Internal Thermal Control System Hose Fluid Thermal Expansion - NASA
NASA/TM--2001-211330 Internal Thermal Control System Hose Heat Transfer Fluid Thermal Expansion Evaluation Test Report P.O. Wieland Marshall Space Flight Center, Marshall Space Flight Center, Alabama Summer Marshall High School Apprenticeship Research Program Space Flight Center, Marshall Space Flight Center, Alabama October 2001 H.D. Hawk
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NASA/TM--2001-211330 Internal Thermal Control System Hose Heat Transfer Fluid Thermal Expansion Evaluation Test Report P.O. Wieland Marshall Space Flight Center, Marshall Space Flight Center, Alabama H.D. Hawk Summer High School Marshall Space National Aeronautics Space Flight Apprenticeship Center, Marshall Research Space Program Flight Center, and Administration Marshall Space October 2001 Flight Center MSFC, Alabama 35812 Alabama
Acknowledgments Daniell Hawk participated in this project via the Summer High School Apprenticeship Research Program and assisted in collecting and evaluating test data, preparing plots, and assembling this Technical Memorandum. Bill Barnett, FD21, Marshall Space Flight Center, prepared the test article and test preparation sheet, and John Lowery and Amos Glenn, ASRI, operated the environmental chamber during the test. Jamie Miernik, Boeing, obtained the hose and end cap that were tested. Available from: NASA Center for AeroSpace 7121 Standard Drive Hanover, MD 21076 1320 (301) 621 0390 National Information Technical Information Service 5285 Port Royal Road Springfield, VA 22161 (703) 487 4650 ii
TABLE 1. INTRODUCTION . 2. TEST OBJECTIVE 3. APPLICABLE 4. TESTING OF CONTENTS AND PURPOSE DOCUMENTS . . . 1 1 2 2 4.1 Test Method . 4.2 Test Article . 2 2 4.3 Test Facility . 3 5. PRETEST PREPARATION AND MEASUREMENTS . 6. TEST RESULTS AND DISCUSSION 7. CONCLUSIONS . APPENDIX A--ITCS HOSE EVALUATION APPENDIX B--ITCS TEST HEAT . TRANSFER TEST PLAN INTEGRATED PREPARATION HOSE FLUID THERMAL ASSEMBLY COOLANT 6 9 EXPANSION . 111 4 EXPANSION . SHEET 4 17
LIST OF FIGURES IHA test article . 3 2. Test article pressure . 4 3. Test article pressure profiles 5 4. Estimated temperature . to reach the maximum iv pressure . 7
LIST OF ACRONYMS HTF heat transfer IHA integrated ISS International ITCS Internal MSFC Marshall Space Flight Center PACRATS Payloads and Components PTFE polytetrafluoroethylene QD quick disconnect RFCA rack flow control TPS test preparation fluid hose assembly Space Station Thermal Control assembly sheet System Real-Time Automated Test System
TECHNICALMEMORANDUM INTERNAL THERMAL CONTROL THERMAL SYSTEM EXPANSION HOSE EVALUATION HEAT TRANSFER FLUID TEST REPORT 1. INTRODUCTION The Internal to transfer Thermal heat to maintain Control optimum System (ITCS) temperatures of the International Space for the crew and equipment Station (ISS) is designed inside the modules. Excess heat is removed and cool locations are warmed as needed. During assembly of the ISS, jumper hoses are used by the astronauts on board to connect the ITCS loops in adjacent modules. A jumper hose with quick disconnects It would be preferable (QDs) and end caps attached to launch the IHAs prefilled that in the event of high temperature damaged due to excessive pressure. during to as an integrated with heat transfer storage To address is referred fluid (HTF), or transportation, this concern, hose assembly but there is a concern the IHAs may leak or become a test was requested by the ISS Program Thermal Control Lead, Joe Chambliss, to evaluate the ability of an IHA to be launched "wet" accommodate the increased pressure of the HTF if the temperature increased to the worst-case of 60 C (140 F). This testing a flightlike was performed at Marshall hose with a flight end cap to evaluate Space Flight the maximum (IHA). Center pressure (MSFC) that would and safely condition in June 2000 on occur under the worst-case temperature condition. Four cases were run with test conditions subjecting the test article up to 71 C (160 F), and results show that the pressure at this temperature reached - 228 kPa (33 psia), well below the design maximum Technical Memorandum. of 689 kPa (100 psia). The test conditions 2. TEST OBJECTIVE The objective of this test is to simulate and results are described AND PURPOSE the conditions that may be experienced IHA, filled with HTF and capped on both ends. The purpose is to determine whether accommodate the increased pressure due to HTF expansion when heated from room to 60 C (140 F) without or being damaged. exceeding In addition, in the filled hose are needed the design measurement for designing in this maximum pressure of the bend radius the transportation by an isolated the IHA can temperature of 689 kPa (100 psia), leaking, of the hose and of the mass of HTF containers.
