CHALLENGES IN CRYOGENIC DEVELOPMENT PRESENT & THE FUTURE
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1 CHALLENGES IN CRYOGENIC DEVELOPMENT PRESENT & THE FUTURE Presentation by NK GUPTA Project Director, C25 LPSC-ISRO, Trivandrum Twentieth National Conference New Delhi April 10-11, 2006
2 SATELLITE C25 L110 (ES) S200(2 Nos) GSLV MARK III VEHICLE
3 Fig 1. STAGE FLOW DIAGRAM
4 Fig 2. ENGINE OPERATING CYCLES Expander Cycle Staged combustion Cycle GG Cycle
5 PERFORMANCE COMPARISON OF VARIOUS CYCLES (Comb. Chamber Pc=60Ksc, MR=6.4, AR=200) LH2 Pump Outlet Pr. (Ksc) Gas Generator Cycle 99 Staged Combustion Cycle 129 Expander Cycle 155 Engine lsp. (s) Engine Mixture Ratio Engine Thrust (T) Engine Weight (Kg) Thrust/weight Ratio #Incr. P/L from GG Cycle (Kg)
6 Fig 1. ENGINE / SUBSYSTEMS GAS GENERATOR LOX TURBOPUMP LH2 TURBOPUMP INTEGRATED TURBOPUMP THRUST CHAMBER FLUID COMPONENTS INTEGRATED ENGINE (SL)
7 Fig 3 STAGES OF COPPER CONVERGENT INNER SHELL DEEP DRAWING 2 5
8 STAGES OF COPPER DIVERGENT INNER SHELL DEEP DRAWING
9 Combustion chamber helical channel milling
10 C20 INJECTOR BODY
11 GAS GENERATOR
12 Fig 6. IGNITORS FOR CRYO ENGINES 54 EBW 2 EBW Electric igniter 17 Pyrogen igniter 1
13 INJECTION VALVES LOX GG EXHAUST GAS DUCT LH2 GG WITH FEED CIRCUIT FOR TESTING
14 CE20 GAS GENERATOR MOUNTED AT TEST BED
15 Fig 5. GG HOT TEST SEQUENCE HELIUM PURGE VALVE OPEN To-20 To OPEN Tf+0.2 CLOSE To+ 1.5 Tf =To + 50 s CLOSE Tf+10 LH2 VENT VALVE (HVV1) CLOSE To-3.3 OPEN Tf+2.5 LOX VENT VALVE (OVV1) LOX VENT VALVE (OVV2) LH2 INJECTION VALVE(HIV1) LH2 INJECTION VALVE(HIV2) IGNITER CLOSE To-3 CLOSE To-5 OPEN To CLOSE To-6.5 OPEN To+ 1.5 ON To+0.2 To+ 2.7 OPEN Tf+1.5 CLOSE Tf CLOSE Tf + 1 LOX INJECTION VALVE(OIV1) LOX INJECTION VALVE(OIV2) CLOSE To-10 OPEN To+0.3 OPEN To+ 2.7 CLOSE Tf - 4 CLOSE Tf
16 Fig 7. PERFORMANCE OF GG IN HOT TEST 40 GG02HT02 TEST s)
17 CE20 GAS GENERATOR HOT TEST VIDEO FOOTAGE
18 Fig 8 CE20 ENGINE- TURBINES ARRANGEMENT LH2 TURBINE LOX TURBINE TURBINE EXHAUST NOZZLE
19 Fig 4. DOUBLE LAYERED RING SINTERED BRONZE SEALRING
20 DETAILS OF DOUBLE LAYERED RING Major specifications : Property External layer Internal layer Composition Cu-10%Sn Cu-10%Sn-5%BN Porosity(%) 30 Max Hardness(BHN) 50 Min. 35 Max Bending strength 250 min(mpa) 100 min (MPa) UTS 150 min. (MPa) 50 min (MPa) Present status of Technology : The technology of processing double layered seal rings of all 3 sizes has been established through powder metallurgy route for application in C-25
21 Bronze Sealring(YMB (YMB-22) OD 53 x ID 44 x 11.3 mm OD 110 x ID 100 x 12 mm OD 126 x ID 118 x 9.5 mm C-25 Turbo Pump
22 CE20 TP DEVELOPMENT TESTS A. Cold Flow Tests with water/gn2 1. Pump tests, driven by Electric Motor. 2. Turbine test driven by GN2 absorbed by Dynamometer. 3. Integrated Turbo-pump test with GN2 & water. B. Tests with Cryo Fluids LN2,LOX,LH2 4. Turbine driven by GN2 & Pump working with LN2. 5. Turbine driven by GG & Pump working with LN2. 6. Turbine driven by GG & Pump working with LH2/ LOX C. Integrated Turbo-pump Tests 7. GG-LH2TP-LOXTP integrated tests.
23 LH2 PUMP COLD FLOW TEST Proto LH2 pump at test bed for testing with water & driven by electric motor
24 LH2 TURBINE COLD FLOW TEST LH2 Turbine tested with GN2 at design pressure ratio and low power level. Cd & efficiency as expected. Pi = 8.1 bar, Pout =1 bar, Ti = 284K, Flow =1.1 kg/s PR = 8.1, U/Co = 0.15 Speed= 8300 rpm Power= 80 KW Cd value = Efficiency= 47% at U/Co=0.15
25 LH2 TURBOPUMP LOX TURBOPUMP
26 LOX TP Development tests with LN2
27 CE20 LOX TP test with GN2-LN2 Speed: rpm LN2 Flow: 28 lit/sec Pump Head: 6 MPa
28 Fig 9. LOX TURBOPUMP TEST DATA WITH LN LOX TURBOPUMP TEST m
29 Fig 10 LH2 TANK ITSc LOX TANK ENGINE
30 SPECIFICATIONS OF ENGINE & STAGE Propellant Combination Total propellant loading : LOX/LH2 : kg Operating Cycle : Gas Generator Thrust, Nominal (Vacuum), kn : (±3.0%) Engine Specific Impulse, s : 443 ± 3 Engine Burn Duration (Nom), s : 550 Chamber Pressure, (Nom), MPa : 6.0 Engine Mixture Ratio : 5.05 (±1.5%) LOX Flow Rate, kg/s : LH2 Flow Rate, kg/s : TP speed : rpm(lh2) rpm(lox)
31 Fig. 11 CRYO TANK THERMAL INSULATION Anti static coating Heat shield coating Vapour barrier coating PUF Adhesive Tank wall
32 Fig 12 Thrust Chamber Test Facility
33 Thrust Chamber Test Facility
34
35
36 CE20 ENGINE SUBSYSTEM TESTS SINGLE ELEMENT HOT TESTS GAS GENERATOR DEVELOPMENT TESTS TURBO-PUMP BEARING TESTS WITH LN2; LOX/LH2 LOX TP SEAL TESTS WITH LN2 & LOX LH2 TP SEAL TESTS WITH LN2 & LH2 LOX TURBO-PUMP TESTS GN2 & LN2/LOX; GG & LN2 /LOX LH2 TURBO-PUMP CRYO TESTS GN2/GG & LN2/LH2 INTEGRATED TURBO-PUMP TEST (Pr Fed / Boot Strap) SUB SCALE CHAMBER (19 ELEMENT) TEST INTEGRATED SEA-LEVEL ENGINE TEST
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