csm power generation system nbc.ppt - nasa eps lessons 1. power generation system (pgs)power...
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CSM EPS LessonsCSM EPS Lessons
11 Power Generation System (PGS)Power Generation System (PGS)11 Power Generation System (PGS)Power Generation System (PGS)1.1. Power Generation System (PGS)Power Generation System (PGS)
22 Power Reactant Distribution System (PRDS)Power Reactant Distribution System (PRDS)
1.1. Power Generation System (PGS)Power Generation System (PGS)
22 Power Reactant Distribution System (PRDS)Power Reactant Distribution System (PRDS)2.2. Power Reactant Distribution System (PRDS)Power Reactant Distribution System (PRDS)
El t i l P Di t ib ti S t (EPDS)El t i l P Di t ib ti S t (EPDS)
2.2. Power Reactant Distribution System (PRDS)Power Reactant Distribution System (PRDS)
El t i l P Di t ib ti S t (EPDS)El t i l P Di t ib ti S t (EPDS)3.3. Electrical Power Distribution System (EPDS)Electrical Power Distribution System (EPDS)3.3. Electrical Power Distribution System (EPDS)Electrical Power Distribution System (EPDS)
4.4. BatteriesBatteries4.4. BatteriesBatteries
ObjectivesObjectives
State Basic Design Criteria for FC’sState Basic Design Criteria for FC’sState Basic Design Criteria for FC s
Design considerations during developmental
State Basic Design Criteria for FC s
Design considerations during developmentalDesign considerations during developmental phase that affected Block I and Block II vehiclesDesign considerations during developmental phase that affected Block I and Block II vehicles
Summarize the conditions that led to the failure of components in FC’sSummarize the conditions that led to the failure of components in FC’sof components in FC s
State the solutions implemented for each failure
of components in FC s
State the solutions implemented for each failureState the solutions implemented for each failureState the solutions implemented for each failure
OverviewOverview
Location of FC’sLocation of FC’sLocation of FC’sLocation of FC’sLocation of FC’sLocation of FC’sFC Theory and FC OverviewFC Theory and FC OverviewLocation of FC’sLocation of FC’sFC Theory and FC OverviewFC Theory and FC OverviewDesign Criteria going into Development PhaseDesign Criteria going into Development PhaseDesign Considerations coming fromDesign Considerations coming fromDesign Criteria going into Development PhaseDesign Criteria going into Development PhaseDesign Considerations coming fromDesign Considerations coming fromDesign Considerations coming from Design Considerations coming from Development PhaseDevelopment PhaseBlock I Failures and SolutionsBlock I Failures and Solutions
Design Considerations coming from Design Considerations coming from Development PhaseDevelopment PhaseBlock I Failures and SolutionsBlock I Failures and SolutionsBlock I Failures and SolutionsBlock I Failures and SolutionsBlock II Failures and SolutionsBlock II Failures and SolutionsBlock I Failures and SolutionsBlock I Failures and SolutionsBlock II Failures and SolutionsBlock II Failures and SolutionsLessons LearnedLessons LearnedLessons LearnedLessons Learned
Alkaline Fuel Cell Overview Alkaline Fuel Cell Overview
FC’s produce DC electrical power over a normal rangeFC’s produce DC electrical power over a normal rangeFC’s produce DC electrical power over a normal rangeFC’s produce DC electrical power over a normal rangeFC s produce DC electrical power over a normal range FC s produce DC electrical power over a normal range of 563 to 1420 (W) at a voltage of 27 to 31 (V).of 563 to 1420 (W) at a voltage of 27 to 31 (V).FC s produce DC electrical power over a normal range FC s produce DC electrical power over a normal range of 563 to 1420 (W) at a voltage of 27 to 31 (V).of 563 to 1420 (W) at a voltage of 27 to 31 (V).
1.1. Energy Conversion SectionEnergy Conversion Section1.1. Energy Conversion SectionEnergy Conversion Section
2.2. ReactantReactant--Control SectionControl Section2.2. ReactantReactant--Control SectionControl Section
3.3. ThermalThermal--Control SectionControl Section3.3. ThermalThermal--Control SectionControl Section
4.4. WaterWater--Removal SectionRemoval Section4.4. WaterWater--Removal SectionRemoval Section
Design CriteriaDesign CriteriaCriteria:Criteria:Criteria:Criteria:Criteria:Criteria:
“Shall be designed to supply, regulate, and distribute all “Shall be designed to supply, regulate, and distribute all electrical power required by CSM for mission requirements, and electrical power required by CSM for mission requirements, and LEM during checkout and monitoring.”LEM during checkout and monitoring.”
