2006-2007 - Kennedy Space Center Technology Transfer Office

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Calibrating the Helium Pressurization System for the Space ShuttleLiquid-Hydrogen TankAnalysis of the results from the STS-114 tanking tests and subsequent launch calledHazardous-LeakDetection and into question existing thermal and mass models of helium pressurization of the liquidhydrogentank. This hydrogen tank, which makes up the bottom two-thirds of theIsolationExternal Tank, is pressurized prior to launch to avoid cavitation in the Shuttle MainEngine pumps. At about 2 minutes prior to launch, the main vent valve is closed, and pressurizedhelium flows into the tank ullage space to achieve set point pressure. As the helium gas cools, itspressure drops, calling for additional helium. Subsequent helium flows are provided in short, timedpulses. The number of pulses is taken as a rough leak indicator. An analysis of thermal models byMarshall Space Flight Center showed considerable uncertainty in the pressure-versus-time behaviorof the helium ullage space and the ability to predict the number of pulses normally expected.Kennedy Space Center proposed to calibrate the dime-sized orifice, which together with valves,controls the helium flow quantity (Figure 1). Pressure and temperature sensors were installed toprovide upstream and downstream measurements necessary to compute flow rate based on the orificedischarge coefficient. An assessment of flow testing with helium indicated an extremely costly use ofthis critical resource. In order to reduce costs, we proposed removing the orifices from each MobileLauncher Platform (MLP) and asking Colorado Engineering Experiment Station Inc. (CEESI) tocalibrate the flow. CEESI has a high-pressure air flow system with traceable flow meters capable ofhandling the large flow rates. However, literature research indicated that square-edged orifices ofsmall diameters often exhibit significant hysteresis and nonrepeatability in the vicinity of chokedor sonic flow. Fortunately, the MLP orifices behaved relatively well in testing (Figure 2). UsingFigure 1. The helium flow control oriface and associated instrumentation.72 Fluid System Technologies
0.900.850.80Discharge Coefficient, C d0.750.700.65MLP-3 (0004) P 1= 1,590 psia0.60 MLP-3 (0009) P 1= 525 psiaMLP-3 (0015) P 1= 650 psiaMLP-3 (0014) P 1= 775 psia0.550.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90Exit to Inlet Pressure Ratio, P 2/P 1Figure 2. Typical flow-versus-pressure ratio curve, as measured in air by CEESI.curve fitting of the air-flow data, in conjunction with ASME orifice modelingequations, a method of relating the helium mass flow to measured air flow datawas obtained. This analysis showed that the highest uncertainty in flow occurredin the vicinity of the choking pressure ratio, as would be expected. In addition,analysis of typical flow pulses showed that most of the helium flow occurredeither well below or well above this uncertain area. The final result is the abilityto provide postlaunch estimates of helium mass flows that are within 1.5 percentof the actual value.Contact: Stanley O. Starr , NASA-KSC, (321) 861-2262Participating Organization: United Space Alliance (Thomas J. Clark and Thomas A.Trovillion)KSC Technology Development and Application 2006-200773
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ForewordSuccessful technology devel
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ContentsSpaceport Structures and Ma
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Contents (continued)Process and Hum
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IntroductionJohn F. Kennedy Space C
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Constellation SystemsSurfaceSystems
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Spaceport Structures and MaterialsK
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20181614∆ E1210Modified Sensor Be
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Initial results of the EDEM model o
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Contacts: Dr. Carlos I. Calle ,NASA
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Close examination of the corrosions
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Adhesion at Failure (psi)2500200015
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Figure 1. After 500 hours of salt f
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Contacts: Dr. Paul E. Hintze , NASA
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Figure 2. Repairs to various types
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on top of the cuvette contains the
Page 35 and 36: Figure 2. A corrugated NiTi sheet e
Page 37 and 38: The PLTD can be used to (1) calibra
Page 39 and 40: SEM images of neat MWNT fibers: (a)
Page 41 and 42: Contacts: Trent M. Smith
Page 43 and 44: Figure 1. An isometric cutaway view
Page 45 and 46: Figure 2. Quartz sand flowing in th
Page 47 and 48: Figure 2. Top images show how the e
Page 49 and 50: Sand volume fraction contour at t =
Page 51 and 52: Integrated LWRD/RVC engineering bre
Page 53 and 54: Mean relative percentage change in
Page 55 and 56: We compared the model’s predictio
Page 57 and 58: Figure 2. Three-dimensional simulat
Page 59 and 60: Figure 3. Camera calibration model.
Page 61 and 62: The sketch in Figure 2 shows alaunc
Page 63: Figure 2. Signal generator (right)
Page 66 and 67: Hail Size Distribution MappingA 3-D
Page 68 and 69: Launch Pad 39 Hail Monitor Array Sy
Page 70 and 71: Autonomous Flight Safety System - P
Page 72 and 73: The Photogrammetry CubeSpaceport/Ra
Page 74 and 75: Bird Vision SystemThe Bird Vision s
Page 76 and 77: Automating Range Surveillance Throu
Page 78 and 79: Next-Generation Telemetry Workstati
Page 80 and 81: GPS Metric Tracking UnitAs Global P
Page 82 and 83: Space-Based RangeSpace-Based Range
Page 85: Fluid System TechnologiesKSC Techno
Page 89 and 90: Composite seals for performance eva
Page 91 and 92: 140000120000100000Signal80000600004
Page 93 and 94: Contacts: Dr. Barry J. Meneghelli ,
Page 95 and 96: 60555045Comparative k-value (mW/m-K
Page 97 and 98: a compatible spacecraft model where
Page 99 and 100: In an ongoing effort for improvemen
Page 101: Low-gravity probe prototype test.th
Page 104 and 105: Countermeasure for Radiation Protec
Page 106 and 107: Focused Metabolite Profiling for Di
Page 109 and 110: Process and Human FactorsEngineerin
Page 111 and 112: DON uses game technology to enable
Page 113 and 114: Type of mobile crane that impacted
Page 115 and 116: SALT proof-of-concept communication
Page 117 and 118: SSLM CAD model.Our design offers th
Page 119 and 120: Variables that can be integrated by
Page 121: Exploration Supply Chain Simulation
Page 124 and 125: Nanosensors for Evaluating Hazardou
Page 126 and 127: Sixty-four-Channel Inline Cable Tes
Page 128 and 129: Wireless Inclinometer Calibration S
Page 130 and 131: Generating Safety-Critical PLC Code
Page 132 and 133: Spacecraft Electrostatic Radiation
Page 134 and 135: Ion Beam Propulsion StudySpacecraft
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RT-MATRIX: Measuring Total Organic
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Appendix AKSC High-Priority Technol
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Risk Assessment ToolMission Data Fe
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Appendix BInnovative Partnership Pr
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system for the Government, using th
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tracking objects after launch, and
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2006-2007 - Kennedy Space Center Technology Transfer Office

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