nasa cr-13505lx casd-nas-76-018 final report - core

NASA CR-13505lx

CASD-NAS-76-018

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FINAL REPORT

ENER AL:_pYN AM ICSConvair Division

https://ntrs.nasa.gov/search.jsp?R=19760024361 2020-03-22T13:05:04+00:00Z

1. Rtoolt No.

NASA CK-i :Jf>0514. Titi» mi SuOMn

Thermal Performance ofInsulation ( M L I )

Karl K. Leonhard

General Dynamics ConvaP.O. Box 808-4 7San Diego, CA 9213S

12. Spontofinj Agency N*m» «nd Add'eu

National Aeronautics andLewis Research Center,

2. Govvnmou Acrmiion No,., t-'-C;-

a-iCusiomi/ed Multilayer

t^iSUGMfc-v r'' ''

J>;|3 tlfX* fcij' i' ^>'/^ rBiii«*fe'.<iT' *J ..,' *V '* Wi>(: ' =-' f* S?S

Lr Division

S]>ace AdministraiionCleveland, Ohio

iH^r.c^No.

April 1970

l^fff1?"' ""0nC"'ft. rarfcrming'0>9^»/«tion Report No.

CASD-NAS76-018..\0i Wort Uml No.

II. Concrict or C'lnt I«o.

NAS3-1775G13. '.Type of Report nO Pt/,od Covered

Contractor Report14. Spomcrmg A^mcy CoO* . .

IS. Supplementiry Nol«Project Manager, J. R. Barber. Fluid System Section of Chemical EDivision of the Space Teclinologj- and Material Directorate, NASA LewisT?p<;p.-irf-h ppntpr. rlpvf.lfl.nd. Ohio 41135 ,

18.The study was conducted to expe rim en tally investigate the therm;,! performance of a Libtank on a shroudless vehicle. The 1.52m (GO In) tank was Insulated with 2 MLI blanketsconsisting of 13 double aluuiinh:ed Mylar radiation shields and ID silk net spacers. Thetemperature of outer space was simulated by using a cryoshrouci which was maintainedat near liquid hydrogen temperature. The heating effects of a payload were simulatedby utilizing a thermal payload simulator (TPS) viewing the tank. The tank and cryo-shroud were provided by NASA/LeRC and modified by General Dynamics. The testprogram consisted of three major test categories: 1) null testing, 2) thermal perform-ance testing of the tank installed MLl system, arid 3) thermal testing of a customizedMLI configuration. The TPS was not insulated during test category 1 anJ 2. Null testswere conducted utilizing zero, 0.2, 0.4 watts power input to an Internal tank heater.TPS surface temperatures during the null test were maintained at near hydrogentemperature and during test categories 2 and 3 at 289K (520R). The heat flow ratethrough the "tank Installed MLI" at a tank/TPS spacing of 0. 467 m was 1. 204 wattswith no MLI on the TPS and 0. 059 watts through the customized MLI with three blanketson the TPS. Reducing the tank/TPS spacing from 0. 457 m to 0.152 m the heat flowthrough the customized MLI increased by 10 percent.

17. Kry Wordi (St,7jai*d by AuiSorUH

Customized MLI thermal performance,shroudless vehicle, payload effect

19. S«uri(y Qju.l. (ol lh,» frporll

Unclassified

18. Oisaib>ri>3n Suttm*«i

Unclassified - Unlimited

70. S*cu"ry Ojiwt. tot Uui o*9»l 21. No. ol P»o« 72. *»c*'Unclassified

'fa sale by the National Technical Inftxmjtion Service. SpnnjIieM. Vngin;a 22151

NAXA-C-tM (•»,.

u^ ABSTRACT^, ^

The study was conducted to experimentally investigate the thennal performance of aliquid hydrogen tank on a shroudless vehicle. !ThCJ 1.52 m'((<0 in.) tank was insulatedwith two MLI blankets consisting of 18 double aluminlzcd Mylar 'radiation shields and19 silk net spacers. The temperature of outer space was simulated by using a cryo-shroud which was maintained at near liquid hydrogen temperature. The heatingeffects of a payload were simulated by uti l izing a thermal payload simulator (TPS)viewing the tank. The tank and cryoshrouri were provided by NASA/LeHC and modifiedby General Dynamics Convair Division.

The test program consisted of three major test categories, 1) null testing, 2) thermalperformance testing of the tank installed MI. I system and 3) thermal testing of acustomized MLI configuration. The TPS was not insulated during test category 1 and2. Null tests were conducted utilizing zero, 0.2, 0.4 watts power input to an internallank heater. TPS surface temperatures during the null test were maintained at nearhydrogen temperature and during test categories 2 and a at 289K (5201?).

The heat flow rate through the "tank installed MLI" at a tank/TPS spacing of 0.457 mwas 1.201 watts with no MLI on the TPS and 0.059 watts through the customizedMLI witli three blankets on the TPS.

Reducing the tank/TPS spacing from 0.457 m to 0.152 m the heat flow through thecustomi/ed MLI increased by 10 percent.

PAGE BLANK NOT FILMED!

This report was prepared by General Dynamics. Cony air Division under ContractNAS3-177!j<>, "Thermal Performance of a Customi/.ed Multilayer Insulation.". Thework was administered under the technical direction ofM iv J. R. Barber, FluidSystem Section of Chemical Energy Division of the Space Technology and MaterialDirectorate and Mr. W. R. Johnson, Thermal Technology Section, PropulsionTechnology Branch, Chemical Propulsion Division, NASA/Lewis Research Center.

In addition to the project leader, K. E. Leonhard, the following Convair personnelwere major contributors to the study:

Thermodynamics M. D. WalterG. B. Yates

Predesign

Structural Analysis

Manufacturing Research

Reliability Laboratory

J. P. HancockR. S. llingwald

J. K. Dyer

11. E. KobrichE. CationN. L. FrederickV. V. SowinskiK. L. ChristianC. J. LangfordG. T. Lundquisi

G. Gross\V. L. Colahan

Test Laboratory B. A. GanoeII. G. Brittain

Approved

PAGE -BLANK NOT FTLMEEJ

\. E. TatroChief of Thermodynamics

vii

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

NOMENCLATURE

SUMMARY

1 INTRODUCTION

2 DESIGN OF TEST TANK MODIFICATIONS AND TANKSUPPORT SYSTEM

2.12.1.12.1.22. 1.32.22.2. 12. 2. 22.3

2.3.12.3.22.3.32.3.42.3.52.3.G2.3.72.3.8

TEST TANK MODIFICATIONLarge Manhole Access DoorTank Outlet CapRemoval of the Tank Support Ring AssemblyTANK SUPPORT SYSTEM DESIGNThree Point Support System"A" Frame Handling AidSTRUCTURAL ANALYSIS OF THE MO, IFIEDTANKDesign LoadsAnalysis MethodsMaterial AllowancesDoor Ring Discontinuity AnalysisDoor Ring to Tank Weld AnalysisDoor AnalysisDoor Attachment BoltTank Support Analysis

3 FABRICATION OF TEST TANK MODIFICATION ANDTANK SUPPORT SYSTEM

3.3.3.

1i. i1.2

3. 1.3

2.13.23.9.3.2.°3.3

TEST TANK MODIFICATIONPreparation of TankMachining and Welding of Tank Outlet Cap,Door AssemblyRemoval of Existing Conical Support RingAssemblyTEST TANK SUPPORT FABRICATIONThree Point Support System"A" Frame Handling AidPROOF PRESSURE AND LEAKAGE TEST

Page

xili

xlx

xxl

xxiii

1-1

2-1

2-22-22-62-62-62-62-102-10

2-152-152-172-172-192-202-212-22

3-1

3-13-13-12

3-M

3-193-193-193-19

ix

TABLE OF CONTENTS, Contd

Page

THERMAL PAYLOAD SIMULATOR 4-1

4.1 THERMAL REQUIREMENTS 4-14.2 TPS DESIGN AND FABRICATION 4-24.2.1 Cooling Coils 4-24.2 .2 Electrical Healers 4-4

CRYOSHROUD ASSEMBLY MODIFICATION 5-1

5. 1 CRYOSHROUD MODIFICATION 5-15.2 CRYOSHROUD BAFFLE THERMAL ANALYSIS 5-35.2.1 Thermal Analysis 5-35.2.2 Reflecting Node Model 5-35.2.3 Complete Node Model 5-75.2.4 Finite Numerical Approximation 5-75.2.5 Results 5-75.3 BAFFLE DESIGN AND FABRICATION 5-1]5.3.1 Baffle Location 5-115.3.2 Design 5-115.3.3 Fabrication 5-155.4 BAFFLE AND T H E R M A L PAYLOAD

SIMULATOR POSITIONING MECHANISM 5-1G5.5 G U A R D TANK DESIGN AND FABRICATION 5-1G5.G MODIFIED CRYOSHROUD ASSEMBLY 5-235. G.I Assembly Sequence 5-235. G. 2 Thermal Paint Requirements 5-235. fi. 3 Fluid Tubing ' 5-23

DESIGN AND FABRICATION OF THE THERMAL PAYLOAD G-lSIMULATOR M U L T I L A Y E R INSULATION

G.I B L A N K E T DESIGN f i -1G.2 B L A N K E T ATTACHMENT DESIGN G-lG.3 BLANKET FABRICATION (i-4G.3. 1 MLI Manufacturing Aid Requirements G-f>G.3 .2 Silk Net Stretch-Forming . G-5G.3.3 Blanket Cover Shields G-5G.3 .4 Blanket Lay-Up and Assembly (i-f>l>. 4 B L A N K E T INSTALLATION 6-9

DESIGN AND FABRICATION OF THE TANK MOUNTED 7-1MULTILAYER INSULATION

7.1 VENTING CONSIDERATIONS 7-17.2 INNER B L A N K E T DESIGN 7-1


7.3 .OUTER BLANKET DESIGN7.4 BLANKET ATTACHMENT DESIGN7.5 BLANKET FABRICATION7. 5.1 MANUFACTURING AID REQUIREMENTS7.5.2 Silk Net Stretch Forming7.5.3 Blanket Cover Shield Fabrication7. 5.4 Blanket Layup and Assembly7.(i BLANKET INSTALLATION

TEST FACILITIES

8. 1 VACUUM CHAMBER8.2 TEST TANK PRESSURE CONTROL SYSTEM8. 2.1 Capacitance Manometer MKS Baratron No. 145

AH-1, i 1 mm Hg Differential8. 2. 2 Signal Conditioner, MKS Model 170 M-7A8.2.3 Pressure Indicator, MKS Model 170M-26A8.2. t Balance Digital Offset MKS Model 170M-298.2.5 Controller, Dahl Model C-GOIB8. 2. (i Hammel-Dahl Valve CV 0. 001, Model No.

A40A/V810/DGE42/P4SG88.2.7 Hammel-Dahl Valve, CV 0. 01, Model No.

A40A/V810/DGE42/PWSG88.2.8 Reference Pressure Container Ice Bath8.3 G U A R D TANK PRESSURE CONTROL8.4 FLUID SYSTEM8.5 TEST TANK HEATER

TEST INSTRUMENTATION9. 1 • INSTRUMENTATION DEFINITION9.2 'MEASUREMENTS AND ACCURACIES9. 2. 1 Thermocouples9. 2. 2 Resistance Thermometers9.2.3 Pressure9.2 . - I Vacuum9.2.5 Flow9. 2. (i Power9.2 .7 Positioni'.:: DATA ACQUISITION

Page

7-27-27-G7-6

7-137-137-187-21

8-1

8-18-18-1

8-18-118-118-118-11

8-11

8-118-118-128-15

9-1

9-19-129-129-139-149-149-159-159-159-ID

xi


10 TESTING 10-1

10.1 NULL TESTING 10-G10. 1. 1 Null Test Procedures 10-610.1.2 Test Specimen Preparation 10-710.1.3 Null Test Results 10-810.1.4 Evaluation o£ Null Test Results . 10-1410.1.5 Flow Rate Corrections 10-2110.2 THERMAL TESTING OF TANK INSTALLED 10-23

MLI SYSTEM10.2.1 Tank Installed MLI Test Procedure 10-2310.2.2 Test Specimen Preparation 10-2410.2.3 Thermal Test Results 10-2410.2.4 Evaluation of Thermal Test Results 10-2410.3 CUSTOMIZED MLI THERMAL PERFORMANCE 10-29

TEST10.3.1 Customized MLI Test Procedure 10-3110.3.2 Test Specimen Preparation 10-3310.3.3 Customized MLI Test Results 10-3310.3.4 Evaluation of Customized MLI Test Results 10-50

11 CONCLUSIONS AND RECOMMENDATIONS 11-1

11.1 CONCLUSIONS 11-111.2 RECOMMENDATIONS 11-4

12 REFERENCES 12-1

xii

LIST Or F1GURKS

Figure Page

S-l Schematic of Insulated Test Tank and Thermal Pay load xiiiSimulator, Assembled With the Cryoshroud

2-1 Tank Preparation - Basic 2-3

2-2 Large Manhole Access Door - Customized MLI Test Tank 2-5

2-3 Manhole Access Door Ring - Customized MLI Test Tank 2-7

2-4 Tank Outlet Cap - Customized MLI Test Tank 2-8

2-5 Test Tank - Customized MLI 2-9

2-G Lug - Tank Support, Customized MLI 2-11

2-7 Welded Tank - Customized MLI Test 2-12

2-8 Tank Support System Schematic 2-13

2-9 "A" Frame Handling Aid 2-14

2-10. Large Manhole Access Door Ring and Lug of 1. 52 m (CO in) 2-16Tank

2-11 Simply Supported Circular Plate 2-20

2-12 Bolt Attachment . 2-21

2-13 Loadi> Ac ting on Lug 2-23

3-1 Large Manhole Access Door/Neck After Cutout 3-G

3-2 1. 52 m (GO in) Tank After Large Manhole Access Door Cutout 3-8

3-3 Large Manhole Access Door Area Distortion 3-9

3-4 Close Up of Distortion Measurement at Large Manhole 3-10Access Door Area Cutout

3-0 Tank Setup for Distortion Corrections and Final Cutout J-ll

3-0 Mismatch of Original Tank Halves 3-12

3-7 X-ray of Original 1. 52 m (GO in) Tank Material - Tank 3-13Outlet Cap Area

3-8 Tooling Aid to Correct Large Manhole Access Door King 3-15Opening

3-9 Internal Door Ring Welding to Tank . 3-16

Kill

LIST OF FIGURES, Contd

Figure PageI

3-10 X-ray of'Original 1.52 m (60 in) Tank Material - Conical 3-17Support Weld Area

3-11 X-Ray of Original 1. 52 m (CO in) Tank Conical Support Weld 3-18

3-12 The Modified 1.52 m (60 in) Tank 3-20

4-1 Thermal Paytoad Simulator Schematic 4-2

4-2 Thermal Payload Simulator Design 4-3

4-3 Sketch of Electrical Heater Connect. ,i:s 4-4

4-4 Thermal Payload Simulator Assembly 4-6

5-1 2.44 r.i (06.0 in) Cryoshroud Modification- Top Cover 5-2

i>-2 2.44 m (96.0 in) Cryoshroud Modification - Bottom Cover 5-4

5-3 2.44 m ('J6.0 in) Cryoshroud Modification - Cylindrical Shell 5-5

5-4 Reflecting Node Model of Cryoshroud Illustrating Node Nos. 5-6

D-5 Complete Node Model of Cryoshroud Illustrating Node Nos. .' -6

5-6 Heat Flow From Thermal Payload Simulator (Node 1) to 5-9Cryogenic Tank (Nodes 2, 3, 4) vs Thermal PayloadSimulator Surface Temperature

5-7 Baffle Assembly - Sandwich Construction 5-12

5-8 Baffle Assembly- Cooling Ceil Arrangement 5-13

5-9 Baffle Assembly - Honeycomb Arrangement 5-14

5-11 Thermal Payload Simulator and Cryoshroud Baffle 5-17Positioning Mechanism

5-11 Positioning Screw-Nut 5-18

5-12 Positioning Screw-Washer 5-18

5-13 Positioning Screw - Adapter Ring 5-19

5-14 Positioning Meahanisrn - Jack Screw 5-19

5-15 Positioning Mechanism - Guide 5-20

5-1G Positioning Mechanism - Angle 5-20

5-17 Guard Tank Assembly 5-21

5-18 Guard Tank - Facility Lines 5-22

xiv

LIST OF FIGUKKS, Contd

Figure • Page

5-19 Cryoshroud Assembly - Top View 5-24

5-20 Cryoshroud Assembly - Side View 5-25

5-21 Assembly of the Guard Tank and Cryoshroud Cover 5-26

5-22 Assembly of Cryoshroud Cover/Guard Tank and Test 5-27Tank, Side View

5-23 Assembly of Cryoshroud Cover/Guard Tank and Test 5-28Tank - Top View

5-24 Cryoshroud and Baffle Assembly 5-29

6-1 Thermal Payload Simulator MLI System 6-2

6-2 thermal Payload Simulator Blankets 6-3

6-3 Button Pin Stud 6-4

6-4 Retaining Button Detail 6-4

G-5 Silk Net Stretch Form Manufacturing Aid . G-G

6-(> Thermal Payload Simulator MLI Blanket Manufacturing Aid 6-7

0-^7 Thermal Payload Simulator MLI Blanket Manufacturing Aid 6-8

G-8 . Thermal Payload Simulator Blanket Assembly 6-10

7-1 Test Tank Inner Blanket Arrangement 7-2

7-2 Gore Blankets for Customized MLI - 7-3

7-3 Inner and Outer Circular Blankets, Customized MLI 7-4

7-4 Test Tank Outer Blanket Arrangement 7-5

7-5 Butt Joint Sections of Tank Mounted MLI System . 7-5

7-6 Insulation Assembly, Customized MLI Tank and Thermal 7-7Payload Simulator

7-7 Blanket Manufacturing and Lay-up Aids . 7-8

7-8. Schematic of Fabrication Process of Gore and Circular 7-9Blanket Layup Aids

7-9 Inner Gore Blanket Manufacturing Aid - First Layer of 7-10Fiberglass Cloth on Tank .

7-10 Inner Gore Blanket Manufacturing Aid - Gore Layup With 7-11Seven Layers of Fiberglass Cloth on Tank

xv . •

\


Figures Page

7-11 Inner Gore Blanket Manufacturing Aid With Wax Spacer 7-12

7-12 Inner and Outer Gore and Circular Blanket Manufacturing 7-14Aids

7-13 Cover Shield Vacuum Form Tolling <sid - Lay up on Tank 7-15

7-14 Cover Shield Vacuum Form Tooling Aid - Ready for 7-16Mounting

7-15 Vacuum Form Tooling Aid for Cover Shield Manufacturing 7-17

7-16 Base Plate for Gore Blanket Manufacturing Aid 7-19

7-17 Blanket Layup and Assembly Sequential Operation 7-20

7-18 The Modified 1.52 ir (GO in) Tank 7-22

7-19 Inner Gore Blanket Layup and Velcro Fastener Mounting 7-23

7-20 Inner Gore Blanket Assembly 7-25

7-21 Outer Gore Blanket With Velcro Fastener Mounting . 7-26

7-22 Superinsulated, 1.52 m (60 in) Tank 7-27

8-1 Test Facility - South View 8-2

8-2 Test Facility - North View 8-3

8-3 Test Tank Pressure Control System Schematic 8-4

8-4 MKS Baratron Head Mounting and Reference Pressure 8-5Container

8-5 Test Tank Pressure Control System 8-G

8-f5 MKS Baratron Capacitance Manometer Head Mounting rf-7

8-7 Reference Pressure Volume and Ice Bath 8-8

8-8 NBS Barostat Assembly 8-9

8-9 Test Tank Ullage Pressure Versus Time 8-10

8-10 Schematic of Test Apparatus and Fluid System 8-13

8-11 Test Tank Heater . . 8-16

8-12 Test Tank Heater - Attached to Instrumentation Tree 8-17

9-1 Guard Tank, Support, Fill Line and Vent Line 9-1Instrumentation . . •

xvi

LIST Or FIGURES, Contd

Figure paSe

9-2 Test Tank and MLI Instrumentation 9-2

9-3 Shroud Thermocouple Location 9-2

9-4 Baffle Thermocouple Location 9-3

9-5 Thermal Payload Simulator Instrumentation Location 9-3

9-6 Instrumentation for Auxiliary Hardware 9-4

9-7 Watev Displacement Flow Setup 9-16

9-8 Water Displacement Flow Setup 9-17

10-1 Test Set-Up Definition 10-1

10-2 Schematic of Test Article and Cryoshroud Assembly 10-3

10-3 Cryoshroud Assembly Ready for Installation Into the 10-5Vacuum Chamber

10-4 Null Tost No. 1, Zero Power Input (Elapsed Hours: 10-90 to 73) - Sheet 1 of 3

Null Test No. 2, 0.2 Watt Power Input (Elapsed Hours: 10-1073 to 145) - Sheet 2 of 3

Null Test No. 3 (0.4 Watt)and No. 4 (0.2 Watt) Power 10-11Input (Elapsed Hours: 146 to 221) - Sheet 3 of 3

10-5 Test Tank Heater Power Input Vs Test Tank Boiloff 10-14Rates During Null Testing

10-6 Thermal Test of Tank Installed MLI - Start of Test 10-2b(Elapsed Hours: 219 to 294) - Sheet 1 of 2

Thermal Test of Tank Installed MLI - Elapsed Hours: 10-26294 to 372) - Sheet 2 of 2

10-7 Test Tank MLI Temperature Distribution at 240 and 10-30290 Hours A > ~ e r 0-Time

10-8 Test Tank MLI Temperature Distribution at 344 and 372 10-30Hours After 0-Time

10-9 Test Tank MLI Temperature Distribution Between 2.'p 10-31and 372 Hours After 0-Time

xvii


Figure Page

10-10 Customized MLI Thermal Test -

Start of Initial Null Test and Approach to Thermal 10-35Equilibrium (Elapsed Hours: 0 to 73) - Sheet 1 of 10

Initial Null Test Thermal Equilibrium and Start of 10-30Customized MLI Test No. 1 (Elapsed Hours: 73 to 145) -Sheet 2 of 10

Approach to Thermal Equilibrium of Test No. 1 (Elapsed 10-37Hours: 135 to 205) - Sheet 3 of 10

Start of Equilibrium Period of Test No. 1 (Elapsed Hours: 10-38205 to 275) - Sheet 4 of 10

Completion of Test No. 1 and Start of Test No. 2 (Elapsed 10-39Hours: 275 to 345) - Sheet 5 of 10

Approach to Equilibrium of Test No. 2, 0.305 m (12 in) 10-40TPS/Test Tank Spacing (Elapsed Hours: 345 to 415) -Sheet 6 of 10

Equilibrium Period of Test No. 2, 0.305 m (12 in) TPS/ 10-41Test-Tank Spacing and Start of Test No. 3, 0.152 m (G in)TPS/Test Tank Spacing (Elapsed Hours: 415 to 485) -Sheet 7 of 10

Equilibrium Period of Test No. 3, 0.152 m (G in) TPS/' 10-42Test Spacing (Elapsed Hours: 485 to 555) - Sheet 8 of 10

Equilibrium Period of Test No. 3, 0.152 m (G In) TPS/ 10-43Test Tank Spacing; Start of Final Null Test (ElapsedTime: 555 to (>25) - Sheet 9 of 10

Final Null Test (Elapsed Hours: G25 to 719) - 10-44S!.eet .vO of 10

10-11 Experimental Thermal Performance of Customized MLI 10-59Versus Thermal Payload Simulator and Test Tank Spacing

xvlil

LIST OF TABLES

Table paSc

s~! SumiiKiiy of Tost Results xxvl

2-1 Tank Geometry and Weights 2-1

2-2 T:mk Design Requirements 2-2

3-1 1.52 m (HO in) Tank Modification Sequence 15-2

3-2 Tank Thickness Variations at the Large Manhole Access 3-7Door Area Cutout

5-1 Model Node Description 5-8

Heat Transfer From Thermal Payload Simulator to 5-10Tank Bottom Hemisphere

Conoseal Flanges, Tubing Joints ami Gaskets 5-30

(i-1 -Properties of Blanket'Cover Shield Material (>-9

9-1 Measurement Description Summary 9-5

10-1 Test Objectives and Conditions 10-2

10-2 Null Test No. I, '/.i-ro Watt Power Input Boiloff Data 10-8During the Thermal [Equilibrium Period

!()-:? Test Data at Beginning and End of the Thermal 10-13Equilibrium Period of Null Test No. 1

10-; Null Test No. 2, 0.2 Watt Power Input Boiloff Data 10-11During The Thermal Equilibrium Period

10-5 Test Data at Beginning and End of the Thermal 10-15Equilibrium Period at Null Test No, 2

I0-(i Null Test No. 3, O.-l Watt Power Input Boiloff Data 10-l(iDuring the Thermal Equilibrium Period

10-7 Null Test No. -1, 0. 2 Watt Power Input Boiloff bu«a 10-1GDuring the Thermal Equilibrium Period

10-8 Test Data at Beginning and End of Thermal Equilibrium 10-17Period of Null Test No. 4

10-9 Summary of Nul l Test Results 10-18

10-10 Estimated Extraneous Heat Flow Mo the LII2 Test Tank 10-18

10-11 Flow Correci.ion Factor (FT) for Air Temperature (° H) 10-23

10-12 Thermal Test of Tank Installed MI.I 15oiloff Data During 10-2-1the Final 29 Hour Period

xL\

LIST OF TABLES, Contd

Table Page

10-13 Tost Data at 2-10 and 290 Hours After 0-Time During 10-27Thermal Testing of the Tank Installed MLJSystem

10-14 Test Data 3-14 and 372 Hours After 0-Time During Thermal 10-28Testing of the Tank Installed MLI System

10-15 Initial Null Test -0 .2 Watt Power Input, Boiloff Data 10-34During the Thermal Equilibrium Period

10-lfi Test Data at Beginning and End of the Thermal Equilibrium 10-45Period of Initial Null Test During the Customized MLIPerformance Testing

10-17 Customix.ed MLI Thermal Test Ny. 1, 0.457 m (18 in) 10-46TPS/Test Tank Spacing, Boiloff Data During the ThermalEquilibrium Period

10-18 Test Data at Beginning and End of the Thermal Equilibrium 10-47Period of Test No. 1 During the Customized MLI Perform-ance Testing

10-19 Customized MLI Thermal Test No. 2, 0.305 m (12 in) 10-48TPS/Test Tank Spacing, Boiloff Data During the ThermalEquilibrium Period

10-20 Test Data Beginning and End of the Thermal Equilibrium 10-49Period of Test No. 2 During the Customized MLI ThermalPerformance Testing

10-21 Customized MLI - Thermal Test, No. 3, 0.152 m (6 in) 10-51TPS/Test Tank Spacing Thermal Equilibrium Boilcff Data

10-22 Tec-t Data at Beginning and End of the Thermal Equilibrium 10-52Period of Test No. 3 During the Customized MLI ThermalPerformance Tccting

10-23 Final Null Test, 0.2 Watt Power Input-Boiloff Data 10-53During the Thermal Equilibrium Period

10-24 Test Data at Beginning and End of the Thermal Equilib- . 10-54rium Period of Final Null Test During the CustomizedMLI Thermal Performance Testing

10-25 Comparison of Null Test Results . 10-55

10-i»ti Comparison Between the Tank Installed MLI and Custom- 10-58i/ed MLI Test Results . .

l°-27 Summary of Test Results 10-60xx

NOMF.NCLATUHE

2 2A, a area, m (in )

c weld distance, m (in)

Cr constant '--S>. 39 x 10~s for N in layers/m (Tin°K, andq inW/m")

Cr constant - 1.10 x 10"11 for N in layers/in (Tin°R, andqinBtu/hrft2)r ~ 2

Cs constant - 8.95 x ]0~" for N in layers/m-(Tin"K.ancK; inW/m )

Cs constant - 8. 06 x i<r10 for N in layers/in (Tin°R, and q inBhi/hrft2)2

K modulus of elasticity, kN/m (psi)2

Fsu ultin.aie shear, kN/m (psi)2

F[W ultimate strength, kN/m (psi)2

Fty yield strength, kN/m (psi)

Fbru ultimate bearing stress, kN/ivT (psi)4 4

I moment of inertia, (section area), m (in )

M moment, m-kN/m (in-lb/in)

m reciprocal of Poisson's ratio, dimensionless

M.S. margin of safety, dimensionless

Ns numljer of radiation shield layers

N number of layers/m or layers/in

Nx shear load; kN/m (Ib/'in)

P pressure, kN/m- (psi)

P vertical load, kN (lb)o

q heat flux, \V/m2 (BTU/hr ft") ,

Qc corrected flow rate, kg/hr (Ib/hr)

Qi\I measured flow rate, kg/hr (Ib/hr)

R . radius, m (in)

T temperature, K (R)

I thickness, m (in)

I time, rf, hr

xxi

W total applied load, kN (lb)2 2

w unit applied load, kN/m (Ib/ln )

e emissivity, dimensionless

u Poisson's ration, dimensionless2a total stress, kN/m (psi;

0Subscripts

c center; cold

h hot

m mean

s shear

t tension

tot total

u ultimate

w weld

x location

y yield

xxli

SUMMARY

This program report covers the work performed under NASA contract NAS3-1775G,"Thermal Performance of a Customized Multilayer Insulation (MLI)." The majorobjective of the total program was to design, fabricate, and experimentally evaluatethe thermal performance of a selected, customized MLI system. NASA/LeRC providedthe basic design of the MLI configuration to be tested, the 1. 52m (GO in) test tank to beinsulated, and the 2,44 in (9G in) cryoshroud for simulating a deep space environment.

