Adam Swanger

ASME Section VIII Recertification of a 33,000 Gallon Vacuum-jacketed LH2 Storage Vessel for Densified Hydrogen Testing at NASA Kennedy Space Center

The Ground Operations Demonstration Unit for Liquid Hydrogen (GODU-LH2) has been developed at NASA Kennedy Space Center in Florida. GODU-LH2 has three main objectives: zero-loss storage and transfer, liquefaction, and densification of liquid hydrogen. A cryogenic refrigerator has been integrated into an existing, previously certified, 33,000 gallon vacuum-jacketed storage vessel built by Minnesota Valley Engineering in 1991 for the Titan program. The dewar has an inner diameter of 9.5’ and a length of 71.5’; original design temperature and pressure ranges are −423°F to 100°F and 0 to 95 psig respectively. During densification operations the liquid temperature will be decreased below the normal boiling point by the refrigerator, and consequently the pressure inside the inner vessel will be sub-atmospheric. These new operational conditions rendered the original certification invalid, so an effort was undertaken to recertify the tank to the new pressure and temperature requirements (−12.7 to 95 psig and −433°F to 100°F respectively) per ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. This paper will discuss the unique design, analysis and implementation issues encountered during the vessel recertification process.Copyright

In-Space Propellant Production Using Water

A new era of space exploration is being planned. Manned exploration architectures under consideration require the long term storage of cryogenic propellants in space, and larger science mission directorate payloads can be delivered using cryogenic propulsion stages. Several architecture studies have shown that in-space cryogenic propulsion depots offer benefits including lower launch costs, smaller launch vehicles, and enhanced mission flexibility. NASA is currently planning a Cryogenic Propellant Storage and Transfer (CPST) technology demonstration mission that will use existing technology to demonstrate long duration storage, acquisition, mass gauging, and transfer of liquid hydrogen in low Earth orbit. This mission will demonstrate key technologies, but the CPST architecture is not designed for optimal mission operations for a true propellant depot. This paper will consider cryogenic propellant depots that are designed for operability. The operability principles considered are reusability, commonality, designing for the unique environment of space, and use of active control systems, both thermal and fluid. After considering these operability principles, a proposed depot architecture will be presented that uses water launch and on orbit electrolysis and liquefaction. This could serve as the first true space factory. Critical technologies needed for this depot architecture, including on orbit electrolysis, zero-g liquefaction and storage, rendezvous and docking, and propellant transfer, will be discussed and a developmental path forward will be presented. Finally, use of the depot to support the NASA Science Mission Directorate exploration goals will be presented.

Ground Operations Demonstration Unit for Liquid Hydrogen Initial Test Results

NASA operations for handling cryogens in ground support equipment have not changed substantially in 50 years, despite major technology advances in the field of cryogenics. NASA loses approximately 50% of the hydrogen purchased because of a continuous heat leak into ground and flight vessels, transient chill down of warm cryogenic equipment, liquid bleeds, and vent losses. NASA Kennedy Space Center (KSC) needs to develop energy-efficient cryogenic ground systems to minimize propellant losses, simplify operations, and reduce cost associated with hydrogen usage. The GODU LH2 project has designed, assembled, and started testing of a prototype storage and distribution system for liquid hydrogen that represents an advanced end-to-end cryogenic propellant system for a ground launch complex. The project has multiple objectives including zero loss storage and transfer, liquefaction of gaseous hydrogen, and densification of liquid hydrogen. The system is unique because it uses an integrated refrigeration and storage system (IRAS) to control the state of the fluid. This paper will present and discuss the results of the initial phase of testing of the GODU LH2 system.

Thermal conductivity of aerogel blanket insulation under cryogenic-vacuum conditions in different gas environments

Thermal conductivity of low-density materials in thermal insulation systems varies dramatically with the environment: cold vacuum pressure, residual gas composition, and boundary temperatures. Using a reference material of aerogel composite blanket (reinforcement fibers surrounded by silica aerogel), an experimental basis for the physical heat transmission model of aerogel composites and other low-density, porous materials is suggested. Cryogenic-vacuum testing between the boundary temperatures of 78 K and 293 K is performed using a one meter cylindrical, absolute heat flow calorimeter with an aerogel blanket specimen exposed to different gas environments of nitrogen, helium, argon, or CO2. Cold vacuum pressures include the full range from 1×10-5 torr to 760 torr. The soft vacuum region, from about 0.1 torr to 10 torr, is complex and difficult to model because all modes of heat transfer – solid conduction, radiation, gas conduction, and convection – are significant contributors to the total heat flow. Therefore, the soft vacuum tests are emphasized for both heat transfer analysis and practical thermal data. Results for the aerogel composite blanket are analyzed and compared to data for its component materials. With the new thermal conductivity data, future applications of aerogel-based insulation systems are also surveyed. These include Mars exploration and surface systems in the 5 torr CO2 environment, field joints for vacuum-jacketed cryogenic piping systems, common bulkhead panels for cryogenic tanks on space launch vehicles, and liquid hydrogen cryofuel systems with helium purged conduits or enclosures.