Criteria:Criteria:“Shall be designed to supply, regulate, and distribute all “Shall be designed to supply, regulate, and distribute all electrical power required by CSM for mission requirements, and electrical power required by CSM for mission requirements, and LEM during checkout and monitoring.”LEM during checkout and monitoring.”g gg g
System had to possess adequate mission flexibilitySystem had to possess adequate mission flexibilityNo constraints imposed on launch datesNo constraints imposed on launch dates
g gg g
System had to possess adequate mission flexibilitySystem had to possess adequate mission flexibilityNo constraints imposed on launch datesNo constraints imposed on launch datesNo constraints imposed on launch datesNo constraints imposed on launch datesHad to be operationally adaptable to changing requirements for Had to be operationally adaptable to changing requirements for successive missions without a subsequent requirement for successive missions without a subsequent requirement for design changesdesign changes
No constraints imposed on launch datesNo constraints imposed on launch datesHad to be operationally adaptable to changing requirements for Had to be operationally adaptable to changing requirements for successive missions without a subsequent requirement for successive missions without a subsequent requirement for design changesdesign changesdesign changesdesign changes
High reliability and safety that were consistent with High reliability and safety that were consistent with t i htt i ht
design changesdesign changes
High reliability and safety that were consistent with High reliability and safety that were consistent with t i htt i htsystem weightsystem weight
Factors affecting reliability, such as multiple starts, were to be Factors affecting reliability, such as multiple starts, were to be avoided, and simplicity of design was desiredavoided, and simplicity of design was desired
system weightsystem weightFactors affecting reliability, such as multiple starts, were to be Factors affecting reliability, such as multiple starts, were to be avoided, and simplicity of design was desiredavoided, and simplicity of design was desired
Development PhaseDevelopment Phase
Concept for 1 5 (kW) FC came from the GeminiConcept for 1 5 (kW) FC came from the GeminiConcept for 1 5 (kW) FC came from the GeminiConcept for 1 5 (kW) FC came from the GeminiConcept for 1.5 (kW) FC came from the Gemini Concept for 1.5 (kW) FC came from the Gemini programprogram
Gemini program utilized Ion Exchange Membrane (IEM) FCGemini program utilized Ion Exchange Membrane (IEM) FC
Concept for 1.5 (kW) FC came from the Gemini Concept for 1.5 (kW) FC came from the Gemini programprogram
Gemini program utilized Ion Exchange Membrane (IEM) FCGemini program utilized Ion Exchange Membrane (IEM) FCg g ( )g g ( )g g ( )g g ( )
Electrolyte Seal Electrolyte Seal
Leakage of electrolyte at the periphery of theLeakage of electrolyte at the periphery of theLeakage of electrolyte at the periphery of theLeakage of electrolyte at the periphery of theLeakage of electrolyte at the periphery of the Leakage of electrolyte at the periphery of the unit cellunit cellLeakage of electrolyte at the periphery of the Leakage of electrolyte at the periphery of the unit cellunit cell
Cell Flooding Cell Flooding
If either hydrogen or oxygen gas pressure isIf either hydrogen or oxygen gas pressure isIf either hydrogen or oxygen gas pressure isIf either hydrogen or oxygen gas pressure isIf either hydrogen or oxygen gas pressure is If either hydrogen or oxygen gas pressure is more than 2.5 (psi) below or 10.5 (psi) above the more than 2.5 (psi) below or 10.5 (psi) above the electrolyte pressure, a breakdown of theelectrolyte pressure, a breakdown of the
If either hydrogen or oxygen gas pressure is If either hydrogen or oxygen gas pressure is more than 2.5 (psi) below or 10.5 (psi) above the more than 2.5 (psi) below or 10.5 (psi) above the electrolyte pressure, a breakdown of theelectrolyte pressure, a breakdown of theelectrolyte pressure, a breakdown of the electrolyte pressure, a breakdown of the liquid/gas interface was possibleliquid/gas interface was possibleelectrolyte pressure, a breakdown of the electrolyte pressure, a breakdown of the liquid/gas interface was possibleliquid/gas interface was possible
Nickel back-platediaphragm section
Nickel plus nickel oxideelectrode
Weld
Nitrogen blanket pressure
KOH
Oxygen reactant cavity Hydrogen reactantNickel electrode Oxygen reactant cavity
Dendrite FormationDendrite Formation
FC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdownFC shorted out internally during shutdown
il d d i i f dd d li hil d d i i f dd d li hSilver dendrite experiment from Goddard Space Flight CenterSilver dendrite experiment from Goddard Space Flight Center
AccumulatorAccumulator