The total pi-ogrnm objective accomplished were:

• Design and Fabrication of Test Tajik Modifications

• Design and Fabrication of Test Tank Support System

• Design and Fabrication of the Thermal Payload Simulator

o Modification of the Cryoshroud Assembly

• Design and Fabrication of the Thermal Payload Simul:itor MultilayerInsulation

• Design and Fabrication of the Tank Mounted Multilayer Insulation

• Design and Fabrication of Test Equipment, Test Facilities and Instrumentation

» Thermal Performance Testing and Evaluation of the "Tank Installed" and"Customized" MultilayerInsulation System

DESIGN OF TEST TANK MODIFICATIONS AND TANK SUPPORT SYSTEM

Modification drawings were established for

1. Replacement of the existing tank manhole access door/neckwith a flush door design. :

2. Removal of the outlet flange and replacing it with a contoured, outletcap design.

3. Removal of the existing conical support ring assembly at its mechanicaljoint.

xxiil

The new access door, 0.5GG m (22.3 in) In diameter, is a 0.038 m (1.5 in) thickcircular, flat plate of GO(il-T6 aluminum alloy material. The design provides openingsthrough the door for a f i l l and drain line/vent line and electrical pass throughs. DoubleConoseals were used to further reduce anticipated leakage. An outlet cap0.215 m ,8.43 in) diameter was formed to a spherical radius of 0.762 m(30.0 in' from a 0.008 m (0. 32 in)thtck 6061 aluminum alloy plate. The existingconical support ring at the tank equator was removed.

The new tank support system is a three point system, designed to suspend the tankinside the cryoshroud. It consists of three lugs at the tank door ring, threeadjustable turnbuckles and three attachment fittings located at the LH2 guard tank.

A structural analysis was performed to verify the capability of the basic test tank andthe modifications performed by GD/C to support the required test loads. Theinvestigation included a combined membrane and discontinuity stress analysis of thetank wall near the door and the tank support. Conservative methods used showed apositive margin of safety.

FABRICATION OF TEST TANK MODIFICATIONS AND TANK SUPPORT SYSTEM

The tank modifications included:

1. Preparation of the tank for welding the new large manhole access door ringand tank outlet cap.

2. Machining of the door, door ring, tank outlet cap and tank support lugs.

3. Wdding of the tank outlet cap.

4. Welding of the manhole access door ring.

5. Welding of the tank support lugs onto the tank.

6. Removal of the existing conical support.

The inspection methods included dye penetrant and radiography. Unforeseen severedistortions were encountered in cutting out the original manhole access door ring.The distortion problems were directly attributed to the initial fabrication of the1.52i7i (GO in) tank by its original manufacturer. The original welding resulted in

.excessive defects causing resident distortions in the tack. A combination of mechani-cal and machining techniques was used to reduce mismatch and distortion to asatisfactory level. In an effort to define conditions in the original weld zones, x-rayswere taken in various areas untouched by the modification of the tank. The x-raysshowod the presence of tungsten inclusions, porosities, weld folds, foreign materialand cracks. Repair work was considered outside the scope of the program.

xxiv

The test lank was proof pressure tested at 27f i .O kN/.ii CIO psig). A final leak testwas conducted utilizing helium gas and a Veeco leak detector, Model MS17. Theleakage measured at a pressure differential of i;)S.O kN/ni" (20 p.sid), was 2.0 x 10"'sec/sue. This amount of gas leakage was less than the allowable leakage of 1 x 10~(>

sec/sec.

THERMAL PAVLOAD SIMULATOR (TPS)

The thermal payload simulator was designed and fabricated to provide a constanttemperature surface in the range of 20. 5 to 417K (37 to 750K) for the iasulated lankto view. It consist.; of a 1.83m (72 in) diameter 0.0095 m (0.375 in) thick, highlypolished aluminum disc. An emissivity of 0. 03 was measured utilizing the Lioncmissometer Model 25 D-7. The thermal payload simulator is cooled by liquidhydrogen flowing through circumferential, aluminum coils. The TPS heaters weredesigned for an operating range of 0.01 to 55 watts. Due to the radially nonuniformheat load on the TPS, individual heaters were mounted in the Inner, mid and outerzone.

CRYO°MROUD ASSEMBLY MODIFICATION

The NASA/I.eRC furnished cryoshroud, 2.44 m (06.0 in) in diameter was modifiedto establish a low temperature black body cavity while l imi t ing liquid hydrogenusage to a minimum feasible rate. The modification of the cryoshroud wasperformed in these steps:

1. Cryoshroud shell modifications2. Cryoshroud thermal analysis3. Cryoshroud baffle design and fabrication4. Thermal payload simulator and baffle |X>sitioning mechanism design and

fabrication5. Guard tank design and fabricationG. Assembly of the cryoshroud components

The cryoshroud shell modification consisted of reworking the top cover to accommodatethe guard tank, removal of the existing baffles and preparing the bottom cover for thebaffle positioning mechanism. An analysis was performed to determine the numberand location of the 1 iquid hydrogen cooled baffles required to intercept the thermalradiation within the cryoshroud. The analysis revealed that three briffles arerequired, one fixed baffle located at the test lank equator, one baffle in the same planeas the (normal payload simulator and one baffle between the thermal payload simulatorand fixed baffle. The baffle structure is a sandwich consisting of a flat plate withcooling coils welded to its upper surface as the main structural element and honeycombbonded to one or both of the surfaces. The lower two baffles and the thermal payloadsimulator are designed to move together. The bottom baffle remains in the sameplane with the payload simulator as it is positioned by the jack screw mechanism.

xxv

All lines going to the test tank pass through the O.GlO'm (24 In) diameter liquidhydrogen guard t;mk as shown Ln Figure S-l in order to prevent entry of extraneousheat to the test tank. All instrumentation lines into the lest tank are passed throughthe vent line.

Before installing the test tank all interior surfaces Including cryoshroud, baffles, andattachment hardware in view of the test package were painted with 3M "Nextcl" BlackVelvet paint to achieve the highest emissivity possible. Where welding was notpossible for tubing joints, single Conoseals were utilized for stainless steel jointswhile double Conoseals were applied for bi-metal joints.

DESIGN AND FABRICATION OF THE THERMAL PAYLOAD SIMULATOR (TPS)MULTILAYER INSULATION

The goal of this task was to design and fabricate the multilayer insulation (MLI) for thethermal payload simulator. The application of this insulation is shown in figure S-l<.The multilayer insulation system is composed of three blankets each consisting of 18double aluminized Mylar radiation shields (DAM) and 19 double silk net spacers.Both sides of each blanket are prot</:ted by a cover shield which is a laminate ofMylar and aluminum foil, bonded together. The aluminum provides high lateralconductivity. The radiation shields and spacers of each blanket are interconnectedby nylon button pin studs to control the blanket thickness to 0.008 m (0. 312 in).Velcro hook and pile type fasteners are used to attach adjacent blankets together aswell as attaching the initial blanket to the TPS surface. An annulus zone on theblanket facing the test tank is painted with a low gloss, low out-massing, black velvetpaint to increase the emissivity of th» area. The manufacturing aids required forfabricating the thermal payload simulator blankets consisted of a wooden frame tostretch-form the silk net spacer material and a MLI manufacturing aid to lay up thecover shields, the radiation shields and spacers.

DESIGN AND FABRICATION OF THE TANK MOUNTED MULTILAYER INSULATION

The tank mounted MLI consists of an inner and outer blanket lay up. The material,number of layers, and construction of these blankets was similar to the designof the TPS blankets. The primary differences from the TPS system are (he require-ments for forming all. components .1 fit the spherical tank. The inner blanket layupconsists of six 1.047 rad (GO deg) gore sections and one 0.406 in (16 in) diametercircular blanket, located at the tank pole, viewing the TPS (Figure S-l). The goresections are assemblies running continuously from the access tank door to thecircular blanket; Butt joints are used between the gore and circular sections. Theouter blanket lay up is the same as that outlined for the inner blanket except for theaddition of cover shield strips applied over the butt joints between the gore sectionsand between the gore sections and the circular blankets. The butt joints are ;staggered relative to the inner blanket sections. The girth area of the outer blanket

xxvi

Mi

Note; All fill and vent lines are insulated with 10 layers of MLI.

Test Tank Fill \ _j[_Jest TlUlk Vcnt

Guard Fill

30 LayersMLI iiljT^j*-- Baffle Vcnt

8f-.- MLI Support Ring

•«-- 3* Layers MLI

Diner Blanket

—,--3 MLI Blankets

Guard Vent

Thermal Payload Simulator —\Down

TPS AdjustmentMechanism

Outer Blanket— Fixed Baffle

— Movable Baffle

Inner Circ. Blkt.-- Outer Circ. Blkt.

Movable Baffle10 Layers MLI Between

TPS and BaffleV-- Cryoshroud i- Baffle

Fill30 Layers MLI

- 10 Layers MLI BetweenTPS & Shroud Bottom

Fi»xire S-l. Schematic of Test Article and Cryoshroud Assembly

xxvii

is coated with Black Velvet paint. The outer and inner blankets are attached lo eachother and to the tank by Vtlcro fasteners. The fabrication of the MLl system for thetank mounted insulation required the manufacturing of a fiberglass inner and outerblanket layup aid for the goro and circular sections. The cover shields for the goresections were manufactured utilizing a vacuum forming tooling aid. The silk netspacer material for each blanket was stretch-formed using the appropriate layup aid.

The blanket lay up and assembly operation consisted of joining the prefabricatedcomponents into the required multilayer lay up of cover shields, radiation shields andsiik net spacers. A female cover plate of the lay up manufacturing aid was used^asboth a hole template and in combination with the male base plate as a guide fortrimming the blanket periphery. The button pin assemblies were then installed. Allblankets were outgassed in a vacuum chamber at a temperature of 339K (f>10i<).before installation to the tank.

TEST FACILITIES

All systems tests were conducted at the Convair Liquid Hydrogen T.est Center Site"B" thermal vacuum facility. The major components of the test facility are thelest chamber, the test tank pussure control system, the guard tank pressure controlsysiem, the fluid .system and the test tank heater. The lest chamber svas a 3. 66m(144 in) water jacketed vacuum chamber and was serviced by a 0.813 in (32 in) oildiffusion pump, a L'N2 cold trap, and backed by two 14. 2 nt /min (500'ffVmin).Kinney mechanical vaccum -pumps. Controls for these pumps, along with all f luidsystem controls and the data acquisition equipment, were located in a blockhouse.

A Ivi^S Baratron pressure control -ystem was used during testing to control theullage pressure in the liquid hydrogen test tank. The system maintained the testtank pressure within a 1.38 N/ir.2 (0. 0002 psi) of the set point.

A NBS Barostat device was utilised to control the pressure of the guard tank during•he null test. The guard tanlv boiloff was found to vary from a high of greater than0. 0047 mVsee (10 scfm) immediately after fi l l ing to a low of less than 0. 00024m'Vsec (0.5 scfm) after the temperature had stabilized (approx. 12 hours). Thisresulted in the need for constant adjustments of the Barostat control weights tomaintain the required narrow guard tank pressure band. Before the start of thecustomized ML[ tests, the Barostat was replaced with a pressure transducer/closedloop controller/flow control valve system.

The f luid system was designed to achieve min imum hydrogen usage. The systemconnected the test tank, guard tank, cryoshroud and baffles. Welding and silverbrazing were used as the principal means of joiniiig parts-of the system. All thealuminum fo stainless stc'-.l transitions were made using double seal Conoseal flanger>

- 5 Jwith the interseal cavity vacuum pumped to less than. 1.0 '/. 10 ' m (10 /.i). A 5.7 m'(1500 gal) LH.j supply tank was maintained at an approximate pressure of 4 3 . 4

xxvi ii

(f> psig) all the time by a pneumatic pressure controller and vent valve. Whenempty, the supply tank was filled with liquid hydrogen through the LH2 make-upvalve froni the 49.2 m3 (13,000 gal) site LH2 storage-tank or from the 3. 78 m3

(1000 gal) catch tank through the LK2 recovery valve. The catch tank was ventedto the atmosphere while acting as a liquid vapor separator for the cryoshroud, bafflesand TPS vents. When fu l l , it was isolated from the cryoshroud, baffos and TPSvents, pressurized tc approximately 172.5 kN/m2 (25 psig), and drained into thesupply tank. In normal operation the system was able to run for a minimum of 15hours before the supply tank needed to be filled or for 5 hours before the catch tankneeded to be emptied. Transfer from the catch to supply tank took less than 15minutes. Flow through the cryoshroud, baffle, and the TPS (when required) wascontinuous and was "recovered" about 95% of the time.

.An electric heater installed in the test t'-nk was used to supply a known heat inputto the test tank during the null test. The heater was designed to provide a maximumheat flow of one watt into the tank.

TEST INSTRUMENTATION

Instiiimentation selection for the full sca'e test specimen was based upon measurementof the independent and dependent variables, required for demonstrations of systemoverall thermal performance, system efficiency, and system component operation.Independent variables included hydrogen liquid level, chamber pressure and ullagepressure. Doixmdent variables included temperature distribution, MLI thermalgradients and LH2 boiloff rate. The instrumentation tree platinum resistors withinthe tank permitted LH2 level measurement. Chromel/Constantan thermocoupleswere used for all other temperature measurement; Chamber and shroud pressure.measurements were made .with hot filament ion gages (Bayard-Alpe'rt) in theirrespective ranges. .Liquid hydrogen boiloff flow rates were Measured with TSIhot-film anemometers and n water displacement apparatus. Pressures other than thetest tank pressure wore measured with Statham strain gage transducers.

TESTING

The test program included throe major test categories, 1) null testing, 2) thermaltesting of (he tank installed MLI system and 3), thermal testing of the customizedMLI configuration. The objective of the null'testing was to verify satisfactoryOIK-ration of ail components and to determine extraneous heat flows into the test tank.The thermal pay load simulator surface temperature was maintained below '27.8K(oOR). The objective of the tank installed MLI test was to determine the thermalperformance of the tank insulation at a TPS temperature of 2S9K (520R). Thethermal payload simulator was uninsulated during the preliminary null testing andthe tank installed MLI testing. The objective of the customized MLI lust was todetermine the thermal performance of the tank insulation at a TPS temperature of2R!)K (520R),withdistances between test tank and thermal payloaii simulator of 0.457 m(IS in), 0.305 m (12 in) and 0.152 m (6 in). During this tost tho thermal payload

xxix

simulator was insulated. During all testing the cryoshroud including baff les woremaintained below 27.8K (50 R) to.simulate outer space at :<. vacuum pressure of lessthan 1.333 x 10"^N/m2 (lxiO~6 torr). The criteria for thermal equ i] ibriu.m was thuachievement of. a LII? boilofl rate \vhich changes not more than 0.5% per hour anda temperature variation of three selected test tank MLI thermocouple readings of notmore than ± 0.56K (1R) Ln 10 hours. The test article was designed for a maximumextraneous heat flow ol 0.0293 watt (0.1 BtuAr) Into the test tank when the internalhealer element was turned off.

A summary of the test results is shown in table S-l.

Table S-l. Summary of Test Results NULL TESTING

Four null tests v/cre conductedutilizing 7.ero, 0.2 watts (0.683 BTU/hr), 0.4 watts (1.3652 BTU/hr) and0.2 watts 0.683 BTU/hr) power inputto the Internal tank heater. Thetable S-l indicates, that the measuredheat flow rate oi the zero power inputtest was 2.3 times higher than theestimated heat flow rale. It is anticipatedthat the MLI outgassing was notcompleted and that the presence ofthermal acoustic oscillations withinfill and vent line produced additionalheat leakage into tliu test tank. TheboQoff rates of null test. No. 2 and

* Heat now Through MLI No. 3 were below the predicted i-ates.This indicates that a portion of the energy created by the internal test tank beater wasstored within the bulk of the LH2 fluid. Null Test No. 4, which was a. repetition of NullTest No. 2 resulted in a heat flow rate which was only 4% over the predicted rate.

Test No.

Null Test No 1

Null Test No 2

Null Test No 3

Null Test No 4

Tajik Inst.Tllm! MLI"

Customized MU

Initial Null Test

Thermal Test No !•

Th'.-rmol Test No 3*

Thermal Teat No 3*

Final Null Tost

Hcnt FlowExperimentalWatts(Btu/hr)

0.068 (0.2321)

0.187 (0.63S7)

0.367 (1.2524)

0.239 IO.S170J

1.204 (4.1100)

0.350 (.1.1950)

0.059 (0.2013)

0.083 (0.2167)

0.065 (0.2224)

0.409 (1.391-1)

Pr-dlctedWatts (Btu/hr)

0.0293 (0 1000)

0.2293 (0. 7S26)

0.4233 (1.-1GS2)

0.2293 ,0.7?2C,l

0.3519 (1.201)

0.2293 (0.7526)

0.0: '.'. i 0.0390)

-

-

0.2293 (0.7326)

TANK INSTALLED MLI

This test was conducted immediately after the null test program without increasingthe vacuum chamber pressure or refilling1 of the test tank with LH9. The thermalpayload heater was turned on at 220 hours i£tur 0-time (beginning of f irs t mill lest) .The required TPS temperature of 289K (520R) \\as achieved after 18 hours. Thetest continued for 134 hours at which time the LHo IxDiloff rate was dropping at therate of 0.15% per hour. The decision was made to terminate the test due to theprojection that several days ov weeks would be required to achieve a true; thermalequilibrium condition. It was concluded that the insulation was still outgassing.The final 28 hours of testing resulted in an average heat flow nite through the MLI of1.204 watts (4.110 BTU/hr), not Including the extraneous heat flow of 0. 0293 watts(0.1 BTU/hr) and power input to the internal heater of 0.2 watts (0.683 BTU/hr).

XXX

The heat flow rate was estimated to be 0.3519 watts' (1.201 BTU/hr) not including(lie extraneous hoal How, heat leakage through insulation attachments and heat leok.scaused by thermal acoustic osculations and MLI outgassing.

CUSTOMIZED MLI THERMAL PERFORMANCE TEST

Prior to this test three prcfabrir-vted J.I LI blankets wore :idded to the TPS. The testincluded Iwo mill tests, one at the beginning and one at the end of the test operationand three customized MLI thermal performance tests. The power input to the internaltest tank In ate- was maintained at a level of 0. 2 watts (O.GS3 BTU/hr). The totallest time v/as 710 hours, r tri'.ig the initial and final null test the TP.: surfacetemperature was mainiair d below 27.8 K (50R). The initial null test was conductedfor 91 hours. At this tim~ -he boUoff rate svas dropping at the rate of 0.2% perhour, mainly due to the MLI outgassing. The decision was made to terminate thetest before a-true thermal equilibrium condition was achieved. The total averageheal flow rate achieved within the equilib ' :um criteria including power input .nd extraneousheat How during the final 1G hours was 0. 50 watts (1.1950 BTU/hr). The predictedhunt How (table S-l) was 0.2^93 watts (0. 7826 BTU/hr).

During the final null test the test conditions were the same as those of the Initialnull test except that the spacing between the test tank and thermal payload simulatorwas changed from 0.457 m (1,3 in) to 0.152 m (f> in). The average heat flow rateincluding power input and extraneous heat flow was 0.409 watts (1.3944 BTU/hr).This lest was conducted for a total period of 116 hours. The deviation of the initial andand final null test from the estimated heat flow rotes is mainly due to the incompletethermal equilibrium condition, incomplete oufgassing of the MLI and the presenceof thermal acoustic oscillations through the f i l l and vent line. These effects aresignificant for a cryogenic lank operating in an extremely iow temperature environment,resulting in very low boiloff rates.

The results of the thermal performance of the insulation not including heater powerinput and extraneous heat flow for the customized MLI test No. 1, 2 and 3 with TPS-.lest la..k spacings of 0.457 m (18 in), 0.-505 m (12 in) and 0.152 m (C in) are shownin table S-l. The increase in heat transfer through the MLI, resulting fro;" the TPS!>o.sition change from the 0.457 m (18 in) position to the 0.152 m (G in) jxjsition wasapproximately lO^o. The experimental heat flow through the insulation during thecustomized MLI test No. 1 was approximately five times the estimated heat flow.However, no consideration was given to incomplete equilibrium conditions or heat leaksthrough MLI attachments and heal leaks caused by MLI outgassi.n? or thermal acousticoscillations of the hydrogen gas within the fill and vent lino. It ;.a :Jso notedthai the experimental heat flow through the tank installed MLI at the 0.457m(18 in) TPS-test t;urk spacing with no MLI bliuikets on Ihe thermal payload simulator\* as approximately 20 t imes higher than the hc:it flow rate obtained for the customizedMLI during test 'No. 1.

XXXI

g Iho total test operation of 1001 hours the facility performed exceptionallywell. No leakage was experienced within the chamber In spite of the existence of140 in (4 GO ft) of Lib tubing including 9 nv (30 ft) of welds, 100 welded butt jointsand 11 conoscals.

xxxil

1 .

INTRODUCTION

The effective storage of liquid hydrogen in space cnn be accomplished by using highperformance multilayer insulation. Heat-transfer characteristics of those insulationsprotected by a shroi'd and o|x.:raling between runbient and liquid hydrogen temperaturesliave been invest tailed in numerous experiments by NASA and independent contractors.The results of a study conducted by NASA/LelxC (Ref. 1-1) assuming a hyix>lheticalvehicle with a completely unshrouded licjuid hydrogen tank sliowed. that the thermalperformance of a conventional constant thickness MLI can be significantly inipix>vcd by

1. Using a variable MLI thickness over the surface of the t:uik

2. Using several high lateral thermal conductivity shields

Increasing the MLI surface cmisaivity in certain areas

The hyixilhetical vehicle assumed by NASA was sun-oriented, tluis ensuring (heli(juid hydrogen tank to always Ix; in the shadow of the vehicle payload. The payloadexchanges heat with the cryogenic lank. In a shroudless vehicle a |K>rtion of the energye:ui be rejected directly into space. The number of radiation shields for such acryogenic tank would be determined by 1) ground hold and ascent thermal protectionrequirements, 2) estimated t ime of near-planetary operation (albedo effects),o) estimated time during mid-course corrections when the vehicle is not sun-oriented:ind 4) prevention of localized propcllani freezing.

Tlie pur|X>se of this contract was to experimentally investigate the thermal perfor-mance of a liquid_hydrogen tank of a shroudless vehicle. The tank was insulated witha constant thickness mult i layer insulation system. The temperature-of outerspace was simulated by using a cryoshroud which was maintained at near liquidhydrogen temperature. The heating effects of a jxiyload were simulated by ut i l iz inga highly polished, flat disc (payload simulator) viewing the cryogenic tank. The tankand cryoshroud were provided by NASA/LeRC. A variation of the tank insulationthickness, however, was not a requirement of this contract.

1-1

DKSJGN OF TFST TANK MODIFICATIONSAND TANK SUIM'OUT SYSTKM

The task consisted of the evaluation and the design of the 1. 52 m (GO in) diametert h i n walled aluminum tank which was furnished by NASA-LeHC as the tank to beinsulated under this program. The existing versus the modified tank configurationis shown in Figure 2-1. Tank geometry and weights are presented in Table 2-1.

Table 2-1. Tank Geometry and Weights

Nominally Spherical 1.52 m (GO in)

Bulkhead Centers Offset bv O.OIS'i m (l.onr, \n\

Diameter

Volume

Surface Aixia

Maximum Thickness (at welds)

Minimum Thickness (shell)

Total Weight (Approximate)

Basic Shell

Bottom Half

Top Half

Door

Lugs

I3olts, Misc.

l .r .JO in

1.900 m^

G. 87.") m2

0.0070 m

0.0025 m

108.454 kg

82.109kg

3-1.100 kg

".3.009 kg

23.982 kg

0.241 kg

2.127 kg

C',0 in)

. («7 fta)

(74 ft2)

(0.31 in)

(0.10 in)

(238. G Ibs)

(180.64 Ibs)

(75.02 Ibs)

(105. G2 Ibs)

(52.7G Ibs)

(0.53 Ibs)

(•I . ( iSlbs)

2-1

2.1 TEST TANK MODIFICATION

As shown in Figure 2-1, the following tank modifications were required:

1. Removal of the large manhole access door ring, machining of this flange asrequired and replacement of the previous tank neck/door section with aflush door design.

2. Removal of the outlet flange and welding in a contoured plate (tank outletcap) to obtain a smooth exterior contour. This area of the tank will beviewing the thermal payload simulator.

3. Removal of the conical support ring assembly at its mechanical joint andmachining off the outstanding support ring flange.

The design and material requirements are shown in Table 2-2.

Table 2-2. Tank Design Requirements

Design Pressure: 24l.5kN/m2

3G2.2kN/m*

483 . 0 kN/m2

Materials Shell

Door

Ring

Cap

Lugs

Struts

(35. Opsig) Working

(52.5psig) Proof

(70. Opsig) Burst

6061TG Al Aly

G061TG51 Al Aly

G061TG51 Al Aly

GOG1TG51 Al Aly

GOG1TG51 Al Aly

304 CRES

2.1.1 LARGE MANUOLK ACCESS DOOR. The large manhole access doorwas placed in a plane close to the intercepted contour of the tank surface byincorporating a flush door design. The design of the door is shown in Figure2-2. The access door is a 0.03S m (l.!5 in) thick circular flat plate, machinedfrom r.OGl-T'i aluminum alloy plate stock. The diameter of the door is O . o G G m

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POT.DOUT FR/iJaE:

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(22.30 in ). Openings are provided through the door for a fill and drain line, ventlino, and electrical pass throughs. The doov design uses double Aeroquip/MarmanDivision Conoseals. The grooves are suitable for Conoseal gaskets No. 57510-1000AF, also a product of Aeroquip/Marman Division. The dimensions are patented byAcroquip and are not indicated on the drawing. The grooves are designed for theConose:>l, double seal t'lunge No. .~>9102-200S, a product of Aeroquip/Marman Division.Thirty-six bolt holts, 0.01.37 m (0.540 In) in diameter are. equally spaced at a di;uneterof 0.520 m (20.851 in) to bolt the door to the door ring. The door is designed for anoperating pressure of 2-11.5 kN/r.i- (35 psig) with a leakage rate of less than lxiO~Gstandard cubic centimeters of he Hum per second. Due to a bi- metal (al and CUES)condition at the tank to door seal, where dissimilar metal flanges are connected,double conoseals are used to reduce the magnitude of anticipated leaks. The bleedports, shown in Figure 2-2, Section B-B, F/7 arc intended to reduce leakage-duringtransient temperature conditions. These ports are evacuated with an auxiliaryvacuum system. The evacuation lines, leading to the outside of the vacuumchamber can be easily isolated and checked for leakage. The purpose of the six insertsshown in Section A-A of Figure 2-2 is to support internal tank equipment or instru-mentation such at, liquid level sensors and internal heater elements.

The large manhole access door ring is designed to match the co.ntou" of the 1. 52 m(f>0 in) tank. The design is shown in Figure 2-3. All dimensions are coordinatedwith Figure 2-2. The ring has an outside diameter of O.G!)!> m (27.525 in) and aninside diameter of 0.47 m (18.5 m). The thickness is 0.041 in (1.62 in).

2. 1.2 TANK OUTLET CAP. The existing outlet flange was replaced by the lank outletcap design shown in Figure 2-4. The cap is formed from a O.OOS11 r,r (0.32 Ln) thick,GOGl aluminum alloy plate to a spherical radius of 0.7G2 m (30.0 in). The diameter ofthe plate is 0.214 m (S.432 in).

2.1.3 REMOVAL OF THE TANK SUPPORT RING ASSEMBLY. The -existing supportring assembly to be removed from the tank is shown in Figure 2-1. The specitic do-,tails are given in NASA LcRC drawing CF G2055M (not shown in this document"). Thering, 0.04.G m (1.S1 in) high,0. 01005 m (0. 75 in)thick is.located at the lank equator ata diameter of approximately l.'GO m (G3 in). The modification required a remov-al of the ring material to approximately 0.00070 ni (0.030 in) to tin: tank equator . Thistask is shown in Figure 2-5.