Zero Boil-Off Methods for Large Scale Liquid Hydrogen Tanks Using Integrated Refrigeration and Storage

NASA has completed a series of tests at the Kennedy Space Center to demonstrate the capability of using integrated refrigeration and storage (IRAS) to remove energy from a liquid hydrogen (LH2) tank and control the state of the propellant. A primary test objective was the keeping and storing of the liquid in a zero boil-off state, so that the total heat leak entering the tank is removed by a cryogenic refrigerator with an internal heat exchanger. The LH2 is therefore stored and kept with zero losses for an indefinite period of time. The LH2 tank is a horizontal cylindrical geometry with a vacuum-jacketed, multilayer insulation system and a capacity of 125,000 liters. The closed-loop helium refrigeration system was a Linde LR1620 capable of 390W cooling at 20K (without any liquid nitrogen pre-cooling). Three different control methods were used to obtain zero boil-off: temperature control of the helium refrigerant, refrigerator control using the tank pressure sensor, and duty cycling (on/off) of the refrigerator as needed. Summarized are the IRAS design approach, zero boil-off control methods, and results of the series of zero boil-off tests.

Flat-plate boiloff calorimeters for testing of thermal insulation systems

Cryostats have been developed and standardized for laboratory testing of thermal insulation systems in a flat-plate configuration. Boiloff calorimetry is the measurement principle for determining the effective thermal conductivity (ke) and heat flux (q) of test specimens under a wide range of actual conditions. Cryostat-500 is thermally guarded to measure absolute thermal performance when calibrated with a known reference via an adjustable-edge guard ring. With liquid nitrogen as the energy meter, the cold boundary temperature can be adjusted to any temperature between 77 K and approximately 300 K by the interposition of a thermal resistance layer between the cold mass and the specimen. A low thermal conductivity suspension system has compliance rods that adjust for specimen thickness and compression force. Material type, thickness, density, flatness, compliance, outgassing, and temperature sensor placement are important test considerations, and edge effects and calibration techniques for the apparatus are crucial. Over the full vacuum pressure range, the thermal performance capability is nearly four orders of magnitude. The horizontal configuration provides key advantages over the vertical cylindrical cryostats for testing at ambient pressure conditions. Cryostat-500s design and test methods, other flat-plate boiloff calorimeters, and results for select thermal insulation materials (composites, foams, aerogels) are discussed.

Large Scale Production of Densified Hydrogen to the Triple Point and Below

Recent demonstration of advanced liquid hydrogen storage techniques using Integrated Refrigeration and Storage technology at NASA Kennedy Space Center led to the production of large quantities of densified liquid and slush hydrogen in a 125,000 L tank. Production of densified hydrogen was performed at three different liquid levels and LH2 temperatures were measured by twenty silicon diode temperature sensors. Overall densification performance of the system is explored, and solid mass fractions are calculated. Experimental data reveal hydrogen temperatures dropped well below the triple point during testing, and were continuing to trend downward prior to system shutdown. Sub-triple point temperatures were seen to evolve in a time dependent manner along the length of the horizontal, cylindrical vessel. The phenomenon, observed at two fill levels, is detailed herein. The implications of using IRAS for energy storage, propellant densification, and future cryofuel systems are discussed.

Modification of a liquid hydrogen tank for integrated refrigeration and storage

The modification and outfitting of a 125,000-liter liquid hydrogen tank was performed to provide integrated refrigeration and storage capability. These functions include zero boil-off, liquefaction, and densification and therefore require provisions for sub-atmospheric tank pressures within the vacuum-jacketed, multilayer insulated tank. The primary structural modification was to add stiffening rings inside the inner vessel. The internal stiffening rings were designed, built, and installed per the ASME Boiler and Pressure Vessel Code, Section VIII, to prevent collapse in the case of vacuum jacket failure in combination with sub-atmospheric pressure within the tank. For the integrated refrigeration loop, a modular, skeleton-type heat exchanger, with refrigerant temperature instrumentation, was constructed using the stiffening rings as supports. To support the system thermal performance testing, three custom temperature rakes were designed and installed along the 21-meter length of the tank, once again using rings as supports. The temperature rakes included a total of 20 silicon diode temperature sensors mounted both vertically and radially to map the bulk liquid temperature within the tank. The tank modifications were successful and the system is now operational for the research and development of integrated refrigeration technology.