3. APPLICABLE The following documents "ITCS Rack Flow Control "ITCS Hose HTF Thermal axe applicable Assembly Expansion DOCUMENTS to this test: Fill Procedure," Evaluation SK683-53379, 21 April 1999 Test Plan," May 2000 (revised June 21, 2000) (app. A) "Test Preparation Sheet," FD21TST-TPS-ITCS-00-001 (app. B). 4. TESTING The test was performed scribed in sections from June 27-30, 4.1 through 2000. The test method, article, and facility axe de- 4.3. 4.1 Test Method A flightlike IHA was tested by simulating the worst-case condition plus 11 C (20 F); i.e., 71 C (160 F). The pressure was monitored and the hose was regularly checked for any signs of leakage or other damage. Four cases were run with increasing temperature profiles: two cases at 60 C (140 F), one case at 66 C (150 F), and one case at 71 C (160 F). The rate of temperature and decreasing, change, increasing for each case was 17 C/hr (30 F/hr). The test plan is in appendix A and the test preparation sheet (TPS) is in appendix B. 4.2 Test Article The test article consisted of an IHA, plus an aluminum adapter block fabricated to attach a pressure transducer and a three-way valve for connecting a vacuum source and a pressurized tank conraining HTE The serial number of the IHA is 683-56836-385. This had been a flight IHA but was rejected due to a change in materials. hose. The hose is made of convoluted of 12.7 mm (0.5 in) and a length shown schematically 2 in figure 1. A flight-qualified teflon end cap covered (polytetrafluoroethylene of 762 mm (30 in), including fittings. the QD at the other end of the (PTFE)) with a nominal The assembled diameter test article is
Vacuum Source Pressure Transducer P1 QD Connector With Cap QD1 1/2-in-DiameterHose Approximately36 in Long Valve Vl MS Fitting Adapter Block AB1 HTFSupply Figure 1. IHA 4.3 The Despatch environmental (model capable of maintaining chamber allows (48 in) deep, a 610-mm user to maintain mm multiloop program. with to 2 C (3.6 Temperature Automated The the ITCS process controller and data IHA was pressure (PACRATS) filled facility. with HTF were every to 180 of the door. the of the nominal within to 356 has a front the allowable is F). The 1,219 mm opening and enables vary the temperature to manually by as TH3, measuring of the chamber or to continuously the operator - C (-94 chamber operation chamber designated shaped, in the center allows recorded of-70 is cube The up to 100 h. Temperatures or wet bulb, System that thermal/humidity chamber, (46 in) wide. manages value F), dry bulb Test simulator times mm controller This in the range located at a constant The Watlow segment at MSFC. volume 1,168 window Facility test is an Ecosphere 4619 internal and view the temperature perature for this anywhere usable (44 in) high, square to a predefined tained used in Building the temperature (24-in) A Watlow steps, located an unobstructed, 1,118 with chamber 16664) Test test article. enter the according up to 256 range door tem- can be main- value. by the Payloads and Components Real-Time 20 s. in Building 4755, using the same equipment as was used to fill