2-2 TANK SUPPORT SYSTEM DESIGN

2 - 2 . 1 :DJlik£ POINT SUPPORT SYSTEM. The tank support sys tem- i s a th reepoint system designed to suspend the tankinside the eryo.shroiu!. The .systemconsists of three lugs welded to the test lank door ring, ihree a d j u s t a b l e :iO-l steel

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struts, and three attachment fittings welded to the main body of the Ll lo guard tank.This system has a minimum effect on the MLI blanket .design ami offers practicallyno interference during the M LI installation.

The suj>port lug is shown in Figure 2-0. These lugs arc welded to the door ring afterthe ring is welded to the tank. The MLI blankets can be easily slit and fitted aroundeach lug. The width of the lug is 0.05G m (2.2 in) and Lts thickness is 0.013 m(0.5 in).

During the layout phase, it was noted that an auxiliary support was necessary in thetank support lugs to be used in the ground handling. This became uppurant whenit was noted that the access door would be installed before the cold guard tank wasbrought into place. Thus the door ring holes could not be used in support handling anda second hole was added. Both holes are equal in six.e. Figure 2-7 shows the tankwith the welded door ring and lugs. In Figure 2-5, the door is mounted to the modifiedtank.

The basic strut is a threaded steel rod with clevises and lock nuts on both ends.These struts are in effect tumbuckles that can be adjusted during tank installation.The struts used in the design are Merrill Brothers, N. Y., M-1GST 0.01G in x 0.102cm (0.5 in :- (i in) turnbuckles. The tank is supported from the door itself duringinsulation installation. During preparation of the tank for installation into thecryoshroud, the cryoshroud lid is positioned above the support beam and the supportstruts attached. The support struts are attached directly to the Lllo guard tankstructure, which guards the tank fill and drain, vent and electrical lines (Figure 2-8).Thus, the single tank will act as a guard tank for all the test tank penetrations andsupports.

2.2.2 "A" FRAME HANDLING AID. During the modification of the tank, the existingtank support is used until the large manhole access door and outlet flange modificationsax~e accomplished. \Vhen the large manhole access door ring has been installed, thesupport of the tank is transferred to the "A" frame handling aid design presented inFigure 2-9. The design consists of a woldcd steel tube construction except for thealuminum cross channels which support the lank. The usable height of the aid is1.G7 m (73.5 in). The overall height and width is 2.0-15 m (SO.3 in) and 2 .20 m(90 in), respectively. The aluminum channels are designed to be removable topermit the transfer of the tank to the top cover and guard tank of the cryoshroud asshown in Figure 2-9.

2.3 STRUCTURAL ANALYSIS OF THK MODIFI1-JD T A N K

The purpose of the structural analysis was to verily the capabi l i ty <>f the bask- ie-; itank and the modification performed by Convair to support the required test loads.The primary concern in the analysis of the modified tank was the combined m

2-10

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ORIGINAL PAGE ISOP POOR

GUARD TANK

ATTACHMENTFITTING

TANK-STRUTS

FILL LINEBELLOWS

•VENT LINEDOORLUGDOOR RING

TANK

Figure 2-3. Tank Support System Schematic

2-13

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:iiul discontinuity stresses in the tank wall near the door. Figure 2-10 shows tlie newt:ink coni|)onents which were analyzed.

2 . o . l DESIGN LOADS. The test tank was originally designed for an piieratingpressure of 1130..') UN/in (165 psi) and a proof pressure of 1725 k-N/in" (250 psi)per NASA Dwg. CFG20559.

The modified test tank will be filled with LII2 at a maximum operating pressureof 241.5 kN/m- (35 psi;;). The analysis was based on the following loads :

1. Internal Pressure

r > • . . • • •Operating •= 241.5 kM/m" (55. 0 psig)

Proof = 363.GkN/m2 (52.5 psig)

Burst = 483.0 kN/m2 (70.0 psig)

2. Inertia Loads

2.0g longitudinal combined with i. 5 g lateral acceleration actingon the tank f i l l ed with LH.

3. Design Weights (Table 2-1)

LH.,, 134 kg (295 Ib)

Tank Weight . 109 kg (233.6 Ib) -

Actual Weight 251 kg (:>:>,3.6 Ib)

Weight Assumed for Analysis 273 kg (GOO Ib)

2.3.2 ANALYSIS METHODS. The analysis was an investigation of the combined mem-brane and discontinuity stresses in the tank wall near the door. To accurately establishstresses in this region, a detailed computerized analysis was required.,.The actual anal-ysis performed on the 1.52 m (GOin) test tank was limited due to the following considerations:

1. The tank was originally sized for an operating pressure of 1138.5 kN/ni- (1G5psig). The maximum test pressure is 2-11.5 kN/m- (35 psig}. This pressureis less than 1/4 of the original pressure. Thereiore, extremely conservativemethods can be used to estimate discontinuity slresses and st i l l show apositive margin of safety.

2-15

0.6G m (2G in) DIA

O.Gl m (23 in) DIA '>»i

0.567 m (22.3 in) DL\

0.53 m (20.85 in)B.C.

0.013 m (0.5 in)HOLT

0.038 m (1.5 In)

0.014 in (0.54 in) HOLE

; 0.010 m (.7 in) RADIUS

0.015 m (0.4 in) HOLE*

0.013 in (0.50 in) RADIUS

: THICKNESS 0.013 ni (0.50 in)

RKDl .CKD TO 0.006 m (0.24 in)

AROUND 0.01 111 (0.4 in) HOLE

0.47G m HU 8 . 7 5 i n )

DIAMETER

O.OOS m (0.31 in)

O.G!)3 m (27.25 in) -^

0.005 m (0.21 in)

•0.0025 m(0.100 in)

POINT A

Figure 2-10. Large Manhole Access Door Ring and Lug of1.52 m (GO in) Tank

* During fabrication of the lug the hole diameter was increased to 0.0l3 m (0.50 in)

2-16

2. A tank of similar geometry, the 1.38 m (54.5 in) diameter melh:uic lankwas analyzed in detail under a NASA Contract NAS3-1-1105 in 1970.Reference 2-1. Results of that analysis were used to predict stressesin the 1.52 m (GO in) diameter test tank.

The test tank analysis includes;

a. Door Ring Discontinuity Analysis

b. Joor & Door Attachment Analysis

c. Tank Support Analy.sis

2.3.3 MATERIAL ALLOWABLES. The entire tank is fabricated from G061-T6Aluminum. The room temperature design mechanical properties for this materialare: . .

Pa rent Material ("A" values, MIL-HDBK-5A, Reference 2-2)

Ultimate Strength F = 289.8 x 103 kN/m2 (-12 > ]0:J psi)

Yield Strength F r = 241.5 x 10" kN/m2 (35 x iOJ psi)

ULT Shear F = 243.4 x lO3 kN/m2 (36 x iO:j psi)su

Modulus of Elasticity E = 60 x iOG kN/m2 (10 x 10G psi)i

Welded Joint (Reference 2-3)

Ftu (°-57) (289.8 x 103) •-= 165.2 - 10s kN/m2 (24 x 103 psi)

Fty = (0.38) (289.8 x 103) =- 110.2 x 103 kN/m2 (1G x 103 psi)

Fsu - (0. 34) (289. 8 x 103) = 98. 5 x 103 kN/m2 (14 x 103 psi)

E - «9 x 10G kN/m2 (10. 0 x 10fi psi)

2.3.4 DOOR RING DISCONTINUITY ANALYSIS. The large manhole access door ringdiscontinuity analysis was based on membrane point "A", Figure 2-10. The corres-ponding point for the methane tank is point 55 from the methane tank ana'vsis (Ref-erence 2-1, Page 18 and 40). The meridianal membrane stress calculated for point

2-17

55, Hef. 2-1, page 18, was 253.6 x 103 kN/m2 (30,752 psi). The merldianal membranestress for the 1. 52 m (GO tn) tank becomes

0 ^0 .75 (253. G x 103 = 190.2 x 103 kN/m2 (275G4 psl)$

where 0.75 Is the r/t ratio for the two tanks and the total stress a, = 197.9 x 103 kN/m^(2SGGG psl) from reference 2-1, ppge 40, including discontinuity stress. The total stressratio Is Kiven by

Ratio - 197.9/190.2 =1.04

The discontinuity stress Is therefore 4^ of the membrane stress for the methane tank.Conservatively, this stress was doubled. For the 1. 52 m (GO In) test tank

°~. proof pressure '>-0 9™ / 2 1

- pr.0. Pressure ' "' °" """ " f" ' «" « "* <•"/-' <"" **>(2) (2.29 x 10-3)

and(1.08)(483.0) (0.7G)

(2) (2.29 * 10~3)

where

P - pressure, kN'/m2 (psl)

R - radius, m (in)

t - thickness, m (in)

fhc mai-pin of safety Is then

F ' . ' 3M.S. (Proof) = -- ^ -- 1 =• 241'5 X W— - 1 -= 2.70

°'. Proof ,55.2 x 10

and

M.S. (Burst) ^— - 1 - ———X l -1 = '2.35°~ Burst 88. Cx 10

These margins of safety are adequate.

2-18

2.3.5 POOR RING 'IX) TANK WE.LD ANALYSIS. Figure 2-10, Point "B", was usedfor this analysis. The 'cur responding point for the methane tank is Point 24 (Reference2-1). The meritlianal membrane stress was calculated using the methane tank analysispresented in Reference 2-1. The membrane stress for the 1.52m (GO in )tank becomes;

o? = 44.2X10° kN/m2 (6416 psi)

and Die total stress cu = 05.2 x 103 kN/m2 (13788 pst)•».

the resulting stress ratio becomes:

Ratio - 95.2/14.2= 2.15

The discontinuity stress is therefore 1 15% of the membrane stress for the methanetank. Conservatively this stress was doubled for the 1.52 m (GO in ) lank. The totalstress is therefore

Oj = (1) PR/21 +2(1. 15) PR/2t = 3.3 PR/2t

For the proof pressure:

(3.30H3U3. (i)(0.7G) •> . •>"-Proof" 5 - " - - 60.0xiO-kN/m-(PG70ps i )

(2)

and for the burst pressure

(2) (7.02 x 10~3)

(3.30)(483.0)(0.7G)o^ --- - _ - _ - '

(2) (7.G2 x 10~3)

•! / o70. \ xiO J kN/nr (11550 psi)

Ihe margin of safety is then:

M.S. (Proof, *GO. 0 x 10'

1G5.2 x 103

M.S. (Burst) = - — -1-1-1 .0879. -, x 10

The safety m.Trgins are adequate.

2-19

2.3.G DQOll ANA LYSIS. The large manhole access door Is conservatively analyzedby using a simply supported circular plate (Figure 2-11).

-0.53m (20.85 In) ^!!

0.038 m (1.50 in)

11: .t ...*.-. +...^ P 241.5 kN/m2 (35 psi))

Figure 2-11. Simply Supported Circular Plate

The total applied load W, from Reference 2-4, page 2-16 is given by the equation

W = wna .= 211.5 « (0.2'!5)2 = 53.3 kN (12000 Ib)

where

w - unit applied load kN/m" (Ib/iiv)

*> Oa - area, mw (in-)

The maximum unit stress at the center of the plate is then from Reference 2-4,page 2-1C:

''max " 3~ (3m + 1) = 14. C x 103 kN/m2 (2120 psi) (operating* 8 IT mt~ pressure1)

where

m - reciprocal of y Poisson's ratio - 3; u •» l/.'i

t - thickness of plate, 0.035 m (1.5 in)

The margin of safety for the operating pressure becomes:

241.5 y. 103

M.S. ^ ~ 1 '- 15.54Operating 1 4 . G x 103 .

2-20

and the margin of safety for the proof pressure:

M.S.. Proof

2-11.5 x io3

- i = 11.03(1.5) (14. G v 10J

Th? margin of safety factors are large for both the operating and proof pressures.

2. 3.7 DOOR ATTACHMENT BOLT. The large manhole access door is attached to thelank with (36) 0.013 in (0.5 in) diameter bolls. The boll attachment is shown in Figure2-12.

m

0.283 m (11.15 in)

0.2G5 m (10.423 in)

Moment M - l - n » (3g-0 iin

r fShear Load. N = ' C 3 . D — (305— )

x «-,i tn

0.0063 m (0.25 in)

P Doll Loudc

Figure 2-12. Bolt Attachment

Based on the methane lank analysis (Reference 2-1, Pg. 53), the fully-fixed edgemoment is 1.C5 m • kN/m (371 in-lb/in). Actual edee moment is 0. (i<; rr> • kN/min-lb/m). The moment ratio is then 0. (50/1. c>5 = 0. 10.

To analyxe^he 1.52 m (GO in) lest lank door attachment, it was assumed that the actualdoor edge fixing moment is 0.40 times the fully fixed moment.

Kul , v fixed moment = « ^ 2.1^! k N - mm

(475 iii-lb/in) (operating p)

2-21

, , . r i 0.843 kN-m in-lbanil actual edge moment for the operating pressure = — ( iDO )in In

and for the burst pressure - 1.69 kN-m bMbm In '

The shear loading N for the operating pressure ccn be calculated from the expressionX

PRN . = ——= 31.9 kN/m (182.5 Ib/in)x. Operating 2 '

and the shear loading for the burst pressure becomes

N - G3.!» kN/m'('365 Ib/in)x. Burst

The load P at the center of the bolt is evaluated as follows:

P =-117. kN/m (G70 Ib/in)

The bolt spacir.g - 0.04G in (1.82 in)

and the ultimate bolt load = 8.38 kN (1880 Ib)

The allowable load from Reference 2-2 is 107. 8 kN (24190 Ib)

The resulting margin of safety

M.S. - - i = + 11.98.08

The value of n.9 represents a large margin of safety.

-.3.8 TANK SUPTORT ANALYSIS. During hoisting and handling of the tankI). 010 m (0.-100 in) diumoter holes in .the three lugs will be used (Figure 2-G.Design limit load factors for handling are 2.0g longitudinal and 0.5 g lateral. Theempty handling weight of the tank is approximately 1.34 kN (300 Ib). The vertical

load/lug - 0.89 kN (200 Ib) (limit).

It is assumed that the entire side load acts on one lug.

Therefore the side load/lug - O.G7 kN (150 Ib) (l imit)

The loads acting on the lug are shown in Figure 2-J3

FullPenetrationWeld

0.89kN(200 Ib)

0.015 m (0.60 in)

O.G7 kN(150 Ib)

0.038 m (1.5 in)

0.054 m(2.12 in) ;

Figure 2-13. Loads Acting on Lug

Lug Bearing

The total lug bearing load becomes:

TOT= yi-89)2 + (.67)2 = 1.1 kN (250 Ib)

and the ultimate bearing stress Is therefore

= (3-°) (1-1)bru

A handling safety factor of 3 was used in this equation.

The bearing area was calculated to be G l .Ox 10~G m2 (O.OOGin2) . The- bearing stressof 53.3 x iO^ kN/m2 (7820 psi) is not criticid.

2-23

Lug Tear Out

The shear area was conservatively calculated to be 9. 3 x 10"5 m2 (0.144 in2). Theapplied shear strength becomes

(3.0 (1.1) .. • „j i <_ kN/m2 (5200psi)9.3 x 10

The ultimate shear allowable for GOG1-T6 material is

F = 241.5 X103 kN/m2 (35000 psi)

Therefore the margin of safety is

241.5x ]03

M.S. ••-• — -l = -4-5.8035.5 x ioj

The margin of safety is large.

Lug Welding

The moments around the center of the lug welding base are calculated as follows:

M = (0.89)(0. 015) f (0. C7)(0. 038) =•• 0.039 kN • m (345 in-lb)

The maximum stress F is given bymax

F ,. J!_+ J^5 = 7. f, x 103 kN/m2 (1109 psi)max

where

P - vertical load, kN (Ib)

2 2A = weld area, m (in )

M - moment, N - m ( i n - l b )

c :: \vuld distance, m (in)

4 . 4I - moment of inertia, m (in )

2-2-1

£=?'-•""•"»to

2-25

FABRICATION OF TEST TANK MODIFICATION

AND TANK SUPPORT SYSTEM

3.1 TEST TANK MODIFICATION

The modification of the test tank %vas initiated by establishing a manufacturingsequence as shown in Table 3-1. The individual tasks consisted of:

1. Preparing the tank for welding of the large manhole access door ringand tank outlet cap.

2. Machining of the manhole access door, door ring, tank outlet cap andtank support lugs.

3. Welding of the tank outlet cap inside and outside of the tank.

4. Welding of the manhole access door ring inside and outside of the tank.

5. Welding of the support lugs onto the tank.

G. Removal of the existing conical support (girth flange) assembly.

The inspection methods included dye penetrant and radiography. It was employedselectively as judged necessary. A new handling "A" frame was fabricated tosupport the modified tank.

3.1.1 PREPARATION OF TANK. The existing anti-vortex baffles, screenassembly and temperature patch harnessing were removed before the tank wasexternally cleaned. The removal of the COSMO.LENE created a cleaning problem.Convair was not in possession of a tank large enough to chemically degreast; thetank. Consequently the tank was cleaned by hand.

Preliminary x-rays were taken at the manhole access door ring and the outlet capareas. The door ring area, adjacent to the weld appeared clean. The tank outlet area,adjacent to the weld contained tungsten and foreign matcrial-throughout. The tank wasplaced into the "King Boring Mill" to cut the openings for the door ring and tank out-let cap.

3-1

Table 3-1. 1.52 m (GO inch) Tank Modification Sequence

Operation

1 Preparation of Tank for Welding

Removal of interior hardware (antivortex baffles, screenand temperature patch harnessing)

Cleaning of tank

Inspection

Retain tank in NASA support, removal of casters

Transportation of tank to King Boring Mill

Large manhole access door boring operation

Tank outlet cap boring operation

Inspection

Transportation of tank to weld lab

2 Fabrication of Large Manhole Access Door and Door-Ring

Ultrasonic Inspection of material

Machining of door and door ring and Conoseal grooves

Inspection

3 Fabrication of Tank Outlet Cap

Ultrasonic inspection of material

Sawing of material

. Machining of tank outlet cap

Inspection

3-2

Table 3-1. 1.52 m (60 inch) Tank Modification Sequence (Cont'd)

Operation

4 Fabrication of Tank Lugs

Layout/sawing of material

Milling/drilling

Inspection

5 Welding of Tank Outlet Cap - Inside

Positioning of tank on side for easy entry of welder

Setting up for inside welding

Fabrication of LNr immersion cryogenic fixture tank£

Welding of closure root

X-raying and repairing if necessary

6 Welding of Tank Cap Outk-t - Outside

Tank in same position as Operation 5

Setting up for external weld

Completion of weld

Dye inspection, x-raying, and repairing if necessary -

3-3

Table 3-1. 1.52 m (60 inch) Tank Modification Sequence (Cont'd)

Operation

7 Welding of Manhole Access Door Ring - Inside

Rebelling of original manhole access door fitting,inversion of tank

Setting up for inside welding

Welding of new manhole access door ring root

X-raying and repairing if necessary

8 Welding of Manhole Access Door Ring - Outside

Tank in upright position

Setting up for external welding

9 Welding of Lugs Onto Tank

Setting up and welding

Inspection

1-0 Removal of Existing Conical Support Assembly

Modifying of an existing machining fixture

Removal of conical support

Grinding of surface

Mounting of tank to new "A" frame support

3-4

The existing large manhole access door ring was removed by making a cut of approxi-mately 0.018 m (0.7 in) beyond the previous ring weld. Unforeseen severe: distortionsdue to the previous (original) wei.' were encountered in cutting out the original doorring. The total dial indicated vertical runout of the tank wall material at the cutoutwas 0.0114m (0.450 in). This greatly exceeded the 0.0015m (O.OG4in ) permissible.runout according to the military specification for welding the 0.008 m (0.320 in)thick joint. The underside of the upper cutout showed a variation of the original weldthickness, weld repair areas and heavy weldments nearby an internal probe (Figure3-1). These were contributing factors to the tank distortion.

A combination of mechanical and machining techniques were used to reduce the runoutand related mismatch to satisfactory levels. For distortion correction the tank wasmoved from the King Boring Mill to the Dullard Mill . Reliable measurements of thecutout dimensions could not be achieved until vibration of the tank during cutting waseliminated. This required the fabrication of a spool-like internal support and additionof 12 steel blocks between the tank and the holding fixture at the location of the coni-cal tank support. Both of these internal and external supports had to be augmented byextensive use of Tooling Stone (casting plaster for rigidizing a part during machining).The runout thickness variation after the improvement is shown in Table 3-2.

A shallow 0. 0005 m (0. 020 in) cut was made by taper technique on the; outside shoulderof the tank next to the cutout. A total of 0. 0009m (0.035 in) mate-rial was finallyremoved to reduce the wall thickness to the required 0, 00812 m (0. 34 in) max. /O. 0079(0.310in) minimum dimension. The diameter of the cutout was increased to the finaldimensions of O.G4S m (27.204 in). This dimension which was used to fabricate thedoor ring was checked by the Convair Quality Control department.

The tank outlet cap bore was accomplished using the same Bullard machine tool.Only minor distortions were experienced and no straightening of the tank was required.

Figure 3-2 shows the cutout of the manhole access door ring. Figure 3-3 indicates thecutout area distortion. Note the difference in thickness at various locations of the cut-out. A closcup of the distortion measurements by the dial indicator at the door ringcut is presented in Figure 3-4. Figure 3-5 shows the setup of the tank on the Bullard

.Boring machine to correct the distortions of the manhole access door area and to com-plete the cutout for the new door ring.

The majority of the problems encountered during the preparation of the tank welding canbe directly attributed to the initial fabrication of the.1.52 m(60 in), tank by its originalmanufacturer. It was noted that there was an excessive amount of trapped welding stress-c'.s and disf.oi1.ions which were relieved when the door rings were removed. In addition,there was a large variation in parent metal thickness adjacent to the location where thenew components were needed. The problems were magnified by the variations in wallthickness in the existing conical tank support weld area resulting from mismatching .the tank halves, as shown in Figure3-G. The mun-.atch 'vas corrected by the original

3-5

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Table o-2. Tan*' Thickness Variations at the- LargeManhole- Access Door Area Cutout

Location

0

1

2

3

4

5

6

7

8

9

10

11

32

13

Runout m (In)

0.00000 ( .000)

+0. 00056 (+.022)

-0.000254(-.010)

-0.0007G2(-.030)

•H).0003S1(+.015)

+0.00004 (+.037)

+0.000 203 (+.003)

+0.00051, (+.022)

+0.0005G (+.022)

+0.00122 (+.04S)

+0.0003U5(+.012)

+9.0U03se(+.014)

+0.00191 (+.075)

+O.OOOS9 (+.035)

Wall Thickness m (En)

0.00979 (.385)

0.00975 (.333)

0.00950 (.374)

0.0095G (.376)

0.00943 (.371)

0.00928 (.3Cr>)

0.00943 (.371)

0.90'J64 (,37'J)

0.00960 (.378)

0.00956 (.37G)

0.0095C (.376)

0.009GO (.373)

0.00910 (.35S)

0.00945 (.372)

3-7

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TANK. WALL HALVKS

-13U1LD-UP PASSES.

MISMATCH

Figure 3-6. Mismatch of Original Tank Halves

m:inufacturcd by building up the off set areas with weld passes.

A series of x-rays were taken of the weld /.one area that confirmed the presenceof |>orosity, weld folds, inclusions, and cracks. Because of the large area involved,it was concluded that the considerable rework performed hi'.d led to the excessivestresses.

The x-ray of the lower tank cap area. Figure 3-7, shows the presence of tungsteninclusions (dark indication), porosities (singular and linear), weld folds, foreignmaterial and cracks (light indication) most of which remained as parent metalproblems after the original fitting was removed.

3 . 1 . 2 MACHINING AND WELDING OF TANK OUTLET CAP, POOH ASSEMBLYAND LUGS. The material from which the parts were machined was GO('il-TG51aluminum alloy. The material was ultrasonically insi>cctcd at Convair Plant 1facility. The door-ring was machined with the outside.diameter O.OOG1 m (0.024 in)oversize for shrink fitting it to the tank O|>ening. All conoseal grooves were machinedto the patented dimensions supplied by Aeroquip Corporation/Marman Division.Special drawings were made to assure that the grooves were correctly machined tothe accuracy necessary for satisfactory seal performance. All machined dimensionswere verified by the Quality Control Department.

The manhole access door ring and tank outlet cap were joined to the tank utilizing man-ual welding procedures. This technique was selected to minimize tooling costs. Theuse of automatic welding re-quires backup tooling to locate ant! support tin- ring andcap during the welding operation. In addition, tooling for the door ring must becollapsible for assembly and disassembly in the tank.

uO

i•s

ix

ORIGINAL PAGE ISOF POOR QUAU1Y

Joining of the manhole access door ring and tank outlet cap was accomplished by wrld-ing from both sides of the joint. This technique was selected to minimize distortion.The door ring and cap were submerged in LN-> thrn shrink fi t ted into the tank openingto offset weld shrinkage.

The cap wa^ welded first from the inside will) 50% minimum penetration. The oppositeside was then prepared for welding from the outside using a routing technique.X-rays were taken after each weld to locate defects for removal before proceedingto subsequent welding. The completed weld was dye penctraht inspected and wasx-rayed for final quality assurance acceptance. The x-ray revealed normallyunacceptable defects in the tank wail in areas untouched by the modification operation.The defects noted included small internal cracks, porosities and indications of tungsteninclusions as shown in Figure :i-7.

After completion of the tank outlet cap weld, the door ring cutout was approximately0.0017R m(. 070 in) out-of-round. The problem was corrected by fabricating a toolingaid to correct the ring opening. The tooling shown in Figure 3-8 consisted of an alum-inum ring, 0.051 m (2 in) thick and 1.22m (-18 ini outside and 0.730m (2!' in) insidediameter, with four aluminum I-beams and threaded rods. The rods were used toapply pressure .on the aluminum ring to correct the out-of-round condition. By applv-ing pressure, the 0.0017" m (0.07 in) oul-of-round was reduced 100.000254 m (0. OHnjwhich was adequate for inserting the ring to be welded. Tin.- welding procedure1 used u>weld the door ring to the tank was the same as that for the cap welding. The internalwelding of the ring to the tank is shown in Figure 3-9.

3.1.3 REMOVAL OF EXISTING CONICAL SUPPORT RING ASSEMBLY. Removal ofthe conical support ring as planned in the contractual tank modification revealed Un-original girth weld. Visual appearance of this weld did not satisfy aerospace standards.The weld condition included an excessive mismatch of the two tank halves. Because ofthe unsatisfactory appearance of this weld, a section of it was x-ray inspected. Fig-ures 3-10 and 3-11 show sections of the- conical support weld, randomly sclecu-d, con-taining weld defects in the parent metal. These defects were created by rework ofbadly offset arc-as in the original weldment.

Since all of the noted defects were not in the modified areas, they have not beenofficial ly rejected and repaired. Considering the GDCA weld procedures followed• lining tank modification ami the qual i ty assurance used, there was no problem inmaintaining the integrity of the modifications through the proof pressure test. Therecan be no such confidence in the remaining original weld areas without a completex-ray investigation of vhe parent mater ia l combined with the necessary repair work .This was considered outside the scojx; of the program and ;i discussion wi th the huHC('OH resulted in a decision that no repair work was necessary for the test task underconsideration.

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3.2 TEST TANK SUPPORT FABRICATION

3.2.1 THREE POINT SUPPORT SYSTEM. The three-point support system consistingof 3 tank lugs (Figure 2-(i), three struts and 3 guard tank attachment fittings, was fab-ricated to support the test tank from the cryoshroud and guard lank structure, as shownin-Figure 2-8. The tank lugs and guard tank attachment fittings were welded to the testtank and guard tank as shown in Figures 2-7 and 2-8, respectively. The proper usageof the individual lug holes (Section 2.2), for "Test Support" or "Ground Support" isidentified on each lug. Commercially available turnbuckles, M-1GST, 1. 7 7 X 0 . 1 5 2 m( . O S x G i n ) which are used as struts were purchased from MERRILL BROTHERSCompany, N . Y . The working load per turnbuckle is 9. (iO-l kN (2150 Ibs). The yieldand ultimate loads are I f i . G k N (4400 lb), and -17. 53 UN <10GS5 lb;, respectively.

3 :2.2 "A" FRAMjb HANDLING AID. A new tank handling aid "A" frame wasfabricated. Its function is to supjwrt the modified tank from its new door-ring lugs.It is also used for installation of the insulation syster.. and to transfer the tank to thecryoshroud. The modified tank supported by the "A" frame is shown in Figure 3-12.

