identify the preferred mission parameters, for an on-orbit refueling system. A companion study was being concurrently conducted by SSD/XRP and NASA/JPL to develop a hardware concept for an on-orbit refueling system. The mass estimates for refueling missions obtained from the companion study were used in conducting the economic analyses of this benefits study. For this study, on-orbit refueling was based on the concept developed in the companion JPL study. The concept involves launching an S/C carrying fuel that would be transferred to another 'target' S/C which is already in orbit. The two S/C would then rendezvous, dock, and transfer fuel. Another fluid, such as a cryogenic, might be included if needed by the target S/C. The hardware concept for refueling was intended to minimize costs. The re-fueler S/C was designated to be expendable and would contain only the minimal capabilities. It would be launched into the orbit plane and altitude of the target S/C(s). The re-fueler S/C would rendezvous and dock with the target S/C and the fluid transfer would occur. When the refueling mission was completed, the re-fueler S/C would be ejected from the orbit. In order to optimize launch costs, some missions involved launching two re-fueler S/C on the LV. In this case the second re-fueler S/C would be placed in a storage orbit until needed.

Smith, Scott↗

NASA NTRSDate not supplied

NASA Gateway Refueling Architecture and Concept of Operation

The Lunar Gateway is a deep space orbiting outpost being developed by NASA in partnership with ESA and other domestic and international partners. It is a critical component of NASA’s Artemis program supporting long-term human exploration of the moon and is designed to be refueled, requiring the on-orbit transfer of propellants. The first two modules of Gateway to be launched will be the Power and Propulsion Element (PPE) and the Habitation and Logistics Outpost (HALO). The PPE contains the bipropellant chemical and electrical propulsion systems that will provide attitude control and orbit raising capability for Gateway. The reaction control system (RCS) utilizes monomethylhydrazine (MMH) and mixed oxides of nitrogen-3 (MON-3) as the fuel and oxidizer, respectively. Helium is used as a pressurant. The Advanced Electric Propulsion Systems (AEPS) and Busek hall thrusters that comprise the solar electric propulsion (SEP) system use xenon as the propellent. The ESPRIT Refueling Module, provided by ESA, will supply the propellant refueling function to Gateway’s propulsion systems. On-orbit refueling is a complex, technically challenging operation that is key to enabling sustainable crewed Lunar and Martian exploration. Numerous systems may be involved in the refueling operation. Also numerous systems are required to enable the successful ability for Gateway to refuel such as, SEP, RCS, Structure & Mechanisms (S&M), Guidance, Navigation and Control (GNC), Thermal, Software, Vehicle System Manager (VSM), Flight Ops, Extra Vehicular Robotics (EVR), Communication and Tracking (C&T), Avionics, and more. This paper will detail the design architecture, concept of operations, and challenges associated with the Gateway refueling system. The methodologies used in Gateway will be compared to those implemented in OSAM-1 and the best practices documented by AIAA and CONFERS (Consortium For Execution Of Rendezvous And Servicing Operations).

Brandie L. Rhodes↗

NASA NTRSDate not supplied

Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Another source of potentially damaging surge pressures is the water hammer transient that occurs when the isolation valves are closed to pause or end the refueling operation. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions to minimize the risk of exceeding pressure limits during flight. Since rapid pressure transients can be difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test article and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.

Refueling↗

NASA NTRS2004

Calculated Drag of an Aerial Refueling Assembly Through Airplane Performance Analysis

The aerodynamic drag of an aerial refueling assembly was calculated during the Automated Aerial Refueling project at the NASA Dryden Flight Research Center. An F/A-18A airplane was specially instrumented to obtain accurate fuel flow measurements and to determine engine thrust. A standard Navy air refueling store with a retractable refueling hose and paradrogue was mounted to the centerline pylon of the F/A-18A airplane. As the paradrogue assembly was deployed and stowed, changes in the calculated thrust of the airplane occurred and were equated to changes in vehicle drag. These drag changes were attributable to the drag of the paradrogue assembly. The drag of the paradrogue assembly was determined to range from 200 to 450 lbf at airspeeds from 170 to 250 KIAS. Analysis of the drag data resulted in a single drag coefficient of 0.0056 for the paradrogue assembly that adequately matched the calculated drag for all flight conditions. The drag relief provided to the tanker airplane when a receiver airplane engaged the paradrogue is also documented from 35 to 270 lbf at the various flight conditions tested. The results support the development of accurate aerodynamic models to be used in refueling simulations and control laws for fully autonomous refueling.