Size was insufficient to function as a pressureSize was insufficient to function as a pressureSize was insufficient to function as a pressureSize was insufficient to function as a pressureSize was insufficient to function as a pressure Size was insufficient to function as a pressure control device for total temp range of FCcontrol device for total temp range of FCSize was insufficient to function as a pressure Size was insufficient to function as a pressure control device for total temp range of FCcontrol device for total temp range of FC
Cell SeparationCell Separation
Occurrence of cold poppingOccurrence of cold poppingOccurrence of cold poppingOccurrence of cold poppingOccurrence of cold poppingOccurrence of cold poppingOccurrence of cold poppingOccurrence of cold popping
Water-Glycol PumpWater-Glycol Pump
Leakage and failure to startLeakage and failure to startLeakage and failure to startLeakage and failure to startLeakage and failure to startLeakage and failure to startLeakage and failure to startLeakage and failure to start
Hydrogen Vent PortHydrogen Vent Port
Under extreme thermal conditions the waterUnder extreme thermal conditions the waterUnder extreme thermal conditions the waterUnder extreme thermal conditions the waterUnder extreme thermal conditions the water Under extreme thermal conditions the water vapor condensed and froze at purgevapor condensed and froze at purge--port port openingopening
Under extreme thermal conditions the water Under extreme thermal conditions the water vapor condensed and froze at purgevapor condensed and froze at purge--port port openingopeningopeningopening
This prevented further hydrogen purgingThis prevented further hydrogen purging
openingopening
This prevented further hydrogen purgingThis prevented further hydrogen purgingp y g p g gp y g p g g
Two heaters were added to subsequent flight Two heaters were added to subsequent flight
p y g p g gp y g p g g
Two heaters were added to subsequent flight Two heaters were added to subsequent flight vehiclesvehiclesvehiclesvehicles
Hydrogen Pump/SeparatorHydrogen Pump/Separator
Because the hydrogen was saturated with waterBecause the hydrogen was saturated with waterBecause the hydrogen was saturated with waterBecause the hydrogen was saturated with waterBecause the hydrogen was saturated with water Because the hydrogen was saturated with water vapor, several electrical problems were vapor, several electrical problems were encountered until a satisfactory waterproofing encountered until a satisfactory waterproofing
Because the hydrogen was saturated with water Because the hydrogen was saturated with water vapor, several electrical problems were vapor, several electrical problems were encountered until a satisfactory waterproofing encountered until a satisfactory waterproofing epoxy insulation was foundepoxy insulation was foundepoxy insulation was foundepoxy insulation was found
W W
TOP
VIEW
BACK
VIE
W
Secondary Coolant LoopSecondary Coolant Loop
Cooling capacity of the secondary coolant loopCooling capacity of the secondary coolant loopCooling capacity of the secondary coolant loopCooling capacity of the secondary coolant loopCooling capacity of the secondary coolant loop Cooling capacity of the secondary coolant loop was reducedwas reducedCooling capacity of the secondary coolant loop Cooling capacity of the secondary coolant loop was reducedwas reduced
TOP VIEWBACK VIEW
Condenser Exit Temperature 2Condenser Exit Temperature 2
Water slugging out of condenserWater slugging out of condenserWater slugging out of condenserWater slugging out of condenserWater slugging out of condenserWater slugging out of condenserWater slugging out of condenserWater slugging out of condenser
Ingestion of Hydrogen Gas Ingestion of Hydrogen Gas
Ingestion of hydrogen gas into drinking waterIngestion of hydrogen gas into drinking waterIngestion of hydrogen gas into drinking waterIngestion of hydrogen gas into drinking waterIngestion of hydrogen gas into drinking water Ingestion of hydrogen gas into drinking water caused discomfort to crewmancaused discomfort to crewman
Solution was the development of hydrogen gasSolution was the development of hydrogen gas
Ingestion of hydrogen gas into drinking water Ingestion of hydrogen gas into drinking water caused discomfort to crewmancaused discomfort to crewman
Solution was the development of hydrogen gasSolution was the development of hydrogen gasSolution was the development of hydrogen gas Solution was the development of hydrogen gas separator which was added to the drinking water separator which was added to the drinking water system system
Solution was the development of hydrogen gas Solution was the development of hydrogen gas separator which was added to the drinking water separator which was added to the drinking water system system
Lessons Learned/ReviewLessons Learned/Review