:',.3 PROOF PRESSURE AND LEAKAGE TEST

The test tank modification task was completed after the performance of Uie tank proofpressure and leakage test. It was decided to proof test the tank at 27G.O kN/m-(40pslg). The proof pressure level was changed from 3G2.2 kN/m- (52. a psig) (Table 2-2)to 27G.OkN/nT (40 psig) because of the defects revealed by x-rays in areas untouchedby the modification operation (Section 3.1.2). A preliminary leakage test was conductedto check all new tank welds tor gas leakage. During this test the t a n k door was sealedwith a 0. 00150 m (0. 002 in) Teflon gasket and not with the regular Conqseals. TheConoseals were used in the final tank leakage test which was conducted afterinstallation of the internal tank instrumentation. The use of the Teflon seal inthe preliminary leakage lest saved expensive Conoseals and reduced Ihe possibility ..of damaging the Conoseal door and ring'surfaces. The tank was pressuri/.edto G!>kN/m2 (10 psig), leak checked wilh.anL'SON Model .~>10 leak detector andproof pressure checked at 27G.O kN/m- (40 nstg) for 0 minutes. The lank was thendepressurizcd to G9kN/m~ (10 psig) and Ijak checked again. There was noevidence of leakage. After fabr icat ion of the internal tank instrumentation tree andaUuclring it *.o the tank door, the door :ind tree assembly was mounted to the lankincluding the Conoseals. Shortly before closing the door the tank was internal lycleaned for LH.> use. The final leak lest was conducted uli l ix. ing helium gas and aV'eeco leak detector, Model MS17. The leakage measured at a pressure d i f f e ren t i a lof 13S kN/m2 (20 psig) was 2. 3 x 10~7 see/sec. This amount of gas leakage is lessthan the allowable leakage rate of 1 x 10~ (> sec/sec, shown in Figure I'-fi.

3-19

5?^ •'

TIIF.NM.U. PAYI.n'AI) S I M U L A T < ) I<

The pur]>ose of the thermal payload s imulator (TI'S) was to provide a constant tempera-ture surface for the insulated l. .~>lirn ( i»0 in) lank to view (Figure S-l j . The Tl'S-. <.>nfiguraiion consisted of a i. Sli m (T'J in) diameter aluminum plate sup|x>rtcd by theeryoshroud assemblv. A schematic of the payload simulator is shown in Figure -1-1,

•!. 1 T1IKK.MAI . K K Q I M H K M F . N T S

The following provisions were incorporated in Use design of the TPS to meet thethermal conditions during the Null lest, the UieniuJ testing of the tank installedsystem :uul thermal testing of the cus;omize<l MM configuration:

1. Provisions for establi.shini'. and maintaining any uniform ste:uJv-stalelenperature in tl'.e range of liO.5 to -117K (.';7 to 7 f > O R ) over the surfaceof the payload .simulator.

2. Provisions for varying thu tank-payioad .simulator spacing to uny valuebetween 0.1.~,L! :)! i«< ini and 0.-157 m i). t ; :nj.

M. Surface viewing the tank mu.st l^e f la t and tree of penetrations.

4. Total hemispheric:!] emittance luss than f\04.

Tin- temperature , '•-7. ~'K ( : ' > ' i H i re<|uired during' tin: te.!f. operation was achieved byc i rcu la t ing . I . H - j t h r c iugh .e i ' o l i nu ' co i l s welded to the imi tom surface <>i ' the a luminumplate. Sini-i the TPS was completelv surr'.'umJed by a 1 . 1 I - - cold \ v a l l , two i-oils < Figure! - I ) retluced thf plah1 temperatui 'e below the rcf|!.iired '27. •?!•-; i;">(''Hi in less th:ui an Iwui".

I H i r i n g the thermal tests e lectr ic heaters were used lu produce the requ'/ed surfacetempera tures . "I'hc mxvimum predicted jsr.n load ot ' a p p r o x i m a t e l y f>S . "i\\ (L ' ( ' l t i Htu perli . i t ,r i was at.L's'.IK {•">•_'()J{i i l u r iny the t;i'ik therm:d test-withi ' i i t the insulation on the plate.Assuming a K>: i .S \ V - m K ti'.u H tu ; ' h r -U K) the mud conduct ivi ty lor the aluminujn plate ,a heater element spacing <>l 0. 151; in tfi in) j jroduceil a tcmper3.ture var ia t ion less thanii.u. :>."»K ( ( » . iU) at tin- maxLr.uim heal load. There is no circtunterential variation inthe normal thermal i lux. ilov.evi r. t i l u - r e was a radial v a r i a t i o n due to the shape olthe t ank bottom and edge loading by the ervoshroud and Laities. This was corrected!iv :!i\ iiiiir.1. the healer i n to -unt . ibb- a n n u l a r sections, w h i c h . w e i e independentlyI 'ont i 'o l led as shuwn in Figure -!-i.

- ..». '/one Heater s^.~~~.i,.ier '/one Heater ir..-^-., •,

Middle /.one Heater .• - v: ;!

Heaters

Cool:TR Coils

-1-1. Thermal I'ayloatl Simulator Schematic

Tlic inner edge of the lower baffle next to the s imulator was shielded by ten layers ofalurnini/ed Mylar to reduce the thermal load on the outer heater band. Further theniKilprotection for the simulator was piovided by a 10-layor alui i i ini ' /ed Myla r insulat ionblanket placed between the s imula to r ami the boii:>n> of the shroud.

The simulator was positioned along w i t h the lower baffle by moving the TPS adjust-ment mechanism (Figure S-l|. This baffle was moved by three jacks-crews whichwere controlled from outside the chamber. A linear displacement transducer wa.-.iused tc lieierminc the platform position.

• ! . • > TPS OKSIGN AND KAmtlCATlON

The TPS design configuration is presented in Figure -1-2. The base plate consisted ofa Jjsl.- 0.0005m (i). :57f> in) thick and l.3:> m (72 in) in diameter. It was fabricated froma highly polished <iO<il-T- '°> a luminum plate. There were no penetrations on the surfacefacing the lank. An cmissivi ty of 0. 0.". was measured by a Lion emissomeler Model2fiH-7. During ins ta l l a t ion of the cool ing coils and.electrical heaters the polishedsurface was protected w i t h a str ippable plastic f i lm, called Spraylab, which wasremoved a f t e r i n s t a l l a t i o n of all components.

•I. 2. 1 C'( « > 1.1 NO (."OILS . The cooling coils were designed and fabricated u t i l i x i n go . O i i r O m (0.7ii in) 0 .1) . x O . O O i . " » l i m ( O . O O O in) th i ck , GOG1-TG a l u m i n u m tubing. The

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Urcur.\:'i;rontial coils were welded in place as shown in Figure -1-2. \Velcls, 0. OU.Vi in( J . O in) Ion-.;, spaced at 0.0254 m (1.0 in) were :ip])licd on alternate sides of the tubingto ensure good heist conduction between the LH9 tubing and the Tl'i- plate. Hadialfccv. l ines were-not fastened to the p'.aU; to min imi / . e thernia; nonuni lb rmi ty circumf<.-n.-n-t ia l iy . The tubing loop was leak chfjckcd with gaseous helium anc a he l ium mass s,*je-l ro<nuter . It was necessary to replace a welded portion of the LH0 tubing, a f t e r aleakage pioblem could not be resolved. The replacement section was re-checked andfound to be free of any le:ikage.

I. ?. •_' !•:L.ECTR'.CAL 11KATKHS. The heat load on the plate at equi l ibr ium tempera-ture was e.\|)ect(i.l to range from O.Ol to 55 watts. To improve the reliability eachof the heater ring's consists of one high power and one low power heater. Kach heaterwas equipped with two parallel elements.

Due to the radially nonuniform heat load on the TPS, the heaters were divided intothree annular /.ones: 1) an inner /.one consisting of three inner rings connected inseries; 2) a mid /.one consisting of two rings connected in series, and '.',) an outer /one-consisting of the outer ring. For versatility, each heater element lead wire wasextended i n d i v i d u a l l y to the outside of the chamber to facilitate regrouping if necessiirv.The heater uesign connections are shown in l-'iirure -4-2 ami -1-3.

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Figure 1-3. Sketch of Electrical Heater Connections

The material selected to const»\ict the electrical heaters was based primari ly.oh therequired temperature limits of 20. 5K (37H) and -117K (7SOK) wi th second considerationbeing thermal conductivity. The heater was constructed ut i l iz ing 0. <)OOLT>'1 m (0. OlO in)Invar and 0.00058 m(0.020 in) thick stainless steel wires. The Teflon f i l m between theTI'S and heater wires was required for electrical insulation. The Teflon f i l m behind theheater wire reduces the area loading on the silicone rubber foani while l imi t ing theforce on the wire to prevent its cutting through the insulating Teflon. The siliconefoam is a resiliant f i l ler to provide good mechanical contact between the heater andthe TPS and some thermal insulation between the heater and the aluminum back-upstrip. HTV 560 potting com|x>und is used primari ly for thermal conductivity and alsoas a mechanical bond. A photo of the completed thermal pay!bad simulator in itsprotective holding fixture is shown in Figure -1—I.

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The .modif ica t ion of t lu i c ryoshi -oud was i r . i i ia tcd by evaluat ing the design of thecryoshroud assembly which was furnished by tin.1 NASA l.el'C In simulate ' tin.; environ-ment of dt-ep sn-H.'-J. - M h.o e ry i i shro ih l was required to be cooled by l iquid hydrogenant! «•.:. iiavi1 a h iuh surface cmi l t ance < > r > . those surfaces viewing the testtank. The- objective of the modification was !o establish as near a low temperatureblac-k hotly cav i lv as feasible, and j i > i i : i m i / < _ - crNoshroud hydrogen

The cryosliroud assembly modifi tMiion effort was subtlivided into five tasUs:

1. Cryosluxiuci modifieation'2. Cryoshitiucl baffle t l iermul analysis•'i. Cryoshroiix I. baffle di.'sivpi and faln'icaiipn-1. Guard tank -desiini and fabr icat ion5. Thermal payload s imulator and baffle posi t ioning inccfianisnt desi«n :uid

fabrication .i>. Asseuiblv of the er\'oshi'oiii.l eompujients

f>. 1 CRVoSllUori) M O D I F I C A T I O N

The cryosliroud was a L ' . - l - l in (,!)<; in) diaim-U-r by 2.14 in pG in) hi^h e y l i : n l r i e a l shdlwith top and bottom covers. Cooling coils were welded to all surfaces. A. schematic.of the cryosliroud is shown in l''iijure S-J. The material used in the construction ofthe cryoshroud was pr ineipal lv I > ( H ; I a luminum allyy. The basic construct ion was aframework of 0. 070 ••'• <'. OV(i :•: o. ih i f ; : ; \\\ ('.', y. :', '••: 0. 2.1 in) an.!;lc and. 0. 070 /. 0. OOfi.'; m ('.', .<0.2") in) bar stocl; material w i t h ".00.';' r.i (l/ ' : in) sh<: f l eoverin;;'. The ton eovi.-r !ia<!a heav\" 0.051 m (2 in) th i ck modal in^ ri:itr a t tached by O.ti.'i.j m (2."> in) < i i a n i : - t r25. 1 em (10 in) f i i^h sleevr. The rim; was braced by four radial struts. The cylind-rical shell had eiivht bai'lle ;ruifk-s which also provided support for the sjdewall s t ruc ture .

The cryosliroud was mounted in the vacuum chamber on pads under the bottom eovt-rrather than supported from the nnjunt in i ; ' r int; in the top. Tlius the radial s t ru t loadwas compression ra ihc r than t i -ns ion . A l u m i n u m angles 0. 07G /. 0.07G .< 0. QO (.;.';' m (I) <<.'! •• 0.25 in) were a t tached to each side of each, radial stn.it ^l-'i.n\nv 5-l 'i. 'I lie lopcover (NASA IH 'awin^ (.'K t i 2 1 : ) l i was also moci i f i t . ' i l by. t i ie addit ion of a 0 .07G (<i i:'.) !iokfor the baff le vent l ine to cy.ii the crvoshroiu!.

The bottom ct.vei' (N'AS.X Draw in:; (." !•' ( I 2 I 0 2 2 ) was modif ied b_v. t.he addi t ion of holesfor cooling tubes and for the payload s imu la to r l i f t i n g jack screws. The new bu t tom

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cover drawing is pres<•!'.!• A! in Figure 5-•:.'. The. only modi f l - anon to l.ho i-v! ir.drioa!stdewalls was the removal o.'.' ;h<; existing baffles and r.:u!uci-in. -.1 i.L' I h . - joints betweenthe upper and lower cooling iu i -cs , Figure .".-.'!. "Double-Seal" (.'onoseal fittings wereattached to the cryoshroud cooling t'jbe f i l l -.UK! vcnl l ines.

The entire inner surface of iho cryoshr«;; id \vas repaim.-.-d w i t h l i > w outgassin-.;. .'i.MN'extel Velvet (T>M • l U l - C J 1 - ' ) -.laini. l .o ach ieve a- hii;!! : i i i <- i i ! i . - : s iv i i \ ' as pDSsihle.

5,2 CKYOSI IUOU) MA F I - ' I . K 'J Ii KIl .M AL A N A i . V S K S

The major objective of llie eryoshroud tl ierma). analysis \s:i.s In t lo lemiine t::u numberand location of the liquid hydroo-cn cooled bafllcs. re(|uired to intercepl a.nH absorb liotl;direct and reflected i he mi nil :\;'iiatic!i w i t h i n the cryo-shnnid. The location of thebaffles had to be t l ievmally acceptable for all three "Tank-TPS" spaein.^.s (.Section•1. V), re(|iiired du i - i n i ; the testi ' iL', 'of the •-•ustomi/ei.! M l . I .

5.2. 1 TI1F.RMAL ANALYSIS. An analysis was performed on ihe radiation inter-change and heat i r ans fe r i n s i f l e the lower hal f of the cryo-;.;;roud w i t h the thermalp:i\ load sir.vahitor and insulated cryoi;enic tank. Two ! asic raf l ia t io i i interoiian^emodels uere considered. The reflecting node mode! is a se^nu-.-.ii uf the - i x i a l l ys\Tiimetric insudlation wi th boundary nodes having xero emis.'.iviiv, )-"i:;xir-.- 5—1.The complete node model, Fi;;xire 5-D, incliuies all the rad ia t ive surface areas insidethe cryoshroud.

5.2.2 HKFLKCTIN 'G XODK .MODKL. The'model con:-isis of 1:; I'ia;. nlaies andrepresents a 1/15 seifmeiu i2-P) of the to ta l i n s t a l l a t i o n . .Since, in acuia l ]))-aclice,the energy excdianfte w i l l be svinmetric:al about the verticiij iank .i\:a, refleeiinRnodes (5, (i, 7, 8, !), 10) wi th an emissivi ty , c ' - - 10":), were pi a cod'on the sides ofthe segment section analy/ed. 'i'hc value, c- 10~:j,- was used because the computerwil l not operate A ith a y.ero value. Use of reflecting looundaries reduces the 'numbe-rof nodes analvxed f rom 10'i 10 1!) wit-h a eorrcspoiulin.u: s a v i n g in setup and computertime. The cost of c.-.niputini; view factors and Script F values for radia t ion increases

•approximately as the 2.5 power of the number of nodes so tha t m i n i m i / i n < j the numberof nodes is significant. !t is noted that the node sixe has been increased fiv/m a 1 'HIsegment to a 1/15 sequent in order to reduce the maximum possible number of nodes».i the complete model ease to less than 2 < > < : i ; a computer program l i m i t a t i o n .

Four geometrical configurat ions were evaluated, (1) cjpen-to-space, ' f L ' t the cryoshroudonly, (3) the cryoshroud and lower baff le , and (I) the ervoshroud and two baff les . Thethermal payload s imula tor in all cases was at its lowest position since this is thelocation where the greatest, amount of reflected energy from the shroud baf f le surfacewill occur. The emiss iv i ty of the the rma l pay'.oad s imula to r inode h was f • [ • [ > < ; n . ' Mand the MI.I surface on the tank (nodes 2, .'!, •!) was f-y : 0.0.",. The emiss iv i ty on theshroud (nodes 13, H, 15) and bafties (nodes ]], 1 2 a r , d 1'i, J7, li, l.'Ji was varied froi! '0.35 to 0. It'i to simulate d i f f e r e n t surface coatings.

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5.2.3 COMPLKTE NODK MODEL. There is some uncertainty in the accuracy of the•thermal model using reflecting tx>undary nodes. 'J'lic Gebhart technique (Reference 5-1)f ~ > r dfterminiiv.j Script F assumes diffuse reflection from all surfaces according to the .I.aml'i-rt cosine law, whereas specular hemispherical reflection is more representativeof the actual case.

The differences are indeterminate except by generating a complete open model with noreflecting nodes. Therefore, for (1) the open-to-space and (2) ti.e cryoshroud withlower baffle configurations, a complete model analysis was made.

The analysis used the same basic node sizes, Figure 5-5, as the reflecting model witheach individual segment being 1/15 of the total installation. The directly transmittedand reflected energy from each emitting segment to a 1/15 receiving segment wascomputed,then the results multiplied by 15 to-determine the heat exchange to the entirecircumferential surface. This technique reduced the number of:. .Jes actuallyanalyzed in the complete model configuration.

5.2.4 FINITE NUMERICAL APPROXIMATION. The.node models consist entirely offlat plates to simulate the curved surfaces. The modeled flat plate surface areas andthe actual curved surface areas are listed in Table 5-1. The view factors weredetermined by breaking each node into smaller finite elements. The node areas andelemental breakdown is listed in Table 5-1. The view factors were computed for thecases of a smaller node to a larger node and the calculated reciprocal used forinterchange from large to small nodes. The view factor projection was computed infinite 5- sweep angle increments. All node sizes and finite element breakdowns wereidentical in the reflecting and complete nods cases, therefore view factors within asegment were also identical. View factors from the payload plate to the three tanknodes are given in Table 5-1.

5 . 2 . f > UKSIM.TS. Heat flow values are plotted in Figure 5-0 for the shroud, f = 0.85,and lower baffle, e - 0.90, configuration for both the reflecting node and completenode models. Emissivity of the fixed top and bottom bi'.fflcs is also 0.9(1. Thecomplete node model for the case where the emissivities are 1.00, open-to-space, isalso plotted in Figure 5-0. Accurate numerical values of the plotted data arc listed inTable 5-2. There is a difference of almost OO'J. between the reflecting and completenode models indicating the reflecting node model is not n suitable representation of theactual installation. It is noted that the heat flow to the shroud and lower baffle con-figuration is within approximately fj',T- of the open-to-spaco case. For example, at aTPS surface temperature of 278K (500H) and a shroud anil baffle cmissivity of (j. 85and 0.!)<; respectively, the heat flow from the thermal payload simulate" 'o the cryo-genic tank is 0. .'!80 watt (1.295 Btu/hr) u t i l i z ing one baffle between the top baff le andthe bottom baffle. Using the same temperature for the "Opcn-to-Space" case, the cal-culated heat flow is 0..°,57 watt (1.219 Btu/hr), resulting in a difference of 0. 022 watt

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(0.077 Btu/hr) or G. :>';;•. Additional ba f f l e s w i t h i n this narrow bawl ;;re not justif ied orpr:ictic:il for such a sm;ill and largely indeterminate gain. The combined accuracy ofthe finite element analysis for radiation, the: know accuracy of the surface emissivilicsand «/£ , and the test measurements are also not considered to be w i t h i n the H'", band.It was therefore decided to use only one intermediate baffle between the top baffle andthe thermal payload simulator.

5.3 BAFFLE UKSIGN AND FABRICATION

The existing internal baffles which were furnished wi th the cryoshroud by NASA/I-eRCwere too small to accommodate the 1. 'j2 r.i (30 in) diameter test tank. In order toenlarge this inside diameter it would have been necessary to remove the baffle surfacecooling coil, making it impractical to rework these baffles into the design required for .the test program. Three new annular-shaped liquid hydrogen cooled baffles for attach-ment to the internal surface of the cryoshroud were designed and fabricated.

5.3. 1 BAFFLE LOCATION'. The first baffle was located at the test tank equatorialplane and was rigidly attached to the cryoshroud. It intercepted and prevented thermalpayload simulator radiant energy from entering into the region of the test tank upperhemisphere (Figure S-l). The lower baffle was aligned with its top surface approxi-mately 0.025 m (1 in) above the top surface of the thermal payload simulator. Thisbaffle was designed to move as a unit with the TPS and remain in that relationship atall positions of the thermal payload simulator to prevent back surface radiation emissionand TPS-MLI interlayer tunneling radiation from entering into the tank lower hemisphereregion. The intermediate baffle was rigidly connected to the lower baffle and moved withthe lower baffle at a distance of 0.47 m (18.5 in).) . .

5.3.2 DESIGN7. The fundamental baffle structure was a sandwich of annular shape .whose main structural element was .a flat, 60G1-T fi aluminum plate, 0.0032 m (0.125in) thick. The annular aluminum base plate had GOG1-T4 aluminum cooling coils weldedto its upper surface. Aluminum honeycomb with 0.0032 m (0.125 in) cells was bondedwith APCO 1252 urethane adhesive and additionally bolted to one or both surfaces. Thisconfiguration was selected to produce good thermal contacts allowing aH baffle surfacesto attain the same temperature as the cryoshroud walls. The design is presented inFigures 5-7, 5-8 and 5-0. . .

The bottom surface of the honeycomb on the bottom'baffle had a faceplate bonded to it tomake a sandwich construction for s t i f fening. Six phenolic blocks were bolted to thelower surface of the movable baffle to provide support for the thermal payload simulatoras well as reducing the load concentration of the baffle oositioning mechanism. Thismechanism allowed the lower two baffles to move wi th respect to the cryoshroud andthe fixed upper baffle. Continuous LII? cooling flow was maintained by means

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of two cooling tube coils extending around the outside ':dge of the baffles. One of thesecoils was below the lower two movable baffles ;md tin- nther coil was between Hit: upperfi.xe<l baffle and the lower two movable baffles (Figures T.-7 and 5-8). These two cuilsextended and compressed like coils in a spring us the two movable baffles wore adjustedup and down. With this method, there was no high spot in Ihc cooling tubes for vaporentrapment. In the sujnc manner, two coils were used between TPS ;uid bottom of thecryosbroud to provide movement for the TPS. At the upper baffle, the tube was ventedup through a hole in the cryoshroud upper cover. Migh t slotted struts were provided atthe outside edge of both the single upper fixed baffle and of the two lower movable baffles.These positioned and guided the baffles as they were moved In the shroud. "U" clampslocked the upper baffle in position and prevented the lower baffles from falling out duringremoval of t'.ie thermal payload simulator.

'5.3.3 FABRICATION. Prior to fabricating the cryoshroud baffles, a sandwich sampleconsisting of 0 00102 m (0.040 in) thick 60G1 aluminum with 1.587 m (O.G25 in) honey-comb attached to both sides was immersed in liquid nitrogen for 2 minutes. Thesjimple was removed from liquid nitrogen and allowed to return to ambient temperature.This test was repeated 1!) times for a total of 20 cycles. Twenty additional tests of thesame kind were conducted using liquid hydrogen. There was no apparent failure of thejoint.

All base plate sections, tubing and honeycomb materials were cut and chemicallycleaned. The tubing was provided with an additional C.02r,4 in (1.0 in) wide aluminumbase plate to avoid warping of the 2.-11 m (96 in) O. IX annular baffle base plates. Weldsof 0. 025-1 m (1.0 in) length at 0. 07G in (3 in) cerJers wore applied on each side of thetube to ensure good heat conduction between tubinfe and base plates. All liquid hydrogent.ubinc w:'.s leak checked and repaired as necessary after the welding operation,rnforcscen distortions of the 0.00102 m (0.040 in) :ihiminum baffle base plates wereencountered during welding of the liquid hydrogen tubing onto the baffle.sheet material.Since proper bonding of the honeycomb to the base plates could not be assured underthese circumstances, the 0.00102 m (0.040 in) thick aluminum plate was replaced by0.00:12 m (0.12:1 in ) thick plate material. Welding of the tubing to UK: new baffle- sheetmaterial was completed without distortions. The honeycomb material type AL-1/8-r>0f>2-0021>-8.1 perforated, w« ; purchased from HEXCEL Aerospace Company. Thismaterial was utilized on the lower surface of the upper baffle, on both surfaces of theintermediate baffle and on the lop su-fac'e of the lower baffle (Figure 5-0). Thehoneycomb material on the lower surfaces of the bottom plate was Hexcel Type AL-l/S-5052-002 N-8.1 Non- Perforated. A fact plate was bonded to it to make a rigidsandwich construction for the movable baffle. The plate w.-j.s cut in sections amiprefi t tod to blue print dimensions. It was then bonded to the baffle base plate undervacuum pressure for 18 hours uti l i / ing APCO 1252 urethane adhesive. The honey-comb was additionally bolted to the plate with C-:52 aluminum bolts to achieve goodthermal conductance and a better mechanical joint.

5-15

ii . t R A F F L K AND TI IF .RMAI . PAY LOAD SIMULATOR POSITIONING MKCIIAN1SM

Tin.1 thermal performance test of the customized mul t i layer insulation required thaithe spacing between test tank ami .thermal payli>ad simulator could ije adjusted .from0.457 m (13 in) to 0.151 m (G in). The lower two baffles anil Uu; thcrmid paylo:id.simulator were designed to move together; the bottom baffle remaining in the sameplane as the payload simulator as they were adjusted up and down. This was pro-vided for by resting the thermal payload simulator on six phenolic blocks )x>lted tothe bottom of the lowest baffle and restiUK three of the phenolic blocks on three 0. 0234i)> (1.0 in) diameter screw-woks'extending through the bottom of the cryoshruud,Figure S-l. The rotating nuts for the jack screws were fabricated from Teflon. Abicycle-chain sprocket '"us attached to the Teflon nut at the bottom of each of screw-jacks and all three; sproc ets were driven simultaneously by a single chain. By changingchain position on the sprocket, very minute adjustments to thermal pay hand simulatorheights were made to level the thermal payload simulator i- ~ing installation. The chainwas driven by a small sprocket and hand Tank on j shaft that passed through the bottomof the chamber. As a back up to the positioning transducer, the sprocket tooth ratio andjack screw threads/inch combined, required l(i<;. 5 turns of the hand crank to produce0. 152 m ( G . Q in) of travel.

Drawings of the positioning mechanism with all details are shown in Figures 5-10through 5-1G. The selection of the material for the positioning mechanism parts wasbased on low heat transfer considerations.

5. 5 GUARD TANK DEISIGN AND FABRICATION

In order to prevent entry of extraneous heat to the test tank, fluid lines going to the testt:uik passed through the liquid hydrogen guard tank as shown in Figure S-l. The testtank was also suspended from the guard lank which was attached to a support ring in the•lop cover of the cryoshroud.

The guard tank was fabricated from 30-1 CRESmaterial. Its construction 'Figures 5-17and 5-18) consisted of two formed 0. GlO m (24 in) diameter toiik hearts connected by a0.1422 m (5.G in) high cylinder. The material gauge was 0.0032 m (?. 125 in). A heavymounting ring was welded to the top of the guard tank to transfer loads from the testtank to the cryoshroud structui'j . Three lugs were welded to th« bottom of the tank atits periphery for attachment of the test tank support s t ruts (Rcf. 5-2).

The test tank fill/drain line and vent line, consisting of 0.051 m (2.0 in) O. D., 0.0000 m(fl. o:)5 in) wall , -'iO-l CRKS tubing, penetrated the guard lank. Both of these lines passedwith a "U" bend through the guard tank to prevent radiation tunneling and to allow forthermal contraction. The guard tank f i l l and vent lines were fabricated from 0.0101 m(0.75 In) O. IX CRF.S-:tO-l tubing. The instrumentation lines going into the tost tankpassed into the tank through the vent line. This eliminated an electrical pass-thru inthe test tank door and an additional line through the guard tank.

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5-18

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5-19

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Figure 5-16. Positioning Mechanism - Angle5-20

PAGE ISQUALITY

SECT 5-17. Guard Tank Ass.

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The electrical harness was foil ihrin'-jv .", separate lube in the guard tank'.to provideRood thermal contact ami to assure con-.-»!o.tc heat removal. Bellows (SS-2000-120-85A, Mini-Flex Corp., Van Nuy.s, CA) wi;ro provided in both the lines between thetest tank and j, iard tank for ease of ins ta l la t ion and to assure that the loads causedby r.i .-cmont of ;!•.,-• lesMank were not t ransmit ted through these lines.

5.G MODIFIED C11 V< S i lKOUD ASSEMBLY

5.6.1 ASSK.MU t.V SKQUKXC E. Figure 5-1:9 shows the assembly o i the c^yoshroudcover including the f i i l / von t lines of the test tank, guard tank, thermal payload simu-lator, cryoshroud am! kiiTles. The assembly of the crj'oshroud and baffles with theguard tank, test tank, tU.-rmal payload simulator and Baffle/TPS positioningmechanism is presented in Figure 5-20. The assembly of the major components wasinitiated by mating the gu:ud tank to the cryoshroud cover. The uninsulated test tankwas attached to the guard ta^./shroud cover (tank assembly) as shown in Figures 5-21through 5-23. 'ihe tank assembly was leak checked with gaseous helium, utilizing ahelium mass spectrometer. After the installation of the baffles to the cryoshroud(Figure 5-24), the tank assembly was temporarily mounted.to the cryosnroucl/baffleassembly. The te- ' t 'ank supports were adjusted to obtain a concentric location of thetest tank ''ithin the cryoshroud/baffle assembly.

