Leon J. Hastings

Cryogenic Tank Modeling for the Saturn AS-203 Experiment

A computational fluid dynamics (CFD) model is developed for the Saturn S-IVB liquid hydrogen (LH2) tank to simulate the 1966 AS-203 flight experiment. This significant experiment is the only known, adequately-instrumented, low-gravity, cryogenic self pressurization test that is well suited for CFD model validation. A 4000-cell, axisymmetric model predicts motion of the LH2 surface including boil-off and thermal stratification in the liquid and gas phases. The model is based on a modified version of the commercially available FLOW3D software. During the experiment, heat enters the LH2 tank through the tank forward dome, side wall, aft dome, and common bulkhead. In both model and test the liquid and gases thermally stratify in the low-gravity natural convection environment. LH2 boils at the free surface which in turn increases the pressure within the tank during the 5360 second experiment. The Saturn S-IVB tank model is shown to accurately simulate the self pressurization and thermal stratification in the 1966 AS-203 test. The average predicted pressurization rate is within 4% of the pressure rise rate suggested by test data. Ullage temperature results are also in good agreement with the test where the model predicts an ullage temperature rise rate within 6% of the measured data. The model is based on first principles only and includes no adjustments to bring the predictions closer to the test data. Although quantitative model validation is achieved or one specific case, a significant step is taken towards demonstrating general use of CFD for low-gravity cryogenic fluid modeling.

CFD Modeling of Helium Pressurant Effects on Cryogenic Tank Pressure Rise Rates in Normal Gravity

A recently developed computational fluid dynamics modeling capability for cryogenic tanks is used to simulate both self-pressurization from external heating and also depressurization from thermodynamic vent operation. Axisymmetric models using a modified version of the commercially available FLOW-3D software are used to simulate actual physical tests. The models assume an incompressible liquid phase with density that is a function of temperature only. A fully compressible formulation is used for the ullage gas mixture that contains both condensable vapor and a noncondensable gas component. The tests, conducted at the NASA Marshall Space Flight Center, include both liquid hydrogen and nitrogen in tanks with ullage gas mixtures of each liquid’s vapor and helium. Pressure and temperature predictions from the model are compared to sensor measurements from the tests and a good agreement is achieved. This further establishes the accuracy of the developed FLOW-3D based modeling approach for cryogenic systems.

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in normal gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-31) software. Quantitative model validation is ,provided by engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage_ Technology Demonstrator (STUSTD) program. The engineering checkout tests provide cryogenic tank self-pressurization test data at various heat leaks and tank fill levels. The predicted self-pressurization rates, ullage and liquid temperatures at discrete locations within the STUSTD tank are in good agreement with test data. The work presented here advances current CFD modeling capabilities for cryogenic pressure control and helps develop a low cost CFD-based design process for space hardware.

Testing of a Spray‐Bar Thermodynamic Vent System in Liquid Nitrogen

To support development of a microgravity pressure control capability for liquid oxygen (LO2), Thermodynamic Vent System (TVS) testing was conducted at Marshall Space Flight Center (MSFC) using liquid nitrogen (LN2) as an LO2 simulant. The spray‐bar TVS hardware used was originally designed by The Boeing Company for testing in liquid hydrogen (LH2). With this concept, a small portion of the tank fluid is passed through a Joule‐Thomson (J‐T) device, and then through a longitudinal spray‐bar mixer/heat exchanger in order to cool the bulk fluid. To accommodate the larger mass flow rates associated with LN2, the TVS hardware was modified by replacing the recirculation pump with an LN2 compatible pump and replacing the J‐T valve. The primary advantage of the spray‐bar configuration is that tank pressure control can be achieved independent of liquid and vapor location, enhancing the applicability of ground test data to microgravity conditions. Performance testing revealed that the spray‐bar TVS was effective in ...

Experimental testing of a foam/multilayer insulation (FMLI) thermal control system (TCS) for use on a cryogenic upper stage

An 18-m3 system-level test bed termed the Multipurpose Hydrogen Test Bed (MHTB has been used to evaluate a foam/multilayer combination insulation concept. The foam element (Isofoam SS-1171) protects against ground hold/ascent flight environments, and allows the use of dry nitrogen purge as opposed to a more complex/heavy helium purge subsystem. The MLI (45 layers of Double Aluminized Mylar with Dacron spacers) is designed for an on-orbit storage period of 45 days. Unique MLI features included; a variable layer density (reduces weight and radiation losses), larger but fewer DAM vent perforations (reduces radiation losses), and a roll wrap installation which resulted in a very robust MLI and reduced both assembly man-hours and seam heat leak. Ground hold testing resulted in an average heat leak of 63 W/m2 and purge gas liquefaction was successfully prevented. The orbit hold simulation produced a heat leak of 0.22 W/m2 with 305 K boundary which, compared to historical data, represents a 50-percent heat leak ...

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks in Reduced Gravity

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in low gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-3D software and simulates low gravity extrapolations of engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage Technology Demonstrator (STUSTD) program. Model results illustrate that stable low gravity liquid-gas interfaces are maintained during all phases of the pressure control cycle. Steady and relatively smooth ullage pressurization rates are predicted. This work advances current low gravity CFD modeling capabilities for cryogenic pressure control and aids the development of a low cost CFD-based design process for space hardware.

Liquid Nitrogen (Oxygen Simulant) Thermodynamic Vent System Test Data Analysis

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.

Large scale demonstration of liquid hydrogen storage with zero boiloff

Cryocooler and passive insulation technology advances have substantially improved prospects for zero boiloff (ZBO) cryogenic storage. Therefore, a cooperative effort by NASA’s Ames Research Center, Glenn Research Center, and Marshall Space Flight Center (MSFC) has been implemented to develop ZBO concepts for in-space cryogenic storage. Described herein is one program element, a large-scale ZBO demonstration using the MSFC Multipurpose Hydrogen Test Bed (MHTB). A commercial cryocooler is interfaced with the existing MHTB spray-bar mixer and insulation system in a manner that enables a balance between incoming and extracted thermal energy. The testing is scheduled for the summer of 2001. In this paper the test objectives, test set-up, and test procedures are presented.

An experiment to demonstrate key cryogenic technologies for solar thermal rockets

This paper discusses the design of a small experiment called Hydrogen On-orbit Storage and Supply (HOSS). The objectives of the experiment are: Show stable gas supply for storage and direct gain solar-thermal thruster designs; and evaluate and compare low-g performance of active and passive pressure control via a thermodynamic vent system (TVS) suitable for solar-thermal upper stages. This paper shows these can be done with a 149 kg spacecraft. This spacecraft is suitable for launch on a low cost launch vehicle. Other topics include the following: Background of cryogenic fluid management efforts; unique requirements of cryogenic fluid management for solar-rocket; how these requirements are met in a small scale experiment.