Some problems were unique to the FC and others wereSome problems were unique to the FC and others wereSome problems were unique to the FC and others wereSome problems were unique to the FC and others wereSome problems were unique to the FC and others were Some problems were unique to the FC and others were caused by integration with other spacecraft systemscaused by integration with other spacecraft systemsSome problems were unique to the FC and others were Some problems were unique to the FC and others were caused by integration with other spacecraft systemscaused by integration with other spacecraft systems
Operational errors caused the costly failure of several Operational errors caused the costly failure of several FC’s during early servicing and checkout operationsFC’s during early servicing and checkout operationsOperational errors caused the costly failure of several Operational errors caused the costly failure of several FC’s during early servicing and checkout operationsFC’s during early servicing and checkout operations
Contamination was a serious problem for spacecraft Contamination was a serious problem for spacecraft subsystemsubsystemContamination was a serious problem for spacecraft Contamination was a serious problem for spacecraft subsystemsubsystemsubsystemsubsystem
Redundancy philosophy that was instituted by FC Redundancy philosophy that was instituted by FC
subsystemsubsystem
Redundancy philosophy that was instituted by FC Redundancy philosophy that was instituted by FC system designers resulted in system and mission system designers resulted in system and mission flexibility flexibility system designers resulted in system and mission system designers resulted in system and mission flexibility flexibility
LESSONS LEARNED/REVIEWLESSONS LEARNED/REVIEW
Recommendations:Recommendations:Recommendations:Recommendations:Recommendations:Recommendations:System selection/design criteria should include System selection/design criteria should include susceptibility to damage as a result of operational susceptibility to damage as a result of operational
Recommendations:Recommendations:System selection/design criteria should include System selection/design criteria should include susceptibility to damage as a result of operational susceptibility to damage as a result of operational p y g pp y g perrorerrorSystem/spacecraft interfaces should be carefully System/spacecraft interfaces should be carefully d fi dd fi d
p y g pp y g perrorerrorSystem/spacecraft interfaces should be carefully System/spacecraft interfaces should be carefully d fi dd fi ddefineddefinedCompatibility of circulating fluids with system Compatibility of circulating fluids with system hardware verifiedhardware verified
defineddefinedCompatibility of circulating fluids with system Compatibility of circulating fluids with system hardware verifiedhardware verifiedAll fluid loops should have filters upstream of critical All fluid loops should have filters upstream of critical componentscomponentsAll fluid loops should have filters upstream of critical All fluid loops should have filters upstream of critical componentscomponentsCritical automatic control devices should be used in Critical automatic control devices should be used in manner to avoid operation in twomanner to avoid operation in two--phasephase--fluid fluid mediummedium
Critical automatic control devices should be used in Critical automatic control devices should be used in manner to avoid operation in twomanner to avoid operation in two--phasephase--fluid fluid mediummediummedium medium medium medium
ObjectivesObjectives
State Basic Design Criteria for FC’sState Basic Design Criteria for FC’sState Basic Design Criteria for FC’sState Basic Design Criteria for FC’sState Basic Design Criteria for FC sState Basic Design Criteria for FC s
Design considerations during developmentalDesign considerations during developmental
State Basic Design Criteria for FC sState Basic Design Criteria for FC s
Design considerations during developmentalDesign considerations during developmentalDesign considerations during developmental Design considerations during developmental phase that affected Block I and Block II vehiclesphase that affected Block I and Block II vehiclesDesign considerations during developmental Design considerations during developmental phase that affected Block I and Block II vehiclesphase that affected Block I and Block II vehicles
Summarize the conditions that led to the failure Summarize the conditions that led to the failure of components in FC’sof components in FC’sSummarize the conditions that led to the failure Summarize the conditions that led to the failure of components in FC’sof components in FC’sof components in FC sof components in FC s
State the solutions implemented for each failureState the solutions implemented for each failure
of components in FC sof components in FC s
State the solutions implemented for each failureState the solutions implemented for each failureState the solutions implemented for each failureState the solutions implemented for each failureState the solutions implemented for each failureState the solutions implemented for each failure