Prior to mounting the baffles on the cryoshroud, all baffle support? were fabricatedand attached to the wall as shown in Figure 5-9. The baffle cooling coils wereextornally cleaned with Freon solvent, then leak checked with helium and repairedas necessary.

As shown in Figure 5-20, the guard trr.k was supported ."rom the cryoshroud liftingstructure. This arrangement permitted assembly and installation of the cryoshroudcover and test tank as a unit. . .

The cryoshroud assembly support consisted of (i micarta and a luminum legs, bolted tothe cryoshroud and resting on the bottom of the vacuum chamber. The micartamaterial is used to minimize heat transfer.

5.f i .2 THERMAL PAIN I' REQUIREMENTS. After assembly, air interior surfacesincluding the cryoshroud, baffles, and attachment hardware viewing the test packagewere completely covered with 3M "Nextel" Black Velvet (3M-101C10) paint to achievethe highest emissivity possible. This paint is designed for surfaces requiring highemissivities and low outgassing in a vacuum.

5. (>. 3 F L U I D TUBING. Single and double Cono '•'•als were used for flange and tubingjoints where welding was not feasible or dcs.-aole. Single Conoscals were utilisedfor stainless steel joints while double Tonoseals were applied where a bi-metal <i. e.,Al - Cres) joint could "caus.e a possible leak. The Conoseals ;uu! Conoseal grooveinformation were provided by Aeroquip M arm an Corporation. The cryoshroud andbaffle f i l l ing operation v.-as accomplished through a single fiU l ine.at the bi.rttom panel.

5-23

The electrical harness was fed rhroiup. .". separate lube in the gm;rd tank to providegood thermal contact ami to assure complete heat removal. Bellows. (SS-2000-I20-S5A, Mini-Flex Corp. , Van Nuys, CA) were proyuicJ in both the lines betv/cen thetest tank and L lard tank for .ease of installation and to assure that the lo-.uls causedby r.r .-ement of liv; test tank were not transmitted through these lines.

5.0 MODIFIED CRYCSI IUOUD ASSEMBLY

5.6.1 ASSEMBLY S't-XjUK'NCE. Figure 5-19 shows the assembly of the c^yoshroudcover including the fill/vent Hues of the test tank, guard tank, thermal payload simu-lator, cryoshroud and !.Rifles. The assembly of the cryoshroud and baffles with theguard tank, test tank, thermal payload Simulator and Baffle/TPS positic/iingmedian ism is presented in figure 5-20. The assembly of the major components wasinitiated by mating the guaid tank to the cryoshroud cover. The uninsulated test tankwas attached to the guard I ;;:v,/shroud cover (tank assembly) as shown in Figures 5-21through 5-23. The tank assembly was leak checked with gaseous helium utilizing ahelium mass spectrometer. After the installation of the baffles to the ci.yoshroud(Figure 5-2-1), the tank assembly was temporarily mounted to the cryoshreud/baffleassembly. The test tank supports were adjusted to obtain a concentric location of thetest tank within the cryoshroud/baffle assembly.

Prior to mounting the baffles on the eryoshroud, all baffle supports were fabricatedand attached to the wall as shown in Figure 5-9. The baffle cooling coils wereexternally cleaned with Freon solvent, then leak checked with helium and repairedas necessary. -

As shown in Figure 5-20, the guard tank was supported from the cryoshroud lift ingstructure. This arrangement permitted assembly and installation of the cryoshroudcover and test tank as a unit.

The cryoshroud assembly support consisted of G micarta and aluminum legs, bolted tothe cryoshroud and resting on the bottom of the vacuum chamber. The micartamaterial is used to minimi/.e heat transfer.

5.G.2 THERMAL PAINT REQUIREMENTS. After assembly, all interior surfacesincluding the cryoshroud, baffles, and attachment hardware viewing the test packagewere completely covered with :3M ''N'extel" Black Velvet (3M-101C10) paint to achievethe highest emissivity possible. Tins paint is designed for surfaces requiring highemissivities and low outgassing in a vacuum.

5. 0. :j FLUID TUBING. Single and double Conosi/als were used for flange and tubingjoints where welding was not feasible or desirable. Single Conoseals were 'ut i l izedfor .stainless steel joints while double Conoseals were.applied where.a bi-metal ( i .e . ,Al i Cres) joint could cause a possible leak. The Conoseals and Conoseal grooveinformation were provided by Aeroquip Marman Corporation. The cryoshroud andbaffle filling operation was accomplished through a single fill l ine at the bottom panel.

5-23

ORIGINAL VAGc; u0? I'C^H.QUALJlTV

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The thermal payload simulator has its own fill and vent lino. The baffle cooling lineis a continuous aluminum tube which makes a circle around the baffle on the lowerside (not attached), goes through the movable baffle plate and makes a double circuiton the upper surface of the movable baffle. It continues with a spiral around thecryoshroud from the lower movable baffle to the fixed baffle. The coil then exitsthrough a hole in the shroud. The Conoseal flanges, tubing, joints and gaskets usedfor the cryoshroud assembly are shown in Table 5-3.

Table 5-3. Conoseal Flanges> Tubing Joints and Gaskets

Item

Tube Joint

Double SealFlange

Double SealFlange

Single SealFlange

Gasket**

Location

Guard Fill/Vent

TPS, BafflesCryoshroud

Test Tank Fill/Vent*

Test FacilityTest Tank Fill/Vent

Seal No.

59190-12SS

591G2-100S591G1-100A

591G2-200S

5G331-200S5G332-220.S

59307- 12A50887-100A50887-150A50887-200A50887-250A

No.

2

55

2

22

Material

Cres

Cres MaleAl Female

Cres Male

Cres MaleCres Female

Al Allov

\

* The mating female flange was machined as a part of the test tank lid.

** All gaskets were Teflon coated before installation.

5-30

DESIGN AND FABRICATION OF THE THERMALPAYLOAD SIMULATOR MULTILAYER INSULATION

The Thermal Payload Simulator (TPS) is a 1.83 m (72 in) diameter disc, insulatedover the entire surface on th - side facir" the test tank (Figure S-l). The objectiveof the TPS is to provide a constant temperature surface for the insulated tank to view.The thermal payload simulator surface viewing the tank is flat and free of penetrationsand requires a total hemispherical emittance of less than O.Oij. The perimeter of thethermal payload simulator is also shielded from an adjacent baffle by the applicationof three radiation shields attached to the baffle structure (Figure S-l).

G.I BLANKET DESIGN

The multilayer insulation (MLI) of the thermal payload simulator is composed of threeindividual Mankets to obtain the required constant thickness 00 shield MLI system overthe entire surface area of the thermal payload simulrtor. A blanket arrangementschematic and the actual design drawing are presented in Figures (>-l ;md 6-2respectively.

Each blanket is a 1.83 m (72 in) diameter sandwich consisting of 20 radiation shieldsand 19 spacers. Two radiation shields are cover shields that establish high lateralthermal conductivity, act as protectors during handling and installation, and providea stronger surface for attaching insulation fasteners. The blanket cover shields arelaminates of 5. OS xiO~° m (2 mil) Mylar and 2.34 x 10"U m (1 mil) aluminum foil bondedtogether. The aluminum portion of the composite shield is located on the outside of the

.blanket.. The cover shield of blanket-No. 3, applied on the outer surface viewing thetest tank is painted with 3M Black Velvet Paint (Section l>.2) in the area shown inFigure G-l. The remaining 18 radiation shields arc double aluminized G. 35 x 10"G

(1/4 rr.il) Mylar shields. Each shield requires between 300 and 500 A of aluminizodvapor deposited on both sides. The spacer is composed of two layers ot 3llk net(silk netting No. 2772, Industrial Textile, Cleveland, Ohio).

All blanket layers are interconnected by Nylon button pin studs (ZYTEL 101 NylonResin) to control blanket thickness at a nominal dimension of 0.00703 m (0.312 in).The button pin stud set (Figure fi-3)consists of a 0.021 m (0.^27 in) loiiii pinintegrally molded with a disc at one end and a notch located 0.00702 1.1 (0.312,) from thedisc. The retaining button (Figure (i-4) slips 'into .the pin notch. The button pins aredistributed on 0.2032 m (0 in) centers throughout the blankets. Installation details ofa typical section of the TPS blanket are shown in Figure G-2.

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(i .2 BLANKET ATTACHMENT DESIGN

The blankets are attached to each other and to the thermal payload simulator using Velcrohook-and-pile-type fasteners that conform to the specifications given in Figure (i-2.

For the first blanket assembly, facing the.thermal payload simulator, the pile sectionsof the tapes are bonded to the simulator surface and the mating hook sections are bondedto the blanket cover shield, using Teledyne Coast Pro-Seal 501 adhesive. This adhesiveis designed for exceptionally high peel strength. Close tolerances for locating thefasteners are not required since the size of the fastener can be established to compensate

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Figure <;-4. Retaining Button Detail

and hook sections at assembly. TheVelcro Looks and piles are arrangedin a cross pattern as shown in Figure(j-2. This will permit easier instal-lation of the blankets and will toleratea slight mismatch in alignment.

The second blanket is attached to thefirst by bonding the pile and hooksections to the adjacent face sheetsbetween blankets. Similarly, thethird blanket, which faces the testtank, is attached to the second blanketassembly. The location of thefasteners is common to all blankets.An annulus /one on the third blanketcover shield facing the test tank ispainted with :iM "Nextel" Black VelvetPaint No. 3M-401C10. This paint isdesigned for spray application tosurfaces requiring low gloss ajid lowoutgassing in vacuum.

(>.:'} BLANKET FABRICATION

Fabrication of the mul t i l aye rinsulation blankets and componentswas conducted in the clean roomfacility in Building 51 at Convair 'sLindbergh Field plant The f ac i l i t ymeasures !.'{..4 in {'/.'/; in) \vid-.-, -0.1m (702 in) loni;' and '•>. O.'i r.i (ll 'O in) hi irh.This environmental and paniculatecontrolled facility is rated as a Class

6-4

C clean room in accordance with Federal Standard 209a "Clean Room and WorkStation Requirements, Controlled Environment, " dated 10 August 1906.. Tlie faci l i tyincludes an air shower and foot scrubber unit in the entrance to assist in maintainingthe environment with the referenced specification. The facility condition was checkedat the beginning of the MLI production. It was found that the facility was controlled ata "Level of 10,000" which was su|>erior to. the level required by NASA.

G.3.1 MLI MANUFACTURING AID REQUIREMENTS. The manufacturing aids requiredfor fabricating the thermal pay load simulator blankets consisted of a frame to stretch-form the silk net spacer material and a MLI blanket manufacturing aid to lay up theblankets for the thermal payload simulator. The frame shown in Figure ii-5 is a woodenconstruction, with an inside width and length of 1. 3:5 m (72 in) and :;.l)(i m. (150 in),respectively. The silk netting which was purchased for this contract, 1.37 m ('A in)wide material, was stretch-formed with the aid uf this tool. The stretch-formmanufacturing,aid was also provided with a trough to cntch the access water during thewetting operation of the silk net. The design and a photo of the thermal payloadsimulator MLI blanket manufacturing aid are presented in Figures <>-(> and.G-7,respectively. This manufacturing aid was fabricated from two pieces of 0.00'.'Ti m(0.375 in) thick plywood. The tool was used for layup ancl assembly of blanketcomponents, for tr imming, as a hole pattern for attachment pins, and to locate theVelcro fasteners. The cover piece and base piece of the manufac tur ing ..kl are discsof 1.83 m (72 in) and 1.93 m (73 in) diameter, respectively. Both pieces nre matchedby locating pins. Fifty-two button pin drill holes are equally distributed at 0.20.'! m(8 in) centers over the surface of the disc. Thirty-two additional dri l l holes arelocated at the periphery of the disc. . '

( i .3.2 SILK NET STRETCH-FORMING. The silk net spacers were first stretch .formed in the f rame described in Section 0.3. 1. The l.:57 m (54 in) wide silk materialwas moistened and then dried for a minimum of 72 hours to remove inherent wrinklesand to provide shape stability. This production method resulted in a uniform layer-density of the MLI system. The silk material, Ko. 2772, v/as manufactured in Franceand purchased through Industrial Textile, Cleveland, Ohio. Thirty-eight sheets of silknet were formed at a time. In order to obtain the required silk net spacer width, 2pieces were butt jointed and tailed wi th aluminix.cd My'...r ta|>e.

0.3.3 BLAMKET CO V EIt SHIELPS. The mater ia l which was used to fabricate thecover shields was Slicldahl GT-75f> material. This material is a standard l amina t e , ' 'available- in stock at G. T. Shrldahl Co., North field, Minnesota. It is composed of 2mi! Myla r T\'\n' A :»ml 1 mil a l u m i n u m foil (1 1 )">-0 alloy), bondi-d together wi th a thermosetting |X>lyestcr adhesive. It has a high lateral conduction and is impermeable lo gasand moisture va|>or. The proi>erties are given in Table <>-!.

U . : i . 4 BLANKET LAY-UP AND ASSEMBLY. The thermal paylond s imulator MLIblanket assembly is shown in Figure <i-2. Since the ref lect ive 'shields , s i lk net spacersand cover shields were oversize relative to the largest sheet materials ava i l ab l e , the

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Table (-1. Propcrtios'of Blanket Cover Shield Material

Tensile Strength: Machine Dii-cction: 7 . f > kN/m (<ir» l l>/ in) of widthTransverse Direction: 7.!> kN/m (45 Ib/in)

~I

Elongation: Machine and Trans-verse Direction:

Weight:

Service Temiwrature: .

Permeability to H^

Moisture Vapor Transmission Rate

10%

0.1 f/J kg/m2 (4.7 ox./yd2)

213 lo :50:i K (3513.-1 to OGfJ-.-l R)

Less than 0.01 liters/m~/2-l hours

nil

assembly Aayup techniques included .provisions for this condition lo mainta in satisfac-tory thermal characteristics. To meet these requirements, each blanket component,was processed as descrilxxl below.

Cover shields were fabricated \vitli an overlap joint using a continuous strip of nlumin-ixed Mylar tape with the tape on the outside surface. Radiation shields were fabricatedwith a butt joint, and held together with short lengths of alumihi/ .ed Mylar tape locatedat intervals along the joint. Silk netting was butt jointed, not overlapped. As an aid dur-ing layup, the silk net was held in place with masking tape attached to areas outside thefinished trim periphery.

During assembly, the above described joints were offset from each other both laterallyand radially to avoid material buildups.

The blanket layup was performed u t i l i x i n g the manufac tur ing aid described in SectionC.3. 1. The operation sequence following-blanket layup was to pierce the pin holes witha hypodermic needle and insert button pins and buttons, apply heat to the portion.of theextruding pin to form a balded head to keep the retaining button in place and f ina l ly t r imthe blanket periphery and remove the template at instal lat ion. Kvery other retaining but-ton pin face was bonded to cover sheets with Pro-seal 501. No adhesive was allowed onany exposed surfaces around the buttons.

The next operation was the attachment of the Vclcro fasteners to the blanket covershields with Pro-seal f>01 in the location provided on the tool template.

Since the Vclcro fasteners are located near the edges of the blanket assembly (Figurefi-2), a normal pressure force between the bonding surfaces was easily applied using"clothspin type" clamps without gross disturbances of the blanket layers or the pinbutton assemblies. The f ina l task was then the pa in t ing of the O.O' . iG in (U . " in) wuk:annular /one on the: th i rd blanket with :'.M-101C10 Black Velvet Paint. A photo of thethree thermal payload s imula tor blankets is presented.in Figure 2-S.

G.-l BLANKET INSTALLATION .

The blanket ins ta l la t ion was conducted as indicated in Scction' i i .2 and shown inFigure li-2.

6-9

£

o•a-3£551

•as

-POORPAG1T IS

DESIGN AND FABRICATION OF THE TANKMOUNTED MULTILAYER INSULATION

During this task the tank mounted MLI, shown in Figure S-l was designed and fabricated.This MLI system covers the entire area of the 1. 52 m (GO in) test tank, except for themain tank door area. The system is composed of the inner and outer blankets, eachcontaining 20 radiation shields. The blankets are supported from the tank wall usingthe Vclcro fasteners described in Section < > . 2 . The design and fabrication of the MLIsystem is in accordance with the procedure used for the thermal pay loud simulatorsystem. The primary differences from the payload mounted system are the require-ments for forming all comiwnents to fit the spherical tank and installation methods toeffectively minimize thermal leaks where the blankets join each other. Both itemsare critical to thermal i>erformauce.

7.1 VENTING CONSIDERATIONS

During vacuum chamber pumpdown, the MLI intcrstilud space is required to vent intothe chamber. As the MLI Interstitial pressure is reduced to the point where freemolecular gas flow venting is predominant (approximately l . o o X 10~;' kN/m-)(lO~^Torr), the MLI venting becomes geometrically sensitive. Thai is, MLI venting ofeach interstitial gas molecule occurs along an unobstructed line-oi'-sight path. Thusthe vent path area must be kept open :mcl unobstructed, by minimizing the MLI inter-stitial vent path blockage resulting from blanket fasteners, supports and /or ]xj net rat ions.

7.2 INNER BLANKET DESIGN

The inner blanket lay up consists of six 1.043 rad (GO dug) gore sections and one 0.-10Gcm (1G in) diameter circular blanket. The circular blanket is located at the tank poleviewing the thermal payload simulator (Figure S-l). The gore sections arc identicalpreformed assc-i ;.lies running continuously from the access t:ink door area to thecircular blanket. Three gore blankets are locally notched at assembly to clear the tanksupport lugs located at the access door ring. Butt joints are used between the gore andcircular sections. All blankets are installed such that physical contact at these buttjoints is achieved over the entire length of the joint. A schema'!c of the test tank innerblanket arrangement is presented in Figure 7-1. The actual design drawings of thegore section and cireul::- '^...ikets are shown in Figures 7-2 and 7-:i, respectively.The .MLI layups consist of 18 double aluminizcd, (> .3G -'•'- 10~G m (1/1 mi l ) Mylar radiat ionshields and 1!) double s i lk spacers sandwiched between two laminated cover shields.Each spacer is comiwscd of two layers of silk netting, and the cover shields are

7-1

\I

I N N E R CO I IKBLANKETS -

I N N E RCIRCULARBLANKET

Figure 7-1. Test Tank Inner Blanket Arrangement

laminates consisting of 3.08 x 10~5 m (2 mil) Mylar and 2.54 x i0~ i j m (1 mil) nluminumfoil. Each of the eighteen radiation shields has between :iOO and 500 Angstroms ofaluminum vapor deposited on each side.

The blanket layers are interconnected with Zytel 10.1 Nylon resin button pin studs asshown in Figure 7-3. Forty three sets of button pin studs and retaining buttonassemblies per gore section are spaced at intervals not exceeding 0.203 m (8 in).The inner blanket gore sections are attached tc the tank wall using 20 Velcro hooksper gore, 0.0254 m (1.0 in) wide and 0.07G m (:!.0 in)'long. The outer suvtocf ot eachinner blanket gore section has 20 Velcro piles, 0.0254 m (1 in) wide :uul 0.050S m (2.0 - :

In) long to which the outer gore blanket will be attached. The inner circular blanketlayup and materials are the same as those described for the inner blanket gore section.The radiation and cover shields are interconnected with 1H button-pin studs/buttonassemblies. Twelve 0.0254 m (1.0 in) x0.0.308 m (2.0 in) Yelcro hook fasteners arc

used to attach the inner circular blanket to the tank . Kight Velcro pile sections ofthe same dimensions are attached to the outer surface of the inner circular blanketto fasten the outer circular blanket. (Figure 7-3).

7.3 OUTER BLANKET DESIGN

A schematic of the outer blanket-arrangement is presented in Figure 7-4. The outerblanket layup. and materials are the same as those outlined for the inner blankets ,Section 7.2, except for the addition of cover shield strips applied over the butt jointsbetween the gore sections and nn annulus cover shield applied over the butt jointsbetween the circular blankets and gores. The gir th area is coated with ;jM BlackVelvet paint No. 401C10. The butt joints are staggered relative to the inner blanketsections (Figure 7-5). The outer circular blanket diameter is O..';05 m (12 in) whichprovides the butt joint offset at the tank outlet cap. The actual designs of the outerblanket gore section and the circular blanket are shown in Figures 7-2 and 7-.'!,respectively.

7.4 BLANKET ATTACHMENT DESIGN

The outer blankets are attached to the inner blanket cover shields using Vtlcrofasteners bonded to the cover shields as shown in the schematic Figure 7-5 and

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7-3. Inner and Outer Circular Blankets, Custonii/.eu MLI ' -: 1'

7-4

0.174RAD>

;{M BLACK OUTER GORE BLANKETS —VELVET ,--'"'PALNT "7

OUTERCmCULAR.BLANKET

L A M I N A T E DSTRIPS O V E RbuTT-JOINT.S

— ANNULUS-SHAPED LAMINATED SHIELDSOVER CIRCULAR BLANKET BUTT-JOINT

Figure 7-4. Test Tank Outer Bhmket Arrangement

-LAMINATED STRIPS

OUTERBLANKET

LAMLNATEDCOVER

T A N K WALL 7 5 '''*'" SHIELD'.. . VELCRO FASTENERS

INNER BLANKET'

(a) Cross-Section of Butt Joints Between Adjacent Gore Bhmkcts

ANNULUS-SHAPEDSHIELD TO BLANKETS

GORE BLANKETS

OUTER

INNER

CIRCULARBLANKETS— OUTER

TANK WALL

VELCRO FASTENERS

COVER

SHIELTK

(b) Cross-Se.ction of Butt Joints Between Gore Blnnkets and Circular Blankets

Figure 7-f,. Butt Joint Sections of Tank Mounted MLI System

1-5

actual design drawing Figure 7-G. The inner olankets are mounted to the tankutilizing Velcro fasteners which are bonded to the lank wall . All butt joints at thegore lines are covered with 5.08 x iO":j m (2 mil) Mylar :mil 2.54 x I0~a m (3 mil) aJuni i iuu. i -foil laminated strips attached to the blanket cover shields with Velcro fasteners asshown in Figure 7-6. The spacing between these farteners provides vent paths andfacilitates installation and removal. For the joints between the gores and circularblanket, a similar arrangement is used, except that an annulus-shaped shield providesa 0.102 m (4 in) overlap at the seam.

7.5 BLANKET FABRICATION •

The tank mounted multilayer insulation system was fab.-i^uted in the Convair cleanroom described in Lection G.3. The fabrication was conii -ised of six inner and outergore blankets, an ianer--and outer circular blanket for the tank outlet cap area, thelaminated strips for the gore butt joints and the annular shaped shields over thecircular blanket butt joints. The insulation system was fabricated in accordance withthe assembly drawing shown in Figure 7-6. Inspection of each part, process, sub-assembly and assembly was performed and recorded at each operation as required bythe dra%ving.

7-. 5.1 MANUFACTURING AID REQUIREMENTS. The fabrication of the M LI systemfor the tank mounted insulation required the manufacturing of the fo'i'.owing tooling a ids :

1. Inner gore blanket layup aid.2. Outer gore blanket layup aid.3. Inner circular blanket layup aid.4. Outer circular blanket layup aid.5. Cover shield vacuum forming tooling aid.

The design drawing of the inner and outer gore and circular blanket is shown in Figure7-7. The inner gore blanket layup, a fiberglass-re in forced blanket shell , was fabricatedutilizing the surface of tha 3 .52 m (GO in) test tank. The fabrication process of the goreand circular blanket layup aids is schematically demonstrated in Figure 7-8. Thesurface of the tank was first cleaned and then coated with Dow Chemical Company X-100 .wax before applying fiberglass. This section was face coated with Poly-Resin GELCoat 111. Seven layers of 1534 Fiber Glass Cloth with 204 Poly Resin were added toform the first inner gore (Figures 7-3, 7-9 and 7-10). After a 24 hour cure, a 0.01Gm (0. 625 in) thick layer of wax was applied to the top of the gore to obtain the repre-sentative 0 .01Gm(O.G25 in) blanket thickness (Figure 7-11). The outer sheM of theinner blanket was then bui l t up over the wax to form the outer shell of the itinzr goremanufacture aid. After a 24 hour cure, this outer shell was removed and fabricationof the outer layup aid was started. Using wax as a spacer turned out to be a v e r y t imeconsuming operation. In order to reduce the fabricat ion t ime , fiberglass covered witha thin sheet of Mylar held by a vacuum, was used as a.spacer. In accordance w i t h thedesign drawing shown in Figure 7-7, for each inner and outer gore and circular blanketmanufac tu r ing aid, one base and one cover plate was required. The base plate extended

' 7 - 6 . ' . - . • •

_-_....,,s..,_-_-:-, - . - r ^ -

" 7-6 . Insuhi t ion AssfCustomi/ecl MLI 'J'.-tnk aiThermal P;iyload Sin in l i

TOUT FRAME / ORIGINAL PA(:-:•..,;-

Dimensions; Ail (Umoasions arc hi Inches

Figure ? • ( > . In su l a t i on Assembly,Ciistomi/cd Mhl 'i'iink :indThermal I 'aylfj.-ui Siim;);itor • • - • • • • - - - -

....... Kii<i/br-"o>; c?^r-•

Blanket M;miif:ictur::i£-

Dimensions: All iltniunsions ai\ in inches

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SIDE VIEW1. Spray Aporox. 1.57 Rnd 2. Layout 1 Gore Config- u. Add Release Agent and Lay(90-Deg) Section of Tank uration to Conform With Fiberglass/Epoxy 0, 051 or0.076 inWith Stripable Protective Loft Dimensions (2.0 or 3.0 in). Beyond LayoutCoatinc

O . O I G m (0.625 in)

« I FIC.FR-

"0.032 m (0.123 in)TANK

SECTION A-A

4. After Cure, Build Glass up With0.00794 in (0.312 in) Wax

WAX

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5. -Layup Second Layer of Fiberglass(Approx 0.003m (0.123 in).. ThickOver \V;ix

FIBERGLASS

L_

SECTION B-liTANK

G. Add Another Layer of Wax and Layup Third Section,0.000 m (0. }2r, in) thick of Filjei^l.-is.s/

TOPVIEWSHOV.'SPIN "^LOCATORS

| ~- PLYWOOD

8. Use Similar Tuehnicjue to.Make C i rcu la r Segments

7. Discard Wax. Add Locating Pins. Machine theEdges of Inner and Outer Gore. Reinforce LowerSection. Sand, Break Edges, etc. Add Holes forLocating Button-Pin Studs.

Figure 7-8. Schematic of Fabrication Process of Gore and Circular Blanket I. ; tyii |> Aids

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approximately 0.07G in (3.0 in) beyond the cover plate lo provide sufficient support ofthe blanket during the edge-trimming operation. 0.01C m (O.G^i in) diameter holeswere dril led through base and cover plates at all button-pin locations. Figure 7-12shows a photo of the finished manufacturing aids.

The blanket cover shields consisting of a laminate of o. OC '/• 10~'J m (2 mil) Mylur and2. 54 x lO--r> m (1 mil) aluminum foil were formed with a vacuum tool. This tool wasfabricated by applying fiberglass shells directly to the tank in a manner similar to thatused on the gore layup manufacturing (Figures 7-13 and 7-14). Figure 7-15 presentsa photo of the completed vacuum form tooling aid.

7.5.2 SILK NET STRETCH FORMING. The silk net spacer material for each blanketwas stretch-formed using the appropriate blanket layup aid. The silk net was firstmoistened wi th water to provide the needed drape characteristics and then draped overthe manufacturing aid, followed by air drying for a minimum of 72 hours. The six.ingof the material becomes rigid during the dry ing process, thus the spacer materialassumes the contour of the manufacturing aid. Approximately 18 layers of s i lk netwere formed at the same t ime, dried on the manufacturing aid and trimmed oversix.e,preparatory to blanket assembly.

7.5.:: BLANKET COVER SHIELD IMBRICATION. The MLI blanket cover shieldmaterial, a Shcldahl GT-7f>r> standard laminate riaterial, was vacuum stretch formedusing the vacuum form tooling ;nu, (Section 7.5. 1). This mate r ia l is composed of 2mil Mylar Type A and l mil 1145-0 alloy a luminum toil, bonded together with a thermo-setting jx)lyester adhesive. The emissivity of the material as received was measuredto be 0.0213 at a temperature of 300K (540°R) and a wavelength of 9.65 x io~G ( 9 . G f > ^ ) .It was necessary to fabricate fourteen (14) cover shields with the aluminum surface andfourteen (l 'l)with the Mylar surface located on the outside of the curvature to meet thedesign requirement (figure 7-2) that the a luminum portion of <iach cover shield mustface toward the outside of each assembled blanket.