5. PRETEST PREPARATION The empty test article was weighed empty hose was measured 53379, which involves The filling procedure of air bubbles AND MEASUREMENTS and the mass was 1403.6 as 76 mm (3 in). The test article evacuating the IHA to 50 milliTorr was designed to ensure would likely result in higher was filled with HTF per procedure before that no air bubbles pressures g (3.07 lb). The bend radius of the SK683- filling with HTF to 207 kPa (30 psia). were present due to the greater in the IHA. (The presence thermal expansion of air com- pared to water.) After filling with HTF, the bend radius was again measured and found to be 76 mm (3 in), and the mass was measured as 1532.5 g (3.35 lb). The mass of HTF in the hose was therefore 128.9 g (0.28 lb), or 4.3 g (0.01 lb) for each inch of hose length. At 101 kPa (14.7 psia) and 25 C (77 F), the volume of HTF in the hose is 0.129 L (0.034 gal), or 0.0043 L (0.0011 gal) for each inch of hose length. 6. TEST RESULTS During pretest (30 psia) during preparation filling with HTE AND DISCUSSION on Friday, June 23, 2000, the test article was pressurized Over the weekend, the pressure dropped to 207 kPa to 117 kPa (17 psia) with no indication that any leakage had occurred. On Monday, June 26, 2000, the test article was repressurized to 207 kPa (30 psia) in Building 4755, then transported to Building 4619 and connected to the data recording equipment. By the time data recording (27 psia). By Tuesday tion of leakage holding morning, (fig. 2). These the pressure pressures at 162 kPa (23.5 psia), indicating was initiated, had dropped were all recorded the pressure had dropped to 162 kPa (23.5 psia), again, at ambient that the pressure temperatures. to 186 kPa with no indica- The pressure drop was not due to leakage, was and it was decided to proceed with test case 1 on Tuesday. (The drops in pressure shortly before the beginning of case 1 axe likely due to temperature drops as air conditioning equipment in the building was activated.) 34 ] Case 1 Case 2 Case3 Case4 32 140 F 140 F 150 F 160 F . t[ / 3o/ A 28 Ambient Temperature 24 22 20 18 . 16 Data Point (time) Figure 4 2. Test article pressure.
As expected, thedataclearlyshowthatthepressureincreases asthe temperature rises,for all cases.However,asshownin figure3, for case1,thepressureprofile is significantlydifferentfromthe followingcases. Forcase1,thecurvehasamuchshallowerslopeandis almostlinear.Thepressureincrease is significantlylessthanfor thefollowing cases,includingcase2 thatfollowedthesametemperature profile.Thisis thoughtto berelatedto expansionof thehosedueto theabove-ambient pressure, which wouldresultin decreasing pressure,mitigatingthe pressureincreasedueto increasingtemperature. However,asthetemperature nears60 C (140 F), theslopechanges to matchthe slopeof case2 above 57.2 C (135 F).Thisindicatesthatexpansionof thehosehadessentiallyceased, sothefinal partof the curveparallelsthelatercases,where,it is assumed, additionalexpansionof thehoseis minimal.At 60 C (140 F)the pressurereachedjust over200kPa(29psia).Whenthetemperature wasreduced to ambient,thepressuredecreased to 134kPa(19.5psia). 