Vachon, Michael Jacob↗

NASA NTRS2024

Development Testing and Analysis of the Integrated Gateway-ESPRIT Bipropellant Refuelling System

The Gateway will be humanity’s first space station orbiting the Moon completed by NASA in partnership with ESA and other US and international partners. The Gateway will provide critical support to sustainable human exploration on the moon through the Artemis program. To enable the Lunar Gateway to complete its mission, on orbit refuelling is essential. The ESPRIT Refuelling Module (ERM) will provide the capability to transfer propellants, MMH and MON-3, through the Habitation and Logistics Outpost (HALO) to the Power and Propulsion Element (PPE). The transfer of these propellants carries known risks and hazards. These hazards include overpressure of the propellant lines during priming sequences between modules and during refuelling pause operations. To support the early system development and to mitigate these risks, a collaborative test program between NASA, ESA and Thales Alenia Space was completed at the Thales Alenia Space test facility in Harwell, UK. This test program integrated fluidic breadboards of the ERM, HALO and PPE modules. The objectives of the test program were to demonstrate and characterise critical performance and transient operations, inform refuelling concept of operations and to calibrate and validate numerical models of the refuelling subsystem in EcosimPro. To support the completion of this final objective a detailed model of the integrated breadboard was developed in EcosimPro and key steady-state and transient test cases were simulated. As an industry first, a National Institute of Standards and Technology (NIST) database correlation for Hydrofluoroether (HFE-7000) was used as a mixed oxides of nitrogen (MON-3) simulant with EcosimPro and European Space Propulsion System Simulation (ESPSS) libraries to result in a more accurate analysis for transient phenomenon such as priming. The test and simulation data showed good agreement validating the model for further system analysis as the ERM design progresses.

Refuelling↗

NASA NTRS2007

Autonomous Airborne Refueling Demonstration: Phase I Flight-Test Results

The first phase of the Autonomous Airborne Refueling Demonstration (AARD) project was completed on August 30, 2006. The goal of this 15-month effort was to develop and flight-test a system to demonstrate an autonomous refueling engagement using the Navy style hose-and-drogue air-to-air refueling method. The prime contractor for this Defense Advanced Research Projects Agency (DARPA) sponsored program was Sierra Nevada Corporation (SNC), Sparks, Nevada. The responsible flight-test organization was the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center (DFRC), Edwards, California, which also provided the F/A-18 receiver airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois). The B-707-300 tanker airplane (The Boeing Company) was contracted through Omega Aerial Refueling Services, Inc., Alexandria, Virginia, and the optical tracking system was contracted through OCTEC Ltd., Bracknell, Berkshire, United Kingdom. Nine research flights were flown, testing the functionality and performance of the system in a stepwise manner, culminating in the plug attempts on the final flight. Relative position keeping was found to be very stable and accurate. The receiver aircraft was capable of following the tanker aircraft through turns while maintaining its relative position. During the last flight, six capture attempts were made, two of which were successful. The four misses demonstrated excellent characteristics, the receiver retreating from the drogue in a controlled, safe, and predictable manner that precluded contact between the drogue and the receiver aircraft. The position of the receiver aircraft when engaged and in position for refueling was found to be 5.5 to 8.5 ft low of the ideal position. The controller inputs to the F/A-18 were found to be extremely small.