Five cover shields with the aluminum surface on the outside of the shield curvaturewere vacuum stretch formed with good results. All shields wen.- of high qualify.The manufacturing procedure that had been used to make the cover shields was asfollows: (1) pull partial vacuum to hold the shield material in place in the tooling aid.(2) heat in oven to 450K ( f?10°U)-hold for c ' r.uiuiles, ('.':) nu l l fu l l v a c u u m , (-1) remove fromoven,cool to room temperature, (5) remove vacuum. The stretnh forming of cover-shields No. 6, 7 and 8, however, was not successful. The shields became jioroususing the same manufacturing methods. It was observed that the defc.-ctive covershields were produced after a splice of the roll of the stock material. The problemwas investigated by Convair's Material and" Process Department.

Tin- objectives of the investiagion were: (11 to determine the c;aise of cracking andtearing during forming of laminated Mylar /a luminum foil obtained f r o m the spliced.end of the supply roll, and (2) recommend corrective action.

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Figure 7-1.1. Cove f Shield V n c u u m Form Tooling Aid - Kcady for Mount ing

7-1C. '

Samples of laminatedMylar/aluminum foil fromthe start of the roll andfrom the spliced end wereexamined. The a luminumwas removed from samplesof each material type andmeasured to see if differ-ences existed in the relativethicknesses of the Mylarand a luminum foil. The twomaterials were examinedmetallographically alongwith material from a vacuumformed gore segment con-taining many minute cracksand tears. In addition,tensile coupons were cutfrom material from thestart of the roll and thespliced end. Threespecimens each weretested to fai lure and one

specimen of each was strained to 14''k.total elongation (lO'.'c |>ermanent set) and relaxed.The tensile specimens were examined at T.<, 20>, and ;;0xto determine any differences instrain behavior. No differences existed in the relative thickness of the Mylar andaluminum between the two materials. The results of the tensile tests are shown below:

Figure 7-15. Vacuum Form Tooling Aid for Cover ShieldManufacturing

ThicknessMvl a r A luminum

Material fromstart of roll

Material fromspliced end ofroll

Spec No.

AlA2A3

131132Ho

m in m in

BreakingStrength

(Load in kN/m(lb/in)of width) Elongation

kN/m lb/in r.' in 0. 051 m

O.OOOOG3 0.0025 0.000033 U; 0013 7.91 -15.4 22.50.000061 0.002-1 0.0000330.0013 7.84 4-1.G 17.0O.OOOOG1 0.0024 0.00003G 0.0014 8.00 51.0 41.0

. O . O O O O G 1 0.0024 0.000033 0.0013 8.04 45.S G5.0O.OOOOG1 0.0024 0.0000330.0013 7.S4 44. S 10.0'0.000053 0.0023 0.000038 0.001C 7.74 44.4 GO. 0

•Specimen B2 failed by tearing which stalled at an edge of the reduced section. The.re la t ively low elongation is at t r ibuted to the tear ing which may have been caused by anotch effect on the edge.

r - i "

The results of tests showed that the breaking .strength of both materials was e q u i v a l e n t .The high elongation of material from the spliced end of ilie roll indicated that ma te r i a l ,elongation was not.the problem and suggested that the forming temperature lor the H .material should not be higher than that used for the A material to make good par t s .The specimens "strained to 10% permanent set showed no "dif ference in material texture.Examinations at 100''and iMKixof cross sect ions of the ma te r i a l did not reveal anydifferences. However, tho sjKcimeu from the vacuum formed segment indicated thatthe polyester adhesive had softened considerably. This also .suggested lower formingtemperatures. . .Vacuum forming the laminated Mylar/aluminum part at room temperature prior toexposing it to heat is desirable whereas heating It first would soften the adhesiveand allow slippage to take place between the Mylar a_nd aluminum. Thu unsupportedalumiaim is vulnerable'to tearing. To conserve material, i'orming tests were con-ducted on a smaller "Liberty Bell'1 vacuum form die. Three forming tests v/ureconducted as follows: (1) Vacuum form - at ambient temperature, then heat to ;:<)4K(710R) (2) heat .to .'3S4K (710.H), then vacuum form at this 'emperature, (3) vacuumform at ambient temperature, then heat to 47PK (S60R).

Tests 2 and 3 resulted In tears and cracks in an area of the die with high materialelongation. It is felt that test 3 resulted in cracks after exposure to the 478K (860.H)temperature because of residual stresses in the material. The stresses caused rela-tive movement between the Mylar and aluminum when the adhesive was softened atthe high temperature. Test 1 resulted in a good part without cracks. Gore segmentswere then formed with the same procedure.

Based on the tests, the following sequence was recommended to the shop: (1) aftersetting the sealing clamp on the laminated material push the material into the centerof the die. This will prevent excessive stretching of the material as it is formed.Allow the material to wrinkle at the edges, (2) pull full vacuum, (3) put into ovenset at .'!D4K (710H)-holcl 8 minutes total t ime, (/t). remove from oven :uirl let eooi toroom temperature, (5) release vacuum.

7. 5. I BLANKET LAVUP AND ASSUMBLV. The blanket layup and assembly operationconsisted of joining the prefabricated components i n t o the required mult i layer l ayup ofcover shields, rad ia t ion shields and si lk net spacers. First, the inner gore b lanket waslaid up onto the base plate of the blanket tool ing m a n u f a c t u r i n g aid (Figure 7 - H i i , lx.-gin-ning with the inner cover shie ld , followed by a l t e rna te layers of IS radia t ion sh ie lds and1!) double silk net spacers, and the ou te r cover shield. The radiation shields were cut-to rough si/.e with electric scissors and thusi pleated to shajie on the base p la t e . Thepleats were held in place w i t h aluminix.ed M y l a r pressure sens i t ive adhesi ' . e t a ix j . .This was a manua l operation which employed a two-lined fork to form the pleats . Thelayup procedure is shown in Steps 1, 2 and :j of Kigmc 7 - 1 7 . To i-ccp ihv l avorscorrectly posi t ioned, mask ing tape wa- used as required to .fasten the i a \ e r s to them a n u f a c t u r i n g aid d u j - i n g l a \ u p . The t a i j e was I'astejicd ou ts ide '.lie for ju li ' .K-. .:i«!discarded as the blanket eduvs were t r i m m e d . :

JL.SI I)K YIKW

1. Pl-.tei- 1 Preformed Sheet and 2 '-. Cut Mylar to Rough :i; Place Mylar on Fixture.Prelormckl Silk Netting Sheets on Si/.e With F.lectrie TajK.- F.nds While l.iglitly • • - • •F ixture . I-'asten to Kdgeol 'Aid With Scissors I.) rawing L'p Myla r to lie moveMa.-king.TaiK.- at Appro*.'• Wrinkles. Pleate and Ta|>e0.^f.-1 in (10 i,i) Spaces Wi th Aluminiy.eci Tape

H Y P O D E R M I C N K K D l . K POINTI'SFI) TO FORM I IOLKS ANDI N S K R T 111 TTON PINS

TRIM K N I F K - — ,

OUTKK TIUM/DRILL SHKLL

COVHU I'l.ATI-CM- MR; AII)

/

/

INSt'LATlON BI.AXKF.T

FIHKRGl.A'SS HASH

C K N T K R D I V I D F . R

-.'ach O;>erauonI ' m i l 1:1 at ire lU.i.-ikct isl .a i i i Up. Add Spacers.I ' in LV'-.'er D iv i ck - r inI ' laec. Repeal J.ayupAssembly t«> Fori.i OuterI'.laiiket

I ' ins . Tr imHlauki't

."i. Add Holes G. Remove-Outer Shell . Add l iui loni One at aFor Button- Time on-Outer Bl.nnket. Sxviige W i t h Tool Held

in Soldering Iron. Bond Yclero Fasteners inPlace From locators on Center Div ide) - .Remove Outer Blanket and Add Pins to InnerBlanket . Note: Last ( i ; th i (rf ire Blankets W i l lNot lie Trimmed U n t i l First ."> Have lieenMounted to Tank.

AI.UM t MYLAR

7/N\. V K I . C R O"~~^ ' FASTKNKliS

Add Velero Fasteners to T.-.iik Usini? Center 3. Ailc! Inner C i r c u l a r Segment to Tank.Div ider a.s locator . .Mount "> Ins ide GoreI ' . lankets . Check Gap. Tr im Blanket t«.) Si/.e.Cqm|X.'iisate in Case of Discrepancy.

Repeat Same Oic ra t ions for Outeri ' i i v u l : i r B l a n k e t .

Itl-i'nL-ot I ri

N e x t , :ill layers were ccrvered w i t h the female e^vcr plate1 "I the blanket m a n u f a c t u r i n gaid (Step - I ) . The female cover plate was used as I x i t h a hole t emp la t e .mil. in cumbiiri-tion with the male base plate as a guide for u-immtn:.1. l l ) > - b lanket periphery. Tl>c b lanketsandwicfi was pierced for the button pins , but ton pins were ins ta l led and tlio blanket wastr immed to si/.e (Step ">). The buttons were added one at a tune . .The pin was .-swagedwi th a soldering iron (Step < ; ) . F ina l ly , the Velcro fasteners were Ijondcd to the covershields with Pro-Seal 501 adhesive. Twenty tour hours nf cur ing t ime weie allowedfor the room I em pe. rat u re- cur ing cycle. All . these operat ion* were repeated on theinner and outer gore and circular blanket m a n u f a c t u r i n g aids u n t i l all b lankets werefabricated. All gore blankets were t r immed net si/.e except one each ul the inner andouter gore blankets. These were tailored as required to !it the t a n k , ilurin;; the l i n a linstallat ion operation.

7.« iJLANKKT INSTALLATION

The inner blankets of the customized MLI system were p re l imina r i ly attached to thetank (Figure :!-18) at the clean room assembly area, using « \\i white polyester Velcrofasteners manufactured by American Velcro Coin-pany. The ;si/.es and location of thefasteners are indicated in the detailed design, shown in Figures :;-:: and :',-:?. Ho foreinstallation of the Velcro fasteners, the tank surface was cleaned w i t h MKK (me thy l ,ethyl, kctone). A template wilts used to locate the Yelcro i»sitions. A prime coat of1'lybbond 4001/4004 was applied to these positions and was allowed to cure for il-l hours.The pile section of each fastener was bonded to the tank wall with 1'lyobond and washeld in place with masking tape for -•! hours during the room teinpcntture curing p.i-riod.X'elcro hooks, 0. 025 ! m (1 in) •< 0. O.'O^ m<L ' in), were !>o:u!'..! onto l!u: outer blanl-;:.l .s;i rl:;c-jto match the X'elcit) piles on the tank and the outer blanket surfaces. The hooks werebonded with Pi-o Seal 501 adhesive and also cured for 2-1 hours at room temperatun-.The use of local patch type fasteners rather than continuous strips provided ventingpaths and aided in the aligmnent of the blanket sections at installation. Op|>ositc .each fastener, located at the manhole access door, the outer cover shield of eachgore blanket was attached to the Lank door ring using Mylar tape strips as shown inFigure 3-:<, This arrangement provided support for the blankets.

The inner blanket ins ta l la t ion started w i t h the centering and at tachment of the c i rcu la rblanket to the |>ole region of .the t ank by engaging the fas teners . A gore b lanke t wasnext positioned with one end butted f i r m l y to the c i rcu la r , b l anke t and the fastenersengaged. The blanket was then l igh t ly rolled onto the t ank while engaging thefasteners near the gore lines and at the .end near the. tank door. The above techniquewas repeated for the remaining gore sections wh i l e c a r e f u l l y a l i gn ing the but t ; o in t> .Figure-"-111 is a photo which shows the l ank p a r t i a l l y i n s u l a t e d and the m o u n t i n g of

. t h e inner b lanke t Velcro fasteners.- •• A.

StaridarM procedure at Convair is t o t r i n i the f i n a l gore blankets at as.scmbly. At th i st i m e , i f there a rc -any discrepancies , the f i n a l .gore b l a n k e t w i l l be a l te red to ensuretha t there are no gaps or overlaps at the seams. Very i i l t l e a l t e r a t i o n was required

7-ls. The M u t i i f i c d 1. :*i:J in ( ' ' •* ) ini 'I'a

7-l!». IIUHT Cloix- ni:inki:l l.:iyup :ind \ 'clcT<i

on the Cith :nul f inal inner gore. The outer b lanke ts we re- then f i t ted over the inner ,lull i t was decided to t r i m the ( > t h and final outer blanket ai the test s i te . A f t e r l i n i n g ,Ihc blankets were 'remove*! I'rom the tank, stored in sealed plastic b:ig-.s containingdessieaiit, and purged with dry nit rogen.

Although the blankets were assembled in a clean room having an average humid i ty of: > " > , it was deeitled to place the blankets in a heated vacuum chainlx:r ami outgasscd ata tem|)eratuiv of ;t:i!)K ( C ' O H ) befoi-e the blankets were attached to the t a n k . Thisextra precaution was taken in the event that ;iny moisture remained in the silk net .

Alter removal from the vacuum chamber, the blankets were re-bagged and moved toSycamore Canyon Test Site.

At f i n a l assembly.it was discovered that the blankets h:i<! shrunk approximately 0.0032 m(0. 12.r> in) in width. Since the f inal inner blanket had already been t r immed , it wasnecessary to take corrective action. The possibility of stretching the blankets tightlyover the Velcro fasteners and ;tllovving gaps approximately O.OOOS m(0.o:: in) wide toexist was discarded as Ihermodynamical ly undesirable. The problem wa.s correctedby splicing sections of alumini/ed Mylar and silk net with alumini/.cd tape onto oneof the existing gores. The gore was retrimmed so the gap would be closed.

The inner circular blanket was completely rebuilt and was custom fi t ted. Al thoughthese techniques were t ime consuming, complete closure of the seams'was attainedwithout creating thermodynamic shorts caused by having excessive tension on thegores.

Strips of 0.0100 m (0.7") in) wide and 0. O.'JS m (1.5 in) long a luminum Mylar tape wereplaced hor izon ta l ly on approximately 0.152-1 m (G in) centers-on all of the Seams tofur ther minimise gaps and to provide additional strength. F ina l assembly of the innergores is presented in Figure 7- 'JO.

Instal la t ion of the outer gore blankets was the same as that outl ined for the innerblankets except for the addition of the butt joint shields, paint ing at the g i r t h /.one,and the angular orientation to assure ;m offset Ixstwcen the inner and outer butt joints.Three gore blankets were locally notched to clear the t ank supixjil lugs.

Since the f i n a l outer gore was not pre- t r immed, it was ixissible to t r im th i s gore toobtain complete closure (Figure 7-21).

The ver t ica l seams were covered wi th vacuum formed O . l O l f i m (•! in) wide strips oflaminated sheet mater ia l O.OOOOfU m (0.002 in ) Mylar bonded to 0.00002.", m (0 .00] in)a l u m i n u m ] . The strips were held in three places wi th V'clcro fas teners . A s i m i l a rannulus s t r ip was placed over the c i rcular gap and was cont inuously adhesively bondedto the outer gore blankets on the forward side only. 13oth the inner and outer blanketswere ta|>ed to the access door ring at the forward section. F ina l assembly of the outerbhuikrls is shown on Figure 7-22. Finally, after completion of the MLI Installation, a:;.M--' ,OI-C10 velvet coating was applied as shown in Figure 7-4.

7-24

7-'.!0. Inner Cure Hhmket Assembly

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1' POORPAGE IH

TKST FACIUTIKS

All system tests wore conducted at the Conv:iiv Liquid Hydrogen Test Cantor Site "Ji"thermal vacuum facility, 'lias site lies on a 2400-aere parcel ol hind located 19..'! x10J in (12 miles) north of the Kearny Mesa plant, approximately -"2.2 x lO^'m (20 miles)north ol downtown San Diego. The site test complex ha.s the cap;ibility of testing :t widevariety of aerospace systems, components, and materi:ds using l iquid hydrogen or liquidnitrogen as a working fluid, thus providing a complete testing environment.

8. 1 VACTUM C I I A M 1 3 K K

The tesi chamber (Figures S-i and 3-2) was a .'!. < ' . i i m (1-M in) diameter by 4.f m(102 in)water jacketed vacuum chamber and w;is serviced by a O.PI;; m (.'32 in) oil d i f fus ionpump, :t 1.N.I cold trap, and backed by two 1-1.2 nr '/niin iTiOli I ' r ' /min) Kiimey mechan-ical vacuum pump.-:. Controls for these pumps, along w i t h 'all f l u i d system controlsand die data acquisition equipment , were located in a blockhouse aj /pro.xi i iKUelv 2-'! m(000 in) from the test pad.

*.2 TKST TANK PRKSSrUK CON'I'HOL SYSTL.M

The pressure control system-^hown in Figures S-3 th rough S-S was used dur ing tes t ingto control the ullage pressure in the liquici hydrogen lest lank. The system wasdesigned to mainta in the test tank pressure within >. l.:iS N'/ni- (0. 0002 psi) of the setp»int. The MKS Barairon, d i f ferent ia l capacitance manometer. Model- M-T) A l l - 1 (• 1mm llg d i f f . ) was u t i l i / i - d to sense veiy small positive or negative pressure var ia t ionsin the test lank relative to a conshuit reference pressure of a fixed volume of gas,maintained at a eonsUuu temperature. The electrical output of the Raratron systemwas fed to tin.- pressure controller, I):ihl Model C i i O l B , which actuates the Marnmcl-Dahl vent valves Model A I O A located in the test tank vent l ine. Figure S-9 is arandomly selected 1"> minu te segment of the test tar.k pressure recording. A ' b r i e fdescription of the major components is given in the fo l lowing paragraphs.

8.2.1 CAl 'ACITANCK M A X O M K T K U MKS BARATKOS No. Mf. Al l -1 , • I m m ' l l g1)11'FI- . 'KKN'riAI. - The MKS Haralron 'lypc 1 15A capacil:mcc manometer head is atensjoned diaphragm pressure gauge wi th the bridge c i rcui t and preamplif ier insidethi ' diaphragm case. The head was mounted inside a t empera tu re controlled chamberand attached to a 5-15-1 kg (12000 lb) mass block to e l i m i n a t e vibrations. The MKSHaralron Head mounting is .shown in Figure s-G.

8.2.2 SIGNAL C'cNDITlOXKl}, MKS M O D K l . 170 M-7A - This electronic u n i t providedexci ta t ion to the lle.ad, and converted the Mead output to a propor t ional l ) ( ' ' ou tpu t of

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8...2.-J IU1.AKCK niC.lTAL lll^TJW^NHU) K I M / T O ^!~'J1i~ Tilis l l l l i l provided forsetting the nKuumu'ter head output null point anywhere w i t h i n i 1 nun lid of thereference pressure. .

3.2.5 CONTKOLl.KU. D A I H . MODKI . C - « i < » l » - The C-MHH is a throe mode- analogcontroller which permits full time automatic control. It accepts all standard trans-mittcr :uid remote- set-point si

S.2.(i H A M M K l . - D A I I l . V'ALVK_CV_<7^00i,j\iôni-;jLNC). A WA/VS 10/n<7K 12/P tSG^ -This was a .'U<; stainless steel, spline t r i m , ^loho valve w i t l i an air t<> open actuator,nuuiual open l im i t stop, plain bonnet, teflon packing, :uid a micro positioner.

S . -2 .7 H A M M K l . - n A i a . VA1.VK. O'J)- 0 » . _ A l ( > n K _ L X < ) . A-»'>A/y_S_U» ' 'I'f.i.l-'J^/.L'W.Sf'R -Same as Spec. No. 8. '2. <i.

8.2.8 l i K F K K K N C K PHKSSPHI-; C O N T A I N K J t 1CK HATH - Tin- reference pressurevolume ice baili (Ki.nures 8-1 and S-7) consisted of a O.l ' i iti (0 in) dhimclcr , O..'j05 n;(12 in) lontr stainless slot... vessel containing livdroêii pis. This vessel was niounteiiwi th in the inner vacuum jacketed dewar, ft .2~>4m (10 in) diameter ;UK! 0.-1")7 \ - , \ ( \~ in)deep. This assembly was contained w i t h i n :ui outer dewar, 0. 7G2 m (.'{0 in) diameU-r:uid 0. 772 m ('.",() in) deep. Holli dewars were f i l l ed wi th ice, covered w i t h 0. ]0 m (-1 in)thick foam lids and equipped wi th lulies to -siphon water away. The reference pressurevessel was connected wi th the Baratron Head by a O.OCK12 m (0. 125 in) ( ' . ianutcr , 0.000?,-m (0.0o2 in) wall, 2.44 m (OG in) I i> iv4 stainless steel tulx.- . 'I'lie ouiei- dewar siphontube was designed to keep the water' level below the bottom of the inner dewar, and theinner dewar siphon tube was designed to keep the water level below the bottom of thereference pressure vessel. The outer dewar held appro.ximatoly 132 k.U (-100 Ib) ofice and required ;ui additional -55 to (>8 kjj ( l o o to l.">0 Ib) of iec'every :; to -1 oays. Theinner dewar held appi'oximalely 0.9 ktf (2 Ib) of distilled water ice and required anadditional 0. 0!) k-j (0. 2 Ib) every 3 to -I weeks. . . , . . , . -

s.:! G l ' A H I . ) ' I A N K PHKSSURK CONTHO1.

The NUS barostat device was used to control the pressure of the u\iard tank durhrj. then u l l and thermal tests. The NHS barostal was developed by the N a t i o n a l Hurcau ofSt:uidards (NHS) , U 'as l i inuton, to m a i n t a i n constant tank back pressure wi th smallvariat ions in vent âs How rate. .The barostat was used successful ly at N A S A . MS1-Vand at Convair on a 2. 21 m (S7 in) diameter test tank thermal test program ( K e f . 3- 1).Convair's experience in calibration of tlie unit indicates that w i t h an 0.002">-1 m (O. i injdiameti 'r o r i f i ce , pressure control was main ta ined over a kind of • K i . S N \ \ \ - ( . 11.0112psi ) provided the flow rate does not change more than •. u . i i O i H M H m : > > /see (: D. 2 scfnV).

8-11 • ' ' - . '

•\

Tin.- ini t ial predicted guard lank boiloff rate was approximately (i. 01 1 m'Vsec (MO sefm).llecause iif this, the Haroslal was set up wi th a larger 0. Oi-'J in ( O . f i in) diameter orifice.

Figure 8-3 is a schematic of the NliS barostut. The basic principle of operation of theunit is bahuice between the pressure in tlie lower cavity and weights suspended fromtins bellows assembly. In order to reach equil ibrium, die bellows respond to thepressure, from the lank and open or close the orif ice by moving the ball and plungerassembly. This plunder is spring loaded to prevent damage to the lapped orificeseat \vlu-n tlie unit closes. The :unouni of weigh', placed on the weight platformdetermines the pressure at which the unit will control. The upper bellows section isevacuated to provide a constant pressure reference for the com rolling bellows that isnot affected by changes in atmospheric pressure.

During the null test, the guard lank lx>iloff was found to vary from a high of greaterthan 0. 0017 m;5/scc (10 sct'm) immediately after f i l l ing to a low of less th;ui 0.0002-1m:!/sec (0. "> scl'm) a f te r the temperature had stabili/ed (approx. 1'J hours). A f t e rtemperature s tabi l i /a t ion there st i l l remained a large day to night to day variationin the boiloff. This resulted in the need for constant ad jus tments of the I'.arostat controlweights lo maintain tlie required narrow guard tank pressure bond. He fore the start ofthe cuslomi/ed MI. I tests, the Haroslal was replaced w i t h a pressure transducer.'closedloop controller/flow control valve system.

In this system a Slatliam Model IMJ-S'Jli 3-1.5 UN"/ n\- (5 psid) pressure: tnuvsduccr. wasused to sense Iht: guard tank ullage pressure relative to the lest tank ullage pressure.The output of the transducer w;is led in to a Koxboro Model Miii ' closed loop conirol lerwi th variable rate ;uul reset. The process control signal from the controller was thenused to position an Annen Domotor valve w i t h a < ) . < ) ] : ; m (0.5 in.) proportional plug.Kxcept for the f i r s t few minutes af ter f i l l i ng , t h i s system mainta ined the proper guardtank pressure without the need of constant adjus tment .

s. I F l : r i l > SYSTKM

l-'igure8-]o is an overall schematic of the fluid systems required for the thermal test.

The syslems'for the guard tank, payload s imula to r , crvoshroud, and baffles uere fabri-cated and leak cheeked before lest lank installat ion. U 'eh l inu :uid si lver bru/.ing were.nse'd as the principal means of jo in ing parts of (he system. All the a luminum lo stain-less steel lr;;nsilions were made using double seal Conosi.-al flanges w i t h the intersealcav i t y v:'cimr:i pumped to less t.h:m l.'.i'J N/m- (0.01 tori'). A f t e r assembly and in.st.'il-l a l i o n of th.;1 fvsl lank-a complete sec-Lion by section leak check was performed.

To assure adequate performance of the \ a c u u m system dur ing the tes t ing phase, a loia lsysiems leal.; clk'ck.was j ie r formed. Several leaks were found and repaired a f t e r w h i c hno leakage c i -u ld be measured by I he mass spectrometer leak detector.

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r;r:/x v/.cfc ~£ . 3-13POUR ouAi.riY .

The 1'ill l ine lor tin; lest lank extended to the bollom of the t a n k p r ima r i l v ;ts :i sa le tvmeasure; Since the f i l l l ine was guarded at l . l l - j t empera ture , i!u.-n- was no need ioterminate tin* line- in the ullage space. In :m emergency, tin.- t : t nU could have beenemptied through I ho f i l l lino by pressuri/.ing tho l:mk, opening t l io t i l l valve, :indforcing the- lit | iiid back into iho sito storage t:ink. Thu t'ill valve was located immedi -ately outsido tho chamber wal l . This valve was a prupor t ional lv control led globevalvo permi t t ing ; meter ing of the LI I -_» supply dur ing t i l l i n g operations.

The vent lino terni inalecla l thel :uik door. This l ino was also guarded and penetrated thechamber wall at a level just above the cryoshroud. Tho primary tank vent valve tha twas used during f i l l i n g and ini t ial chilldown was also a proportionally coin rolled valve .Alter the f i l l ingt rans icnls disappeared and the te.-l l ank boi lof f had dropped to l< ss t h a n0. (.)<)<; 172 nv!/sec (1 .0 sol'm), the large primarv vent valve was isolated I'rom the ventlino anil vent gases wore passotl through the test tank pressure control system <*. 2i.

The majority of tho components shown in Figure S-10 were remotely operated from ihcblockhouse. A 5.7 nv' (1500 gal) l . l lv; supply l;ink was ma in ta ined at an approximatepressure of - I I . -I k.\ in- (<> ,isig) all the t ime by a-pneimial ie pressure control ler aiv.lvent valve. U'hen empty, the supply tajik was f i l led w i t h l i qu id hydrogen through the I.I!..make-up valve from the l!>. J nv'! ( J o . O O O gal) sito LH0 storage t:u>k 01- 1'roisi the ::. 7-^ ;n:i

(1000 gal) caleli t:uik ilirough the 1. 1 1./ recovery valve. The f i l l rate was l imi t ed toprevent pressure surges in tho t ru ik . The catch t;mk was vented to the a inio-- - ->icrewhile acting as a liquid vapor separator for the eryoshroud, baff les ;uul TPS voi i is .When ful l , it was isolated frorii the cryoshroud, baffles and TPS' vents, pressuri x e < ito approximately 172. 5 kN/m- (-;"> psig), and drmncid into the supply uuik.

In nomial operation the system was able to run for a m i n i m u m of 15 hours beforethe supply l:uik needed to be f i l led or for 5 hours bo.foro ihe c ra t ch t a n k needed to In-emptied. Transfer from the catch to supply tank took less than lf> 'minutes. There-fore, the vents were "recovered" about- 9f>'7 of the time, l-'low through '.he crvoshrouu,baffle, ami the Tl'S (when required by the procedure) was continuous. Vent How wasnormally through the vein shutoff valves into the catch lank. D u r i n g I . I I - - 1 f i l l i n g andtransfer operations the vent shutoff valves were closed and the vent flow dumped u>atmosphere through the vent bypass valves.