35 3O Case 1 Case 2 A 25 Case 4 20 O. 15 10 60 I I I I I 80 100 120 140 160 180 Temperature ( F) Figure Cases 2, 3, and 4 show closely 3. Test article pressureprofiles. parallel pressure profiles, successively peaking higher pressures due to the higher successive temperatures. With each successive slight decrease in pressure (3.4 to 9 kPa (0.5 to 1.3 psia)) at a given temperature. or totally related provided to effusion by Ahmad Sleiman of the HTF through of Boeing, g/min/in 2 at 48.9 C (120 F). (Precise some insight At the target temperature those temperatures. The reported effusion rates, are 1.74 10 3 g/min/in 2 at 18.3 C (65 F) and 7.68 10 3 measurement into the mass of HTF lost during taken for this test were not sufficiently the PTFE hose material. at somewhat case, there is also a This decrease is partly precise of the mass before the test related to effusion, but the mass measurements for this purpose.) of each case, a short, vertical This is due to thermal and after the test would provide equalization portion indicates of the test article, on one end and a metal QD with a cap on the other. The thermal contributes to this pressure increase. a pressure increase which has an aluminum lag of the masses of these items at block
7. CONCLUSIONS Thetestarticlewasinitially pressurized to 207kPa(30psia)with HTF,perthe Boeingprocedure for filling therackflow controlassembly(RFCA).Asdemonstrated duringthis test,thepressurewill decrease to nearambientwithin a fewdays,dueprimarilyto expansionof theflexiblehose.Forthis test, thetestarticlewasrepressurized, whichwill makethetestresultsconservative; i.e.,withoutthe repressurization, whichis not calledfor in theprocedure,themaximumpressures wouldhavebeen results: 1. Theinitial dropin pressureatambienttemperatures beforecase1is relatedto expansion of the flexiblehose. Thisconclusionis supportedby thepressuredroplevelingoutpriorto case1,indicating thatexpansionhadceased,aswell asthebehavioraftercase1,whenthe pressurecurves areessentiallyparallelandthelow pressurepointsaxeveryclose,indicatingthatexpansion of thehosehadessentiallystopped. 2. Theshapeof thecase1pressureprofileis dueto expansionofthehoseaswell asexpansion of the HTFwhileheatingis occurring. Simultaneous influenceof thetwo opposingeffectscausedtheresultingshapefor case1. Expansionof thehoseleadsto decreased pressurewhileincreased temperature leadsto increasedpressureof theHTE It is thoughtthatthehighertemperatures allowedadditional nttemperature. Withoutadditional hoseexpansion, themaximumpressurewouldhavebeen- 241kPa(35psia)for case1. 3. Theslightdropin pressures atthesametemperatures with succeeding casesis dueto effusion of the HTFthroughthe PTFEhose. Whilecontinuedexpansionof thehosemightalsocausesucharesult,the evenspacingand smoothcurvesof theprofilesaxemoreconsistentwith gradualfluid loss,whichcouldoccur by effusion.Theincreasein effusionrateasthetemperature increases is reflectedin the slightly broadening spacingbetweenthecurvesasthetemperature increases. 4. Undertheexpectedworst-case thermalconditions,thepressurein a filled IHA will remain well belowthemaximumdesignpressure(689kPa(100psia)). Extrapolatingfromthetestdatato estimatethemaximumallowabletemperature, figure4 showsthat689kPa(100psia)wouldnot bereacheduntil- 115 C (240 F).