Dibley, Ryan P.↗

NASA NTRS2007

Autonomous Airborne Refueling Demonstration, Phase I Flight-Test Results

The first phase of the Autonomous Airborne Refueling Demonstration (AARD) project was completed on August 30, 2006. The goal of this 15-month effort was to develop and flight-test a system to demonstrate an autonomous refueling engagement using the Navy style hose-and-drogue air-to-air refueling method. The prime contractor for this Defense Advanced Research Projects Agency (DARPA) sponsored program was Sierra Nevada Corporation (SNC), Sparks, Nevada. The responsible flight-test organization was the NASA Dryden Flight Research Center (DFRC), Edwards, California, which also provided the F/A-18 receiver airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois). The B-707-300 tanker airplane (The Boeing Company) was contracted through Omega Aerial Refueling Services, Inc., Alexandria, Virginia, and the optical tracking system was contracted through OCTEC Ltd., Bracknell, Berkshire, United Kingdom. Nine research flights were flown, testing the functionality and performance of the system in a stepwise manner, culminating in the plug attempts on the final flight. Relative position keeping was found to be very stable and accurate. The receiver aircraft was capable of following the tanker aircraft through turns while maintaining its relative position. During the last flight, six capture attempts were made, two of which were successful. The four misses demonstrated excellent characteristics, the receiver retreating from the drogue in a controlled, safe, and predictable manner that precluded contact between the drogue and the receiver aircraft. The position of the receiver aircraft when engaged and in position for refueling was found to be 5.5 to 8.5 ft low of the ideal position. The controller inputs to the F/A-18 were found to be extremely small

Dibley, Ryan P.↗

NASA NTRSDate not supplied

Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions. Since priming transients are difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test system and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.

Brian S Lusby↗

NASA NTRS1986

Tethered orbital refueling study

One of the major applications of the space station will be to act as a refueling depot for cryogenic-fueled space-based orbital transfer vehicles (OTV), Earth-storable fueled orbit maneuvering vehicles, and refurbishable satellite spacecraft using hydrazine. One alternative for fuel storage at the space station is a tethered orbital refueling facility (TORF), separated from the space station by a sufficient distance to induce a gravity gradient force that settles the stored fuels. The technical feasibility was examined with the primary focus on the refueling of LO2/LH2 orbital transfer vehicles. Also examined was the tethered facility on the space station. It was compared to a zero-gravity facility. A tethered refueling facility should be considered as a viable alternative to a zero-gravity facility if the zero-gravity fluid transfer technology, such as the propellant management device and no vent fill, proves to be difficult to develop with the required performance.

Fester, Dale A.↗

NASA NTRS2004

Calculated Drag of an Aerial Refueling Assembly Through Airplane Performance Analysis

This viewgraph document reviews NASA Dryden's work on Aerial refueling, with specific interest in calculating the drag of the refueling system. The aerodynamic drag of an aerial refueling assembly was calculated during the Automated Aerial Refueling project at the NASA Dryden Flight Research Center. An F/A-18A airplane was specially instrumented to obtain accurate fuel flow measurements and to determine engine thrust

Vachon, Jake↗

NASA NTRS2010

Risk Analysis of On-Orbit Spacecraft Refueling Concepts

On-orbit refueling of spacecraft has been proposed as an alternative to the exclusive use of Heavy-lift Launch Vehicles to enable human exploration beyond Low Earth Orbit (LEO). In these scenarios, beyond LEO spacecraft are launched dry (without propellant) or partially dry into orbit, using smaller or fewer element launch vehicles. Propellant is then launched into LEO on separate launch vehicles and transferred to the spacecraft. Refueling concepts are potentially attractive because they reduce the maximum individual payload that must be placed in Earth orbit. However, these types of approaches add significant complexity to mission operations and introduce more uncertainty and opportunities for failure to the mission. In order to evaluate these complex scenarios, the authors developed a Monte Carlo based discrete-event model that simulates the operational risks involved with such strategies, including launch processing delays, transportation system failures, and onorbit element lifetimes. This paper describes the methodology used to simulate the mission risks for refueling concepts, the strategies that were evaluated, and the results of the investigation. The results of the investigation show that scenarios that employ refueling concepts will likely have to include long launch and assembly timelines, as well as the use of spare tanker launch vehicles, in order to achieve high levels of mission success through Trans Lunar Injection.