The guard t:uik, once it was cold and the temperature stabili /etl , needed ref i l l ing onlyonce evcrv f ive days. Tho guard tajik vent bypass was used only dur ing f i l l i n g . A!oilier t ime's the guard tank venting was controlled by the guard tank pressure cont ro l .The schematic in Figure s M i > shows thai each Uuik a m i - l i n o segment was protected bya relief valve and tha t no l iquid or cold gas could be t rapped in an unprotected cav i ty .

ionMost of the valves which were, operated from the blockho.use required manipula t iodur ing test operations. Since the I . I I ; > Supply T.tnk pressure was consumt throuuho',;;the lost, manual stops on the L l l ; _ > supply valves were i n i . i a l l y a d j u s l e d ' t o provide theappropriate l . l l - > flow to each' segment of the system and remained set dur ing test

3-1

operations. Plat inum resist:uiec thermometers ;mil .thermocouple's ins t ; i lU- i ! on allsurfaces were monitored during trst operations and used lo measure ami controlsystem performance. • • .,

S . f > TKST TANK I I K A T K R ,

An electrical heater (Figures S-ll and 8-12) \vas used tu siniula'c payloail t l icrmalin])ut to the.tc-st tank iluring the null test. The heater \vas desi^iuxl to provide anuLxinium heat How of one wat t into the tank. In order to provide a lar^e enough areato eliminate nucleate hoilinji on the heater surface, the heater was fabricated fromNiehrom Kiblion 1.1IM m (-17 in)loh- , 0.000013 ni (0.002 in) thiek l»y 0.00:!17 r.i (O . lUr ,in) wide. The; ribbon was mounted on two pieees of tormina! Ix ia rd as shown in Figure8-11. The ribbon was divided into ei^ht sepnents and connected in a parallel/scriescircuit w i th a total resistance of approximately one .ohm.

The terminal board was mounted to the lower end of the inst rumentat ioivtree as showi.in Figure 8-12. The triuisition from heater ribbon to a m i n i m u m l(i-irau<;e power leadwas made at the bottom of the tank.

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S-]7 • .

9

TEST INSTRUMENT ATION

9.1 INSTRUMENTATION7 DEFINITION

Instrumentation selection for the full scale test specimen was based upon measurementof the independent and dependent variables required for demonstration of system over-all thermal performance-, system efficiency, and system cuuiponent operation, inde-pendent variables included hydrogen liquid level, chamber.pressure anJ ullage pres-sure. Dependent variables included temperature dis t r ibut ion, M l . I thermal gradientsand LH-j boiloff rate. The instrumentation tree p l a t i num resistors wi th in the tank per-mitted LH2 level as well as temperature measurement. Chromel/Constantan thermo •eouples were used for all other temperature measurements. Chamber and shroudpressure, measurements were made; with hot filament ion gages (Bayard-Alpurt) intheir respective ranges. Liquid hydrogen boiloff flow rates were measured with TSIhot - f i lm anemometers and a water displacement apparatus. Pressures other than thetest t ank pressure were.' measured wi th Statham Strain gage tran.--.duc«.-rs. Test speci-ment instrumentation locations are presented in Figures ! i - l through 9-'i. '( 'al)le !i-'summarises measurement description and location de f in i t i on .

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9-11

9.2 MEASUREMENTS AND ACCURACIES

9.2.1 THERMOCOUPLES - All thermocouples were fabricated from Chromel/Constantan teflon insulated thermocouple wire. Thirty-six gage wire was used on theMLI, on the test tank outer skin, and on the upper surface of the TPS. All othermeaairuig thermocouples were fabricated from 28 gage or heavier wue. All of theMLI thermocouples (Channels 1 thi-u 58, Ref. Table 9-1) were fabricated with the 36gage wire extending from the measuring junction to outside of the shroud where theywere spliced to a 22 gage Chromel/Constantan chamber harnesses that connectedthem to the vacuum chamber passthrough. The seven thermocouples on the uppersurface of the TPS (Channels 59 through 65 Table 9-1) were fabricated with the 36gage wire extending from the measuring junction to a point approximately 0.305 m(12 in) from the edge of the TPS where they were spliced to an Intermediate Chromel/Constantan harness fabricated from 28 gage wire that led to the outside of the shroud.The intermediate extension wire was then spliced to the 22 gage chamber harnessleading to the chamber passthrough. A large but unknov/- part of the ambient to 22K(40R) thermal gradient existed in this 28 gage extension wire. With the TPS at LH2 tem-perature this resulted in a maximum lower temperature reading in these channels (5lJ-65)of approximately 4.4K (8R) when compared with the readings of thermocouples 183,184, and 195 (figure 9-5 and Table 9-1). These three thermocouples were added tothe top surface of the TPS when the vacuum chamber was open between the thermalperformance testing of tin tank installed MLI and-the customized MLI thermal perfor-mance test. With the TPS at approximately 28'JK (520R) the approximate errors wereas follows:

TPS-Radius m (in)

+ Reading K (R)

- Reading K (R)

0.23 (9)

2.1 (3.8)

0.0 (0.0)

O.G6-(26.6)

1.5 (2.7)

0.28 (0.5)

0.83 (32.5)

0.94 (1.7)

1.06 (1.9)

These values wci-e obtained by comparing the readings of thermocouples No. GO/61, 63and 64/65 witli the readings of thermocouples 185,184 and 183 at tK" comparablelocation during the customized MLI thermal performance test.

All die thermocouples with Channel Numbers 1 thru 80 and 181 thru 185 had theirChromel/coppcr and Constantan/copper reference junctions located outside the vacuumchamber in a liquid nitrogen bath. All the thermocouples with Channel Nos. 81 thru127.(Table 9-1) were referenced to the bottom surface of the test tank, the guard tank,or the TPS and cop)x;r wire run out of me chamber. The primary objective ofreferencing these thermocouples inside the vacuum chamber was to reduce errorsby having the large ambient to liquid hydrogen temperature gradient in the pure ele-ment (copper) wires instead of in the alloy (Chromel and Constantan) wires. Sinceonly-one junction in each chanivjl can be grounded, these thermocouples were Installedwith the reference junctions electrically insulated from the metal surfaces with one

9-12

mil Mylar tape. At the prevailing temperature, 21K (38R) and pressure 1.33xlO~^N/m2 (10~( torr) in the shroud, this electrical insulation turned out (o have an extreme-ly low thermal conductance. This allowed the thermal conduction in the chamberharness wires to heat the reference junctions enough to make these channels unusable.Between the thermal perfoi'mance of the test tank installed MLI and the customizedMLI thermal performance test, thermocouples No. 92 thru 116 were rewired withtheir refcience junctions outside the vacuum chamber in the liquid nitrogen bath, afterwhich they read correctly. At this time TC No. 68 thru 71 (Table 9-1) were discon-nected sifc the number of Chromel and Constantan pins in the chamber wall pass-through was limited.

During the warm-up following the customized MLI tests, all the thermocouples weremonitored and there was an indication that channels 36,48, 52,102 and 115 might nothave maintained good thermal contact. After the warm-up, the circuits were resis-tance checked and channels 10,33 and 97 were found to be open circuit or shorted.Except as noted, all the thermocouples had a usable range of 232K (41rR) to 478K (860R).The absolute accuracies were:

22K ( 40R) to 61K (110R) ±1.7K(3R)61K (110R) to 117K (210R) ±1. IK (2R)

117K (210R) to 200K (360R) ±0.55K(1R)200K (360R) to 533K (960R) ±0. 28K (0. 5R)

The repeatability of relative accuracy for any one chnn.icl was:

22K ( 40R) to 61K (110R) ±1 .7K(3R)61K (110R) to 117K (210R) i l . lK(2R)

117K I.210R) to 20CK (360K) i0.55K(lR)200K (360R) to 533K (960R) ±0.28K(0.5R) ,

9.2.2 RESISTANCE THERMOMETERS - All the resistance thei'moinetcrj wereRoscmount Kngr. Co. Model 118F or 118L platinum film resistors. Each resistor-was wired in one of three scries circuits as forows:

a. The first circuit consisted of the nine combination liquid level/temperature probesinside the test tank.

b. The second circuit consisted of the four liquid level probes in the guard t:mk.

c. The third circuit consisted of seven probes, two each of the bottom surface of thetest tank, guard tank, and the TPS, and one on the surface of the reference volumein the inner ice bath.

The nine probes inside the test tank (Channels 141 thru 149) and the four probes insidethe guard tank (Channels 177 thru 180) were fluid measurements a../. .'.».'. '^o following

9-13

ranges and accuracy. As temperature probes, their range was 19K (35R) to ambientwith an absolute accuracy of ±0. 055K (0. 1R) from 19K (35R) to 33K (6CR) and ±0. 03K(0.05R) from 33K (60R) to ambient. As liquid levels their range »vas go/no go with anaccuracy of ±0.00254 m (0. 1 in). The seven probes in the third circuit (Channels 132thru 138) were all skin probes and all except the reference volume temperature wereinside the shroud. As with the thermocouple reference junctions, the prevailingtemperature, 22K (40R) and pressure 1.33X10"5 N/m2 (10~7 torr) inside the shroudresulted in a low thermal conductance between the ceramic coating onthe probe and themetal surface. Because of this, thermal conduction through the instrumentation leadwires made these (Channel 132 to 138) unusable.

9.2.3 PRESSURE - Six pressure .tata channels were recorded:

Channel No. Range, Full Scale . Measurements

153 0-137.88 kN/m2 (0-20 PSIA) Test Tank Ullage (Secondary)154 0-172. 35 kN/m (0-25 PSIA) Guard Tank Ullage155 0-241.29 kN/m'J (0-35 PSIA) Flow Meter Inlet156 0-172.35 kN/m2 (0-25 PSIA) Atmosph.ve

157 ±34. 5 kN/m2 (± 5 PSID) Test Tank/Guard Ullage Differential161 ±0-133 kN/m2* (±1 TORR) Test Tank Ullage (primary)

* Relative to the reference volume pressure.

Channels 153 thru 157 were recorded using Statham Model PA822 bonded film straingage pressure transducers with a total system absolute accuracy of * 0. 5<J? FS and arepeatability or relative accuracy of ±0. 1% FS. The primary test tank ullagepressure measurement (Channel No. 1(>1) was the output from the MKS BaratronModel 145 AII-1 Capacitance Manometer as described in Section 8.2. This unit has anabsolute accuracy, as stated by the manufacturer, of 1. 33 x 10"^ N/m (1 x 10~5 mm hg)an/! a repeatability of 1.33 x 10~4 N/m2 (1 x 10~G mm hi;).

9. 2.4 VACUUM - The chamber vacuum was measured using a Veeco Model RG-840ionization gage controller and a Veeco Model RG 45 ioni/.ation gage tube. The gr , .• tubefilament was operating Continuously throughout the test and the tube was dcgas.^.-;approximately once a day. In the range from 1.3C x 10"1 N/m2 to 1.33 x io~° N/m2

(1 x iO~3 to 1 x 10 torr), the accuracy was better t'-an ± 10% of the scale reading.

The shroud vacuum was measured using a Veeco Model HG-21A ionization gagecontroller with a Veeco Model iiG 45 ionization gage tube. This gage tube filamentwas turned on only while the gage was being read, and the nrcuracy was thereforedegraded to an estimated A 30% of the scale reading. The. recorder outputs on thesetwo gage controllers were not connected to the digital recorder (Channels lt>7 thru171) but were read and logged manually. The chamber pressure was read at 30minute intervals throughout the entire test. The shroud pressure was read at 30

9-14

minute intervals during the first null tost, then roughly daily for the remainder of thetesting.

9.2.5 FLOW - The test tonk boiloff now measurements were faken with a ThermoSystems Inc. Model 1053B-A1 ronstant temperature anemometer (Channels 164 thru16G). A sadden eight to one increase in the test tank boiloff during the first null test(Paragraph 10.1.3) destroyed th.; sensor ana the back up unit was not available. Atthis time a water displacement flow measurement was substituted using a fivegallon glass water bottle inverted over a stairless steel open top tank as shown inFigure 9-7 and 9-8. The \\2 boiloff flowed continuourly through the bubble tube whichcould be slid back and forth approximately one inch'thereby allowing the gas bubbles torise either inside or outside the neck of the bottle. After each reading, the gas siphonand aspirator were used to remove the gas and refill the bottle with water. <Theplexiglas plate supporting the 'x>ttlc was not quite horizontal with one edge 0. 005 m(0.2 in) higher than the other. The bottle siu-facc of this plate was the reference forthe tank water level which was maintained so that the bottom of the plate was partiallybut not completely wetted. A Meylan stop watch (±0.1 minute) \vas used to time theinterval between moving the bubble tube under the bottle neck and when the first bubblebroke outside the bottle neck. The water volume of the bottle (±0.03%) was determinedby weighing the bottle empty and then filled with distilled water"at 295.6K (532R). Thetemperature of the water in the tank and the air surrounding the bottle were measurediO. 55K (l .OR). Since the "stay nine" of the gas in the bcttlc was large (15 to 60 mm),it was very nearly in equilibrium with the outside air temperature. Using a correctionfactor of 532/1. 8K (532/R), the error is less than 0. 3%. Two other sources of errorconsidered were the solubility of Cl\2 in H2O and th»c creation of F^O vapor in the .dryGH£. At 294K (530R) both these effects could causj a maximum error of less than 2%,however, since they arc of approximate];-equal magnitude but opposite sign, theirtotal error will probably be much less than 1%.

9.2.6 POWER - The test tank heater power was determined from separate recordingscf the voltage across the heater leads in the test tank (Channel 1V2), and the voltagedrop across a 1.10 ohm shunt in series with the heater (Channel 173).

9.2. 7 POSITION - The TPS position (Channel 152) was recorded using a Wai daleResearch Co. Model LTD-160-140 linear motion transducer with a range of C to 1. 27ni(50 in). As installed in the setup the total system accuracy was ±0. 0013m (0.05 in).

9.3 DATA ACQUISITION .

Test data for this MLI test program was recorded by using a Dymec digital recorder.Raw analog data from each measuring device was sampled by the Dymcc at variousrates depending upon the tost conditions and data requirements. Data was recordedas raw voltages printed out on paper tape. The decks of paper tape were labeled atthe beginning and end of each test period and assigned a deck number corresponding to anumerical listing recorded in the test engineering data log of test operations. The Dymecpaper tape decks were then transported from Test Site B to the Kcarny Mesa Plant.

9-15

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9-17

10

TKSTING

The lest progrr..n Included three major test categories, (1) null testing, (2) thermaltesting of the tank installed-MLI system, and (3) thorm.il testing of the customizedMLI configuration. Table 10-1 outlines the objectives and conditions of the testprogram. The null tests a.-u systems operation functional tests. These tests wereperformed to verify satisfactory operation of all hardware components includingcryoshrouJ. thermal payload stmu-.lator (TPS), test tank pressure control systemand guard tank and to determine cxtranecu> ''.cat flow., into the test tank. The lhcrm?lpayload simulator was not insulated during these tests.

The purpose of the tank installed MLI test was to determine the thermal performanceof the tajik insulation at a TPS temperature of 289K (520m. The thermal payloadsimulator surface remained uninsulated.

The objective of the eustomix.cd MLI test was to determine the thermal performanceof the tank insulation at a TPS temperature of 2SDK (520R) and three differentdistances (Table 10-1) between tank and TPS. The TPS was insulated.

Figure .10-1 is a simple schematic which shows the test article installed within theeryoshroud. The test facility is discussed in Section 8. The test article consistedof the Lest tank (Sections 2 and 3), associated insulation (Section 7), tank supportsystem (Section 2.2 and 3.2), guard tank (Section 5.5), fill/drain and vent lines(Section 5. 5) between test and guard tank, and the double seal leakage pumpout line(Section 2. 1. 1). A detailed schematic of the test article, installed within the cryo-shroud assembly (Section 5) including TPS (Section 4) is shown in Figure 10-2. ~The

Test Article

Cryoshroud Assy.

Test Facility

Fill/Drain Line

Vent Line

— Guard Tank~ Double Sen i Pump Out Line

Support System

Test Tank S. MLI

Thcrmal'Payload Simulator

Figure 10-1. Test Set-Up Definition

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TPS and BaffleIrr^t'— Cryoshroud +• Baffle

Fill30 Layers MLI

- 10 Layers MLI BetweenTPS & Shroud Bottom

|

Figure 10-2. Schematic of Test Article and Cryoshroud Assembly

assembly of the cryoshroud with the baffles, guard tank and the test tank wasdiscussed in Section 5.G. 1. The assembly sequence of the test setup was as follows:

1. Installation of the MU on test tank.

2. Installation of the instrumentation on test tank assembly.

10-3

3. Installation of plumbing on baffle/shroud-side assembly and leak checkingof the assembly.

•1. Installation of the instrumentation on baffle/shroud-side assembly, shroudbottom, and thermal payload simulator.

5. Mating of TPS to baffle/shroud-side assembly.

G. Installation of the M LI on bottom of TPS.

7. Mating of shroud-bottom to TPS/baffle/shroud-sidc assembly (shroudassembly).

8. Installation of plumbing on shroud assembly and leak checking of theassembly.

9. Mating of test lank assembly to shroud assembly (lest assembly).

10. Installation of test assembly in chamber and mounting of support legs.

11. Installation of plumbing between tost assembly anu chamber, andleak checking of assembly.

12. Installation of baffle and TPS positioning mechanism.

All liquid hydrogen fill and vent lines between the test configuration and the vacuumchamber were wrapped with ten layers of ML1 fastened with aluminixed Mylar tape.The top of the guard tank and the top, sides, and bottom of the cryoshroud wereinsulated with 30 layers of MLI. As shown in Figure 10-2, the MLI on top of theshroud and guard tank was supported directly by the guard tank and the angle ofbraces, and overlapped the sidewall MLI approximately 0 .25m (10 in). Thesidewall MLI was s^wn onto a tubular support structure approximately 0. 05 m (2 in)from the outer edge of the shroud cover. It was applied to the sidewall and extended0.30 m (12 in) below the shroud bottom. The shroud bottom MLI was supported 0.10m ('1 in) below the bottom surface of the shroud by a layer of wire mesh stretchedbetween the shi'oud support legs. Figure 10-3 presents a photo of the test articleprior to installation into the vacuum chamber.

The test tank and guard tank back pressure control system, instrumentation andauxiliary hardware including the pneumatic and electric valve control systems werechecked out. The plumbing lines of the test apparatus were leak checked with thevacuum chamber open and the chamber closed. Several leaks were found andrepaired. An operational check of the total system was performed after an initialpumpdown of the vacuum chamber.

10-4

1 4 6 9 8 1

Fiimre 10-3. Cryoslirotul Assembly Heady for Insta l la t ion In to the VacuumChamber

io-r,

10. 1 NULL TESTING

Objectives and conditions of the null testing are shown in Table 10-1. The test programwas initiated on 30 May 1975. The following sections present 'he null test procedures,test specimen preparation, test results and evaluation of the .results.

10. 1.1 NULL TKST PROCEDURES - The null test procedures were as follows:

1. Adjustment of test tank/TPS spacing to 0.4G in (18 in).

2. Closing of environmental vacuum chamber.

3. Evacuation of environmental vacuum chamber to G.G5 x 10~3 N/m (5x lO"^ lorr).

4. Purging of vacuum chamber with GHe.

5. Purging of test tank with hot GN2 for G hours at a temperature of 333K (GOOR)maximum.

G. Evacuation of environmental vacuum chamber to G. G5x iQ~^ N/m2 (b x 10~U lorr).

7. Supplying of cold trap with LN-2 and evacuation of chamber to below-G1.33 x 10~4 N/mz (1 x 10~° lorr)

8. Cooling of baffles, cryoshroud, and TPS surface temperatures below 27. 8 K(50R) and maintaining of these temperatures.

9. Filling of test taiiK with LH2.

10. Approach of thermal equilibrium at a constant test tank pressure level.Equilibrium conditions are achieved when the temperature re,adings of testtank thermocouples TC-3, -11, and -31 (Figure 9-2) vary not more thani 0. 5(>K (f IF) in 10 hours and the LIto boiloff rate changes not more than0. 5'if, per hour.

11. Maintaining of the environmental chamber pressure at less than'1.33 xiO"1 N/m2 (l 'x 10~6"torr).

12. Maintaining of baffle, cryoshoud, and TPS surface temperatures at less than•27.-8K (50R).

13. Verification of a hydrogen boiloff rate from the test tank of less than 0. 0002-)Kg/hr (0.00052 Ib/hr) which correlates with the NASA required heat leak of•less than 0.0293W (O.TBTU/hr)..

10-G

1-1. Application of 0.2W (0. G83 MTU/hr) to test tank heater, allowing the tank toreach equilibrium and checking that the total boiloff rate (heat input plus leakage)of 0.00185 Kg/hr (0.00408 Ib/hr) agrees with the knoxvirenergy input. Hoiluffrate corresponding to the 0.2W heat input is 0. O O l f J i Kg/hr (0. 00350 Ib/hr).

15. Repealing of^Step 14 with the following heat inputs to the test tank heater:

Heat Input 0. 5\V (1. 70G5 BTU/hr)Total predicted boiloff rate: 0. 00428 Kg/hr (0. 00941 Ib/hr)Boiloff rate corresponding to 0. 5\V: 0.00404 Kg/hr (0.00889 Ib/hr)

Heat input0.4W (1.3G52 BTU/hr)Total predicted boiloff rate: 0.00347 Kg/hr (0. 00763 Ib/hr)Boiloff rate corresponding to 0.4\V: 0. 00323 Kg/hr (0. 00711 Ib/hr)

Heat Input 0. 2\V (0. 883 BTU/hr)Total predicted boiloff rate: 0. 00185 Kg/hr (0. 00408 Ib/hr)Boiloff rate corresponding to 0.2W: 0.001G1 Kg/hr (0. 00:<5G Ib/hr)

10.1.2 TEST SPECIMEN PREPARATION - A series of purging and evacuation cycleswere initiated to remove conclensible gp.ses from the ML1 and vacuum facility. Purnpdown of the chamber was initiated on Friday, 30 May 1975, utilizing the mechanicalpumping system. Pumping was continued over the weekend. Chamber pressure was199.5N/m2 (1.5 torr) on Monday, 2 June 1975. It was necessai*y to back fill the chamberwith air to repair a leak in the second stage of the diffusion -pump. Mechanical pumpingwas resumed after completion of the repair work. The chamber pressure was 13.3 N/m2

(0.1 torr) on .'> June 1975. The main diffusion pump was turned on and reduced the pres-sure to 5.32 x 10~3 N/m2 (4 x 10~5 torr) within 3 hours. At this time number 2 mechanicalpump failed. The chamber was locked up until 4 June 1975 while the pump was repaired.The chamber was back filled with a mixture of 50% air and 50% helium. After a renewedpump down to 33.25 N/m2 (0.25 torr), gaseous nitrogen was introduced through the fillline into the test tank at a temperature of 344K (620R). The hot purging operation wascontinued for 6 hours. On 5 June 1975, the chamber was evacuated and back filled threetimes with gaseous nitrogen to a pressure of 266 N/m2 (2.0 torr). Utilizing the diffusionpumping system on 6 June 1975, heavy outgassing of the system was observed in thepressure range between 4.65 X10~2 and 6.92 x 10~3N/m2 ( 3 .5x iO~^ and 5 .2x lO~ 5

torr). During the weekend days, June 7 and 8, the chamber was left at a vacuumpressure 39. 9N/m2 (0.3 torr).

On Monday, 9 June 19^5, mechanical and diffusion pumping reduced the pressure to2.39 x -10"a N/m2 (1.8 < 10~5 torr) when chilling of the cold trap was initiated. The Cosmodynesupply tank, the catch tank, cryoshroud and baffles were filled with L I I < > n t an approximatevacuum pressure of 1.33 x lO"4 N/m2 (1.0 x 10~G torr). Thermal payload simulator(TPS), guard tank and test tank were supplied with LII2 on 10 June 1975. At the begin-ning of filling the test tank the pressure was 2. 39 x iO~5 N/m2 (1.8 y- I0~7.torr) and1.73 x 10"J N/m" (1.3 •< 10"^ torr) in the vacuum chamber and within the cryoshroud

10-7

respectively. The pressure within the recovery tank was set at 34.7kN/m (5 psig).Filling of the test tank was intentionally performed over a 4 hour and 20 minute periodto avoid leaks caused by the cooldown process. The pressures of the vacuum chamberami shroud at the end of the filling operation (98% full) were 1.73 x iO'5 N/m2 (1.3 x10~7 torr) and 10.4 x in"6 N/m2 (7.8 x 10~8 torr), respectively. Pressures of thetest tank and guard tank were set 113.08 kN/m2 (16,4 psia) and 114.11 kN/m2

(16.55 psia). A pressure differential of 1.03kN/m2 (O.l5psid) between guard tankand test tank was maintained with a tolerance of 0.344 kN/m (0.05 psid) through theentire test operation.

During June 11 the LH2 boiloff rates were still high therefore no flow rate data wererecorded.

10. 1. 3 NULL TEST RESULTS - The actual test activity started on June 12, 1975.The null test was conducted over a period of 218 continuous test hours. Boiloff flowrates and temperature readings of MLI thermocouples TC-3, TC-11, TC-31 (Table9-1 or. Figure 9-2) and TC-62 (Table 9-1 or Figure 9-5) are plotted in Figures 10-4,Sheet 1 through 3. At 0-time the guard tank was 80% full. An unexpected rise of thevacuum chamber pressure to 1.33 x 10~2 N/m2 (1 xiO"4 torr) after 12 hours reducedthe temperature of the test tank uisulatton by gaseous conduction to near the liquidhydrogen temperature level (Figure 10-4, Sheet 1). The sudden rise in pressurewas caused by a loss of oil in the diffusion pump. Fifteen hours after 0-tlme thevacuum chamber pressure was recovered. The test and guard tanks were refilled.

10.1.3.1 Null Test No. 1, Zero Power Input - The first null test was performed toestablish the extraneous heat leak into the test article. The tank pressure wascontrolled within ±0.68947 N/m2 (i 0. 0001 p.=ia) of the set point. A typical plot of thetank pressure control is shown in Figure 8-9. The vacuum pressure achieved withinthe cryoshroud was approximately 1 x 10~? torr. The thermal equilibrium periodbegan 51 hours after 0-time. Test data of the thermal equilibrium period are shownin Table 10-2. All measured hydrogen boiloff rates were corrected as discussed inSection 10.1. 5. An average equilibrium boiloff rate of 0. 00055 Kg/hr (0. 00121 Ib/hr)

Table 10-2. Null Test No. 1, Zero Watt Power Input Boilofi Data During TheThermal Equilibrium Period

Kquil.Hour

01231

TotalElapsedTime.hr

5152535455

LH2

kg/hr

0.0005450. 0005450.0005450.0005450.000545

Boiloff

Ib/hr

0.001200.001200. 001200.001200.00120

Equil.Hour

5G789

TotalElapsedTime.hr

56575859CO

LII2 l

kg/hr

0.0005450.0006360.0005000.0005000.000591

Joiloff

Ib/hr

0.001200.001400.001100.001100.00130

Average Boiloff: 0.00055 kg/hr (0.00121 Ib/hr)

10-8

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was measured during the nine hour equilibrium period. MLI temperatures of thermo-couples TC-3, 11 :ind 31 are plotted in Figure 10-<l (Sheet 1). During the entire nulltest equilibrium period there was no significant change Ln the test tank MLI temperaturesas shown in Table 10-3. The results are discussed in Section 10.1.4. 1.

10. 1. 3. 2 Null Test No. 2 ,0 .2 Watt Power Input - The second null test (Step 14, Section10.1. 1) was the application of 0. 2 watt to the test tank heater to verify a known heatinput into the test tank. The boiloff rate (Figure 10-4, Sheet 1) was increasing slowlyto approximately 0. OOOG8 Kg/hr (0. 00150 Ib/hr) when a rapid increase in flow rate to0. 00273 Kg/hr (0. OOG Ib/hr) damaged the TSI-IA flowmeter, 69 hours after 0-time.For the following 19 hours boiloff readings were taken with the TSI-2G flov/meter(Table 9-1, Channel 165). Those readings were below the operating range of the TSI-2Gmeter after 88 hours after 0-time. A water displacement flowmeter (Section 9.2.5) wasthen introduced and it was kept in use for the remainder of the test operation. Test tankpressure oscillations occurred after the change of the flowmeter. They were reducedby adjusting the sensitivity and reset rate of the Dahl controller (Cv = 0. 010).

The thermal equilibrium period began 51 hours (111 hours after 0-time) after the 0.2watt power application (Figure 10-4, Sheet 2). Test data of the second null test arelisted in Table 10-4. MLI temperatures (TC-3, 11 and 31) are plotter' in Figure 10-4,Sheet 2. A measured average boiloff rate of 0.00151 Kg/hr (0.00333 Ib/hr) was obtainedduring 10 hours of equilibrium condiiiors. During the entire null test equilibrium periodthere was no significant change of the test tank MLI temperature (Tnble 10-5). Al theend of the test the guard tank was approximately 409f full. The results of null test no.2 are discussed in Section 10. 1.4.2.