120100A D O. 80604020O- 0 I I 100 200 240 300 Temperature ( F) Figure 4. Estimated 5. Based on the given thermal temperature conditions to reach the maximum and the IHA characteristics, pressure. the IHAs can safely be filled with HTF prior to launch. Even if the hoses axe repressurized mated pressure maximum curve but starting 6. The bend radius IHA. This measurement to 207 kPa (30 psia) after expansion has ceased, at 40 C (140 F) is 276 kPa (40 psia), assuming the esti- the same pressure at 207 kPa (30 psia). of the IHA when filled with HTF is very close to the bend radius was made by loosely, but firmly, coiling the IHA, then allowing of an empty it to relax in an unconstrained manner, with the masses of the QD with cap and adapter block with valve attached at the ends. If necessary, it could be coiled tighter than a 76-mm (3-in) radius, but that would induce a higher level of stresses. 7
APPENDIX AmlTCS HOSE EXPANSION HEAT TRANSFER EVALUATION FLUID THERMAL TEST PLAN 9
ITCS Hose HTF Thermal Expansion Evaluation Test Plan Paul Wieland NASA/MSFC/FD21 256-544-7215 May 2000 (Revised 10 June 21, 2000)
Contents 1.0 Introduction 2.0 Test Objective 3.0 Test Approach . 3 . . 3 3 4.0 Applicable Documents . 5.0 Test Method . 3 3 6.0 Test Requirements 4 . 6.1 Materials/Equipment Required . 6.2 Facility Requirements . 6.3 Personnel Requirements . 7.0 Test Procedure . 7.1 Pretest Preparation . 7.2 Test Steps . 7.3 Post Test . 8.0 Evaluation Criteria 9.0 Cost and Schedule 10.0 Documentation and Risks . . . 4 4 5 5 6 6 6 6 7 7 Figures Figure 6.1-1. IHA Test Assembly Figure 6.2-1. IHA Coolant . Expansion Test Setup . 4 5 11
1.0 Introduction Internal Thermal Control System (ITCS) jumper hoses will be used by the astronauts on-board the International Space Station (ISS) to connect the ITCS loops in adjacent modules. A jumper hose with quick disconnects (QD) and end caps attached would be preferable concern become Thermal and safely Control accommodate case condition of 140 1. this test, general 2.0 Test on both ends, and to determine when heated the equipment IHA (serial number requirements to the worstfor performing criteria. the conditions whether 683-56836-385) which may be experienced the IHA can accommodate to 140 1, without will be tested will be monitored by an isolated the increased exceeding IHA, pressure due to the design maximum by simulating the worst-case condition and the hose will also be checked for any signs of or other damage. flight hardware the cap for the hose is flight hardware 4.0 Applicable but is now obsolete and appropriate procedures due to a change in materials, however, must be followed. Documents Thermal Control System Rack Flow Control Assembly Fill Procedure, SK683-53379, 21 April Method The test IHA will be filled with coolant per procedure to 50 milliTorr before filling with HT1. The worst-case coolant-filled, sealed IHA in an environmental chamber, Flight Center (MSFC). SK683-53379, which of 160 E involves evacuating the IHA conditions will be duplicated by heating a located in Building 4619 at the Marshall Space Four cases will be run: two with a target temperature of 150 1, and one with a target 12 increased and facility "wet" Approach Note: The hose was originally 5.0 Test It or being damaged. plus 20 1, i.e., 160 1. The pressure Internal 1999 (IHA). but there is a the ability of an IHA to be launched of the HTF if the temperature from room temperature of 100 psia, leaking, A flight-like leakage pressure and the evaluation of this test is to simulate HTF expansion 3.0 Test to evaluate This test plan describes test procedures, Hose Assembly fluid (HTF), during storage or transportation the IHAs may leak or To address this concern, a test was requested by the ISS Lead (Joe Chambliss) the increased to as an Integrated filled with heat transfer Objective The objective pressure is referred the IHAs already that in the event of high temperature damaged due to excessive pressure. Program capped to launch of 140 1, one with a target