Cirillo, William M.↗

NASA NTRSDate not supplied

Gateway bi-propellant refueling development testing and model validation activities

The Gateway is an upcoming long term lunar exploration program to be completed by NASA in partnership with ESA and other US and international partners. The system design of the Gateway contains both a high performance Xenon based Solar Electric Propulsion system, as well as a bi-propellant attitude control system. Both propulsion systems are designed for on-orbit refueling to enable long life performance of the Gateway. The ESPRIT-RM is a module which will expand the pressurized volume of Gateway, while also providing refueling capability for both the Xenon and Bipropellant propulsion systems, therefore extending the Gateway life on orbit. As part of the Gateway bi-propellant refueling system development, a simplified fluidic breadboard system was created to evaluate system performance and response using simulant fluids. The test plan includes verification activities with simulant (water, HFE-7100) to verify joined subsystem behavior in the critical operations, including propellant transfer demonstration between modules, transient tests and venting tests. Integrated testing occurred at TASUK in collaboration with NASA to support joint verification activities to de-risk the major functions of the ESPRIT BTS and the overall CONOPS of the refueling of the Gateway chemical propulsion system. Initially collected test data from the system testing is presented, as well as initial model validation, and correlated to collected high frequency test data and system response is shown. Initially collected data has shown the architected system performance is closing initial design assumptions, but much forward work remains to characterize and develop the system.

Christopher Daniel Radke↗

NASA NTRSDate not supplied

Joint Development Testing of the Integrated Gateway-Esprit Bipropellant Refuelling System

The Gateway is an upcoming long term lunar exploration program to be completed by NASA in partnership with ESA and other US and international partners. The system design of the Gateway contains both a high performance Xenon based Solar Electric Propulsion system, as well as a bi-propellant attitude control system. Both propulsion systems are designed for on-orbit refuelling to enable long life performance of the Gateway. The ESPRIT-RM is a module which will expand the pressurized volume of Gateway, while also providing refuelling capability for both the Xenon and Bipropellant propulsion systems, therefore extending the Gateway life on orbit. As part of the Gateway bi-propellant refuelling system development, a simplified fluidic breadboard system was created to evaluate system performance and response using simulant fluids. The test plan includes verification activities with simulant (water, HFE-7100) to verify joined subsystem behaviour in the critical operations, including propellant transfer demonstration between modules, transient tests and venting tests. Integrated testing will occur at TASUK in collaboration with NASA to support joint verification activities to de-risk the major functions of the ESPRIT Bipropellant Transfer Subsystem (BTS) and the overall CONOPS of the refuelling of the Gateway chemical propulsion system. Initially collected test data is presented and has shown the architected system performance is closing initial design assumptions, but much forward work is identified to continue to characterize and develop the system.

Sebastian Hill↗

NASA NTRS2014

Refueling with In-Situ Produced Propellants

In-situ produced propellants have been identified in many architecture studies as key to implementing feasible chemical propulsion missions to destinations beyond lunar orbit. Some of the more noteworthy ones include: launching from Mars to return to Earth (either direct from the surface, or via an orbital rendezvous); using the Earth-Moon Lagrange point as a place to refuel Mars transfer stages with Lunar surface produced propellants; and using Mars Moon Phobos as a place to produce propellants for descent and ascent stages bound for the Mars surface. However successful implementation of these strategies require an ability to successfully transfer propellants from the in-situ production equipment into the propellant tankage of the rocket stage used to move to the desired location. In many circumstances the most desirable location for this transfer to occur is in the low-gravity environment of space. In support of low earth orbit propellant depot concepts, extensive studies have been conducted on transferring propellants in-space. Most of these propellant transfer techniques will be applicable to low gravity operations in other locations. Even ground-based transfer operations on the Moon, Mars, and especially Phobos could benefit from the propellant conserving techniques used for depot refueling. This paper will review the literature of in-situ propellants and refueling to: assess the performance benefits of the use in-situ propellants for mission concepts; review the parallels with propellant depot efforts; assess the progress of the techniques required; and provide recommendations for future research.

In-Situ Propellants↗