6.0 Test Requirements Controlled equipment conditions axe needed as well as the means to monitor the pressure in the IHA. The IHA, and that directly connects to the IHA fittings, must be cleaned to cleanliness level 300. Appropri- ate safety precautions must also be taken. support axe described requirements The materials The hose will be filled with HTF according 6.1 Materials/Equipment A suitable operation flight-like that are required and the facility to procedure SK683-53379. Required IHA (undamaged), fittings at 160 1, and HTF axe required. one end and a threaded and equipment below. and connectors, a pressure The IHA to be provided MS fitting on the other. A connector block transducer by Boeing is required transducer, and vacuum and fill valve to the IHA. This configuration pressure transducer must have current calibration for the test. compatible with has a QD connector for attaching is shown in Figure on the pressure 6.1-1. The Vacuum Source Pressure Transducer P1 QD Connector With Cap QD1 1/2-in-DiameterHose Approximately36 in Long MS Fitting Adapter Block AB1 Valve Vl HTFSupply Figure 6.2 Facility Facility support 6.1-1. IHA Test Assembly Requirements requirements include: 1. A suitable test preparation area to prepare the IHA test article for testing, 2. The means to evacuate the IHA test article and fill it with HT1, 3. An environmental chamber capable of cycling between ambient peratures and capable of maintaining the target temperatures ensure thermal equilibrium with the IHA test article), 4. A means to record 5. Suitable precautions the data (pressure, temperature, in the event of leakage time), conditions for the required and the test target temdurations (sufficient to and of the IHA test article or other safety-related The IHA test article will be installed in the environmental chamber pressure transducer will have data lines which connect to recording concerns. as indicated in figure 6.2-1. The equipment outside the chamber. 13
Pressure / Transducer I P] I QD Connector WithCap I I I 1/ -in-Diameter Hose Approximately 36 in Long I m MSFitting Adapter Valve (OttPosition) Block AB1 Environmental Chamber Figure 6.3 Personnel 6.2-1. IHA Coolant Expansion Test Setup Requirements In addition to test personnel from FD21 and ED26, quality assurance approve the test due to the use of a flight hardware end cap. personnel from QS 10 will need to 7.0 Test Procedure The test procedure 7.1 Pretest should include the following Preparation 1. Connect the required article with HTE 2. Attach 3. Fill the test article with HTF by procedure a pressure prior to ensure 4. 5. steps. fittings to the IHA, including gauge and ensure complete proper valve and hoses tightness required for filling the IHA test of all fittings. SK683-53379. (Evacuate the test article to 50 millitorr fill with HTF). Place the test article in the environmental chamber and connect to the monitoring Place paper (or other means to readily detect leakage) under the test article. equipment. 7.2 Test Steps 6. Record the initial pressure maximum quently). 7. rate of 30 F/hour. If the pressure the temperature. 14 reaches ( 15 psig) and temperature. Record 100 psia during the temperature temperature Increase and pressure ramp-up, the temperature every in the chamber 10 minutes at a (or more fre- STOP the test immediately and reduce
8. If thepressure 100psiawhenthetargettemperature is reached(140 1,140 1,150 1,and160 F) holdthetemperature longenoughto ensurethoroughheatingandto checkthroughthechamber windowfor signsof leakage.Noteanyleakagein thetestlog. 9. Reducethetemperature ata maximumrateof 30 F/houruntil neax-ambient temperature is reached. 10.Openthe chamberandcheckthetestarticlefor indicationsof leakageor damage. 11.Returnto step7 for thenexttargettemperature. 12.Uponcompletionof thelasttargettemperature cycle,removethetestarticlefromthechamberand inspectfor indicationsof leakageor damage. 7.3 Post Test Following completion of the test cycles, the test article is to be disassembled cleaned to specification level 300 for return to Boeing. A report on the results 8.0 Evaluation The purpose 140 1. Criteria of the testing To ensure can successfully leakage of the testing and whether will reach Presently, and It is expected cost and time. the IHA can accommodate a high temperature must remain should occur, and the hose should remain below for attaching of 160 1. the worst-case To demonstrate the 100 psia limit while scenario of that the hose at this temperature, no undamaged. this test relate to acquisition the need for funding chase items such as fittings 9.0 Cost Risks do this, the pressure Potential risks to performing personnel. will be prepared. is to determine this, the testing and the cap and hose of materials has not been identified, the pressure and availability though of facilities it may be necessary and to pur- gauge. Schedule
NASA Access Help Desk NASA Center for AeroSpace Information 7121 Standard Drive Hanover, MD 21076-1320. NASA/TM--2001-211330 . "ITCS Rack Flow Control Assembly Fill Procedure," SK683-53379, 21 April 1999 "ITCS Hose HTF Thermal Expansion Evaluation Test Plan," May 2000 (revised June 21, 2000) .
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