10.1. 3. 3 Null Test No. 3, 0. 5 to 0.4 Watt Power Input - The third null test (Section10.1. 1, Step 15) was the application of 0.5 watt to the test tank heater. The predictedhydrogen boiloff at this power level was 0. 00428 Kg/hr (0. 00941 Ib/hr). The test wasstarted 122 hours after 0-time when the guard tank was refilled (Figure 10-4, Sheet 2).The increase in flowrate was extremely small. During a 24 hour period (138 10 1(52hours after 0-time) the boiloff rate increased only by 0. 00027 Kg/hr (0. OOOG Ib/hr).It was decided after 40 hours of total test time to reduce the power level to 0.4 watts dueto the long time projected as being required to reach thermal equilibrium. The thermalequilibrium period begun after 2 hours. A measured average boiloff of 0. 00297 kg/hr(0. OOG53 Ib/hr) was obtained during the following 14 hours of thermal equilibrium (104hours to 178 hours after 0-time). Boiloff rates are presented in Table 10-6. MLItemperatures (TC-3, -11 and -31) and boiloff rates are plotced in Figure 10-4, Sheet3. The results of null test no. 3 are discussed in Section 10. 1.4.3.

10. 1.3.4 Null Test No. 4, 0. 2 Watt Power Input - During the fourth null test (Section10. 1. 1, Step 15), the power level was reduced to the original 0. 2 watt case (secondnull test), to establish the repeatability of the boiloff measurements. The test wasstarted 178 hours after 0-time. The thermal equilibrium began 26 hours after the 0. 2watt power input. A measured average boiloff rate of 0. 00194 Fg/hr (0. 00426 lb/hr>

10-12

fhi

t

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10-13

Table 10-4. Null Tost No. 2, 0.2'Watt Power Input Boil o f f "Data During The Thermal Equilibrium Period

Cqull.tour

01Xa4

Iota!EUpsrdTtCTf.-brs

1111121131.1115

LH]

kt'hr

O.OOI510.001M0.001520.001SI0.00150

gBoUofl (k-quii.

Ih/hr li Hour•" I

0.00311 ||0. 0033 J J0.00331 |0.00333 U0. 003.10 |

U 10

TbUlL'lipiedTlmr.hrs

11«1171181191:01:1

LH,

^t'hr

O.OOliO0.001520.00151n. oo 1530.001490.00151

Bolloff

Ih/hr

O.O03301.G0334C.003J2O.O03300.003290. OO333

Av«ri««

0.004

ff: O.OOUl 0033; lt/hr)

0.003'

- 0.002•a<eh.U.3ca

ITvjp o.ooi

o.ow

0.009

0 J0.6

j^ire I')-.'). To si T:mk Healer Power Input Vs TestTaul; Huilol'f Hales During Null Tesling

10-14

was obtained during 12hours of equ i l ib r ium con-ditions (205 to 217 hoursafter 0-time, Table 10-7,luid Figure 10-1, Sheet 3of 3). Thermocoupletemperature data r.t thebeginning ;uid at the endof the thermal equilibriuniperiod arc pieaented InTable 10-8.

10.1.4 EVALUATION OFNl!LL TKST RKSULTS -The results of null testsno. 1, 2, 3 and 4 aresummarized in Table 10-9and plotted in Figure 10-5.

The re suits include themaximum extraneous heatflow of 0. 02iJJ watt (0. 1Btu/hr ) into the test tankwhen the internal heaterelement was turned off. Thetest apparatus was designedto meet this NASA require-ment. A system thermalperformance analysis andthe analytical determinationof all extraneous heat flowswere beyond the scope ofthis work. Ut i l iz ing testdata, the heat leakage wasre-estimated. The com-pon^nts whirh were investi-gated aiid t ' ir ir contributionto heat leakage are listedin Table 10-10.

The heat ? "•k through theMLI was determined byusing the equation whichdescribes the thermalperformance of :

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Table 10-G. Null Test No. 3, 0..4 Watt Power biput Bolloff Data During the ThermalEquilibrium Period

Equil.hour

0i2

3•t507

TotalElapsed'Time, hr

1G41651GC>Ki7Hi9169170171

LH2 Boiloff

kg/hr

0.0029450.0029550.0029590.0029730. 0029730.0029770.0029860.003036

Ib/hr

0. OOG480. OCG500. OOG510. OOG540. 00654O.OOG550. OOG570. OOGG8

Equil.hour

89

1011121314

TotalElapsedTime, hr

17217317417o17 G177178

LH2 Boiloff

kR/hr

0.0030550.0030230.0029450.0029590. 0020550.0029050.002882

Ib/hr

0. OOG720. OOGG5O.OOG18C. 00(551.0. OOG500. 00(5390. OOG34

_l

Average Doiloff: 0. 00297 kg/hr (0. OOG53 Ib/hr)

Tablr 10-7. Null Test No. 4, 0.2 Watt Power Input Boiloff Data During theThermal Equilibrium Period

Equil.hour

012

315G

TotalKlapsedTime, hr

20520G207208209210211

LH2 Boiloff

kg/hr

0.0019410. 0019320.0019450.0019410.0019500.0019730.001918

Ib/hr

0.004270.004250.004280.004270.004290.004340.00422

Equil.hour

789

101112

TotalElapsedT'Tie.hr

*> Y>21321421521G217

Ll\2 Boiloff

kg/hr

0.0019090.0018860.0019500.0019410.0019450.001959

Ib/hr

0.004200. 004 150.00429

.0.004270.004280.00431

Average Boiloff: 0.00194 kg/hr (0. 00420 Ib/hr)

10-16

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10-17

preconditioned-silk net spacer system (Reference 10-1)

S- r'7 - r>7

(10-1)

where

Cs - 8. 95 x 10-° and Cr - 5. 39 x 10~ K for

Table 10-9. Summary of Null Test Results

Null Test Number. -

(wattd) [

i. Elasped Test Time Ran 3* , ^tFl<vr« 10— 4 1 ihoursi i.

.). Thermal Equilibrium Period t -3

(F«ure 10-41 (ftoursi .

4. Predicted Boiloff Hate, •)Kc/hr i lb /h r s i '.0

i. Av«ra«e Measured Doitoff. 0Kg/hr f lb/hrst ;0

•i. Preaicted Heat Ltaxajfe. 0Watts .BTU'hn tO

'T. Average Measured Heat ' 0

Leak^e, Wm* -BTVhn ."{0

^. 'T Deviation Between ; -Predicted and Measured •Boilol'f Safes j

t '?. c"hainixrr Pressure, N/rn" jl.

iTorr: ll

10. Shroud Pressure, N/m- '2.. To rr : (1

1 ! 2

ero

-•50

.0002400052)-

00055Mill)

1)

.063

.2321)

133

33«10'5

4-10"5

0.2

•iO-121

10

0.00195.0. 00403*

0.00151(0. 003.-J)

0. 2293(0. 732>i)

0. 13710. >>387l

-13.3

9.31x10"*

2.0»10-5

9'10-7!!(1 5'10-7.

J

0.4

,0.2

122-179 ! 17D-217

14

O.OO.H7(0. 007 f,3)

0. 00297IO.IH»M:;I0. 42S3

(1.4652)

11

•). 00135iO. 004081

0. 00194,0.00426)

0. .'293(0.7326)

0.357 0.239ii.2;:4> 1 (0 . M70)

-14.4 -4. 4

2.**10~4 (10.6*10"S

1.9* 10"^ ) 1(8. Ox 10" ^)

3. J2X 1 0 " : 2 . 13x 10"^2 - 5 < * l O ~ ' J ' I . 1 < 1 0 ~ 1 i

• Basod on 0. 0293 watts iO. 1 BTt'/hn beat leakage into the test uuk.

Table 10-10. Estimated Extraneous Heat FlowInto the LII9 Test Tank

Component

1. MLI2. T-it Tank Door3. L-\r ;.t;e F"lcuaUon

I in-•1. 16 •:_•' . to Oulslde

T»nk Wall (liottom)S. 3 Tank Supports6. Vent l.lnc7. Fill Line8. H; C.M In Fill Line

Totml

RptSect.

7.22.1.1

2.1.1

9.1

3.2. 1

5.5

5.5

5.5

Heat Leakage

Watt

0.0041'j0. DOOM0.00.1K1

0. 00795

0.007R90. 00.1000.00300f'. 00£WI

0. 02974

BTLVhr

0. OHOf.0.001120.01232

0.02713

0. 02C:50.010200. Ol'l250.000 If,

0. 10153

Bolloff Rat«

K R / h r

0. 0000330. 0000030. 000029

0. OOOOW

n. OOOOC20. 0000240.000024

Ib/hr

0.000073O.OOOOOG0. OOOOS 1

O.OOOH1

0.0001.170. 0000530. 000053

0.0000'i'M ) o.oonnoi

0. 000239 0. 000529

N in layers/m, T in °K, andq in W/m2

or Cs =•-•• 8. OR x 10-1° andCr = 1.10 x 10-11 for

N in layers/in, T in0 R, and q in BTU/hrft2

fTR -- 0.031

The equation does not includeany heat transfer throughinsulation attachments. Thetemperature TJJ ~ 23. 2K(-41 .75H) was determined by-averaging all TC temperaturesat the outer face sheet of theouter blanket shown in Table10-3. The temperatureT,, 20. OK (37.12R) is thesaturation temperature of thehydrogen at the test tankpressure of 113.08 kN/m^(Hi. 4 psia). The heat leakthrough the test tank door(not insulated) was estimatedby performing a simpleradiation exchrjige calculationbetween guard tank and testtank. A maximum &T of0. 55K ( l .OR) was assumedbecause the guard tank wascontrolled at a pressure of1M.11 kN/m2 (1G.55 psia).The value of the cmissivityfor both tanks was assumedto be 0.5.

10-18

The gas leakage evacuation lino which was intended to reduce leakage from the duorl)U'cd ports shown in Figure 2-2, Section H-l'i, F/7 consisted of a ..'I'M stainless steeltube, O.OOG3~> m (0.25 in) diameter and 0 . ' jOOf>m (0. 020 in) wall thickness. The lengthof the tube between door antl guard lank where it was attached to the outside wall was1.52 m ((iO in) . The temperature of the tube at the guard tank location was estimatedto be filK (110H).

Sixteen thermocouple wires, 28 gauge, were attached to the outside wall of the lowerend of the test tank. F.ach wire was G.I m (240 in) long. The temperature "t the hotend of the wire was approximately 11C.7K (210K).

The length of the t h ' ^ e stainless steel tank supports between ijnard and test tank was0.381 m (15 in). The uiamctcr was 0.013 m (0.5 in). Tiv; temperature differencebet'.veen the cold and warm end of the support was 0. ;>5K (1. OH).

• IJoth the vent and fill-line consisted of 30-1 stainK.-.-.- steel tubing, 0.051 ' m (2.0 in)diameter and a wall thickness of 0. 0009 m(0. O.'!.r> in ) . The length between guard andtest tank was 0.35G m (1-1 in). The AT was assumed to be U. r>f>K ( l .UR) .

Finally, the contribution to heat leakage of the stagnant hydrogen gas w i t h i n the f i l l l inewas analy/.ed. The contribution i.s insignificant as shown in Table 10-10. Ilc-at leak-age through the instrumentation wires leading to the l iquid level sensors was alsoinsignif icant . The electrical harness was fed through.,;! separate'lubo in the guardtank to provide good thermal contact and to assure'complete heat removal.

10. l . - l . 1 Null Test No. 1 - Zero Power Input - Table 10-0 indicates that the mea.suredL1I9 boiloff rate was 2. 3 times higher than the estimated boiloff rate. .There are severalreasons for the large discrepancy between measured and estimated boiloff rates. Reasonnumber one is that the predicted boiloff rates were only estimates. A re-evaluation of theheat leaks af te r the testing was not completely successful because of the guard tankthermocouple: failures (Section 9. 2. 1). No allowance was made for heat transfer

• through MLI attachments. The second reason for th? discrepancy was the incompleteoutgassing of the MLI. An extremely slow outgassing of the system is notsurprising at the low temperature levels which were main ta ined throughout this test.Gas conduction heat transfer through composite MLI systems such as the s i lknet /UAMMLI becomes significant at interstitial r- .ssures above 1.33 x IO"1 N/m- (10~G torr) (Kef .(Ref. 10-1, page 8-1). Interstitial pressures up to three orders of magnitude'higher thanthose maintained within the surrounding vacuum environment can exist in composite MLIsystems for relatively long times (i .e. , for days or even weeks) duo to continuedoutgassing of water vapor. However, it must be realized that the estimated heatleakage through the MLI is only 14 percent of the total heat leakage into the tank (table10-10).

10-19

A third and major reason for the discrepancy between the predicted and measuredhoilbff rate may be the additional heat transfer through the vent and fi l l line causedby thermal acoustic oscillations. Such thermal acoustic oscillations produce largeheat leaks to stored cryogens (Hef. 10-2). Pressure oscillations also occurred duringthese tests.

In general, the temperature and boiloff measurements taken during the equilibriumperiod were stable and within the selected thermal equilibrium criteria (Section 10. i. i).

10. 1. 4. 2 Null Test No. 2 - 0. 2 Watt Pow".Input - The power application of 0. 2 wattduring the first eight hours (Figure 10-4) resulted in an average LH? boiloff rate ofapproximately 0.00008 kg/hr (0.0015 Ib/hr). After eight hours (G9 hours after 0-time)the boiloff rale increased sharply to 0. 0059 kg/hr (0. 013 Ib/hr). The rapid rise of theboiloff rate was caused by a sudden onset of convectivc currents which destroyed theinverse stratification where the fluid layers on the bottom of <he tank were hotter tluuithose on the top. The inverse stratification was created by the internal lank heaterlocated at the bottom of the tank. The tank fluid was capable of storing the incomingenergy Irom the heater for a period of eight hours. The energy was then suddenlyreleased through the top surface of the fluid causing the sharp increase in LII-> boiloff.As shown in Table 10-9, the average measured boiloff rale was 18. 3V! lower than thepredicted rate. Since the operation and the performance of the test equipment andfluid system remained unchanged, the lower boiloff rate can only be explained byassuming that a portion of the energy created by the internal heater was storedwithin the bulk of the fluid, waiting for convectivc currents to be carried throughthe liquid/gas interface. .

During the thermal equilibrium time of 10 hours, insulation temperatures (Table 10-5jand hydrogen boiloff rates (Table 10-4) were very'stable and within the equilibriumcriteria. A comparison between insulation temperatures of null test no. 1 (Table 10-:?)with those of null test no. 2 indicates that the temperatures of test no. 2 are. higheronly by a fraction of a degree.

10.1. 4. 3 Null Test No. 3 - 0. 5 to 0. 4 Watt Power Input - The objective of this testwas to determine the 1.H9 boiloff rate for a power input of 0. 5 watt. The predictedboiloff rate at this power level .vas 0.00428 kg/hr (0. 00941 Ib/hr), (Section 10. 1. 1).A io i lof f rate (Figure 10-4, Shtet 3) of approximately 0. 00318 kg/hr (0. 007 Ib/hr) wasachieved a r 'er 1G hours (122 to )38 hours after 0-time). An additional 24 hours (138 lo1(12 hours after 0-time) of testing increased the boiloff rate to 0. 00332 kg/hr (0. 00730Ib/hr) . At this rate increase (i.2:3Xi:r0]b/hr/faer}iour) the predicted boil of 1 rate wouldhave been achieved in 221 hours, not considering the asymptotic behavior of thecurve to achieve thermal equil ibrium. In order to obtain a thermal equilibrium

10-20

in a reasonable amount of time the power level was reduced from 0.5 watt to 0. 1 wall.Thermal equilibrium was achieved after two hours. As shown in Table 10-ii, thepredicted boiloff rate at this power level was M.4% above the average measuredboiloff rate. This indicates again that a portion of the incoming energy was absorbedby the LH2 storage system. The mixing process was not complete. An assumptionthat energy was absorbed by the LH2 fluid during tht ortho to para cc-nversion processwas ruled out after a discussion with Air Prociu'-cs Company. This company assuredthat liquid hydrogen is delivered to NASA ar.d guaranteed to be 99. 5?f: parahydrogen.

10. 1.4.4 Null Test No. 4 - 0 . 2 Watt Power Input - For the Null Test No. 4 the powerlevel was reduced again to 0. 2 watt to determine the repeatability of boiloff measure-ments at this power level. The average measured L1I2 boiloff rate (Figure 10—r.Sheet 3) during the thermal equilibrium period was -1. -1% above the predictedboiloff. .

10. 1.5 FLOW RATE CORRECTIONS - Theoretically the null test was to provide thecorrection for any constant offset in the flow rate. It was therefore assumed that run-now measurement made under some standard sei of environmental-conditions would heinherently correct and that any further correctio-s would be made only for deviationsfrom this standard environment. After the thermal performance test (Section 10.2)it was obvious that there was a 24 hour cycle in the measured flow rate. During the-customized MLI testing (Section 10.3) it became obvious that there was a secondperiodic variation that coincided with the guard tank liquid level. An effort was madeto derive an exact theoretical equation for correcting the How rate. Three mainsources of errors and the factors that might affect them were considered.

1. Heal changes in the liquid to gas transition rate inside the test tank.

a. Creation and destruction of liquid stratification.b. Variations in test tank pressure.

(1). Temperature of Bar°tron gage.(2) Temperature of Reference volume.(3) Leakage from Reference volume.

c. Test tank heater power.d. Guard tank/test tank A temperature.e. Conduction through -

(1) Instrumentation wires outside test tank.(2) Instrumentation wires inside test tank.(3) Leakage evacuation.(•1) Metal walls of, and gas inside, fill and ven*. lines.

f. Radiation through fill and vent lines.g. Thermal acoustic oscillations of gas in fill and vent lines.h. Variations in chamber pressure.

10-21

2. Leakage in or out of test tank. •

a. To vacuum chamber. ' .b. From guard tank. . ' - •c. To'atmosphere. .d. Apparent leakage due to temperature expansion and contraction of the gas in

the plumbing outside the vacuum chamber.

3. Measurement errors.

a. Effective volume of water displacement bottle.b. Temperature of gas in water displacement bottle.c. Pressure of gas in water displacement bottle.d. Solubility of hydrogen in }\oO.e. Creation of water vapor in water disnlacement bottle.

A number of these factors can be eliminated as being,

1. Non-cyclic.

2. Too small to be meaningful.

3. Highly improbable.

The correction functions for some of the remaining factors can be derived exactly.For others, the form of the correction function can be closely approximated but then-is no way to evaluate the constants. For the remaining terms, even the form of thecorrection function cannot be determined with any certainty. It was therefore decidedto derive the simplest empirical correction that would minimize the periodicvariations. The resulting correction was of the form

-^ 1.5

where

Qc = flow rate corrected , (SCFII)

QM - flow rate measured , (SCFH)

I t ime (hour) Q-^j was taken

'fiTF'"" tinic (hour) -ul last guard tank f i l l i n g

U : ambient air temperature near water bottle at t-1VO-?2

A = constant - 0 for 0 <(t - IQTI.-) £ •»" hours

A = const:mt = 0.0000^5 for 40 •-(t-tGTp> hours

Of all the environmental conditions and test setup operations, the outside air tempera-ture had the overwhelming correlation with the 2 1 hour cycle. Because of thermalinertia, a term containing the time derivative of the air temperature might haveprovided more consistent results. For simplicity a time offset in the air temperaturewas investigated and indeed consistent results \\ere obtained by using the air tempera-ture from one hour previous. In actual use, the exponent in this term wa*> neverevaluated, but instead a table of F-j- (Flow Correction Factor) versus Air Temperature(Table 10-11) was generated so that

FT - A (t-' (10-:; i

Since the guard tank liquid level sensors were discreet point go-no go, the liquid levelwas known only at the instant it was 20,10, f i O o r 3<i' . ' . However, these points in t im--were found to bo highly repeatablc functions of time following guard tank fill. There-fore, the empirical correction factor for the guard tank liquid level was generateddirectly as a function of time. The change in the correction factor constant at-10 hourswas because the fill and vent line thermal traps and the contact wi th the instrumentationwires on the outside surface did not extend all the way to the top of the guard tank. Assuch, the guard tank liquid level could drop to approximately S5'V before any significantincrease in heat leak occurred. The standard conditions (Qc - Q^j) were at an airtemperature of 295. OK (5321?) and with the guard tank liquid level greater than 80'.',.

10.2 T H E R M A L TESTING OF TANK INSTALLED ML1 SYSTEM

Objectives ;uid conditions of the thermal test of thetank installed MLI system are presented in Table10-1. This test was initiated on June 21, 1975, 220hours after the beginning of the null test program.

Thn following sections present the test procedures,test specimen preparation, test results and evalua-tion of the results.

10.2. 1 TANK INSTALLED MLI TEST PKOCEDURE-Thc procedure was as follows:

1. Test tank/TPS spacing: 0.457 m (18 in).2.. Mainta in environmental chamber pressure

at less than 1.33xi(H N/m2 (](rGtorr).::. Apply.0. 2 \V (0. (i.33 BTU/hr) to the test

tank heater and maintain this powerlevel.

Table 10-11. Flow CorrectionFactor (Fj) for AirTemperature " K (° R)

K

510511512513SUSISS1651751S5195:05215225?35-4

526527

5295.1053,

K

283.3283. 9284.4285.0265.0286.1286.7287.2''.(

268.32S5.!/2?9.4290.0290.6191. 12M.7292. i29i. f.2D3.3293.9294.4295.0

»T 1

.070

.06C

.063

.060

.057

.o:.4

.051

.047

. i ' l-4

. 041

.0.15

.CMS

.0.12

.02f

...

.01!-

.016

.013

.UC»

.006

.003

R

532533534535

i37535539540S4Iiti54.1544545OK,

lH54B

J550551552

I 55,3

K

295.6296.1296.7297. L'•!97.629S.3295.9299.4300.1300.6101. 1301.7JOi.2.10::. '301..1301.9.104.430 5. v305.6.106.1306.7.107.1'

FT I1 . 000 '•

0.947 .0.0'Jl !0.9'JI |0.9SS jo.9«: '0.9-.J j

•0.971 ,O.S7». i0. '.•,'! i0. f'7n J0. 0''.-tl.'j:', \0. '.'•;.' 1O.-JV.' i0. 9.'.0o.-s.:: i•l.'j.M.' i

0.941 '

o. snii !

10-23

-I. Maintain baffles and cryoshroud temperature at less than 27. 8K (SOR).5. Heat TPS to 289K (.r>20R). . '(j. Allow test lank to reach thermal equilibrium at a constant pressure level.

Kquilibrium conditions are achieved when the temperature reading of testtank thermocouples TC-3, -11 and -31 vary not more than -i-lF in 10 hoursand the liquid hydrogen boiloff rate changes not more than 0.5" per hour.

7. Measure I.ii2 boiloff rate of the test tank..8. shutdown test facility.

10. 2. 2 TEST SPECIMEN PREPARATION - Test specimen preparation was notrequired. The thermal test of the tank installed MLI system was conductedimmediately after the null tests without increasing the vacuum chamber pressureor refilling the LH? test tank. The thermal payload simulator heater was turnv<: on220 hours after 0-time.

10. 2. 3 THERMAL TEST RESULTS - Liquid hydrogen boiloff and temperatures ofthe tank insulation thermocouples TC-3, -11, -31 {Figure 9-3 and Table 9-1) areplotted in Figure 10-0, .Sheet 1 and 2. The specified thermal payload simulator.temperature (TC-62) of 289K (520R) was achieved after 18 hours (238 hours after0-timei. The test continued for 13-1 hours (372 hours after 0-lime) at which timethe boiloff rate was 0.01086 kg/hr (0. 0239 Ib/hr) and dropping at the rate of 0. Ifr .V/hr.At that time the decision was made, with concurrence of the NASA COR, to terminatethe test due to the projection that additional weeks would be required to achieve atrue equilibrium condition. The final 28 hours of testing resulted in an averagemeasured boiloff rate of 0.0114G kg/hr (0.02521 Ib/hr), Table 10-12. Temperaturetest data at 2;10, 290, 344, and 372 hours after 0-time are presented in Table 10-13and 10-14. The guard tank was refilled 45 hours after the test began and indicateda liquid level of 60% towards the end of the test.

10.2.4 EVALUATION OFTHERMAL TEST RESULTS-The drop of the test tank boil-off rate of 0. 15% per hourleads to the conclusion thatthe insulation was again out-gassing. The temperature of289K (520R) at the TPS sur-face caused an increase in thetemperature and pressure ofthe trapped gases within theMLI layers. The result wasan increase in heat conductionand L.H2 boiloff. Figure 10-6,Sheet 1 of 2 and 2 of 2 showsthat the boiloff rate increased

Table 10-12. Thermal Test of Tank Installed MLIBoiloff Data During the Final 28 Hour Period

Ecjuil.Hour

017j

4

b

6

8ft

in11121314

Total Klspxxi I.M.. 1Time, hr • tc 'hr

341 ' 0.0117:13J5 i I.Oll'.l.31.: • n.or.ir.a:7 j o.o n isy:s ' o . \ > i : : i

' afj j ".or-;:j:.o I o.o -.:..,351 | ll. 011W352 ! o.oirt':333 ! O .Ol l iO354 | n. on:.!>300 j n. nn.'-o356 • o.0!;:,n357 ; 0.01173358 ; 0. Oil if,

••;:•n

i..u.II.

I I .

•).

n.0.

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II 1 Kqull^jTol*! Klip-a-j] l.;i.. FI, i!..|lhr Moui TUnc. Sr j Vt !-.. H, hr

•::osT.M

^ •:.••£•••'.}•:::.!•'.' »S

•r."i'>..-;.; ••L'iO

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0.0:53

«. 02530.0255a. 02i8•1.0261

15 ' 359 i 0. n i l ' - ' i ; f-.oj55\*i ]i 3CO ' o.o; n: i ' i .oL'r?n I' 361 ! o. OIK,-* | o.n^r.:18 jj 362 | o. un.vj | '..(.::,'.19 j 3S3 i 0.-' •» | O.»j-.-,20 'J 364 . 0. » ,177 , 0. TJ.VI•J\227.12425262714

36i O . O l l C i i 'l.lr.T.i

366 o.onir . j o.i.;:,2307 • 0. Oil.".:' I 0..''. 193«s 0.0! 132 ' 0. UMM3C9 .' 0. OII2. ' i j O..''.'l7j70 ' 0.010'jO ! u ."2 l l '371 O.C10V5 ! O.r'. 'll372 I 0. Olbet j 0.1)233 •

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10-24

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10-28

for 9-1 hours-before it started fall'.ng again. The readings of thermocouples TC-3, -11and -31 at the outer face sheet of the inner blanket indicated a rise of the "temperaturefor approximately" 70 hours. The temperatures remained at this level for an additional20 hours before they deereased agair. This trend is also true for the remaining TCreadings along the tank as can be .<«ho\vn in Figures 10-7 and 10-8, The figures arctemperature distribution plots of 2-10, 290, 31 -1 and 372 hours, after 0-time. The riseof temperature forced the frozen interstitial gas molecules such as water, air ornitrogen, to vaporize resulting in higher heat transfer by conduction. A combinationof higher conduction and lateral heat transfer through the MI..1 layers forced tho ML1temperature to drop again. A typical example <>f the combination heat transfer isprovided by (hennocouplc TC-:il, (Figure 10-(i, Sheet 2 of 2). The temperature atthat location started to fall slowly and then sleeper. This indicates a .combinationof lateral and gaseous conduction heat transfer. The temperature changes of TC-32at the inner face sheet of the inner-blanket next to the tank were relatively small asexpected. The temperature variation is shown below;

Hours After 0-TimeTemperature

210 290 .3-1-1 3722C,.8(-18.2) :!5.(i (G-J .O) ° K (° H)

Figures 10-7, 10-8 and 10-9 show that the temperatures along the outer face sheet of theouter blanket rose most significantly in the lower hemisphere (!><> to 180 degree location)due to radiation heal transfer from the heated, uninsulated .thermal payload simulator.The temperature slope of llie. remaining thermocouples became steeper at the l dcgrooto ISO degree location, slnVA'ing again the influence of gaseous conduction between theradiation shields. During the cool-off period of the radiation shields the. l . l lo'boiloff ratedecreased , as expected. A continuation of the test (for days or weeks) beyond 372 hoursafter 0-time would have resulted in a stabilization of the flow rates.

The final heat flow rates were cstimzited utilizing the MLI heat transfer Equation 10-1(Section 10.1.4). The calculation was performed by subdividing the tank in seven nodesections for which the temperatures of the outer face sheets of the outer MLI blanketswere known by thermocouple measurements. The average temperatures (figure 9-2and table 10-2G) used for the calculations were as follows:

TC-1 -5 -9 -13 -17 -21 -2S/-2964.0(115.2) 60.9(125.8) 76.9(138.4)101.2(182.1) 133.1(239.6) 153.2(275.7)163.1(293.5)

The calculation resulted in a heat flow rate of 0.3519 watts (1.201 BTU/hr). This cal-culation does not include heat leaks through Insulation attachments, extraneous heatleaks, the 0.2 watt (0.683 BTuAr) power Input to the Internal heater and heat leakscaused by thermal acoustic oscillations.

10.3 CUSTO.MI7.KD MLI T H E R M A L PF.KFORMANCF. TKST

The objective of the "customixcd" MLI test was to determine the thermal performanceof the lest tank insulation at a TPS temperature of 289K (5201?) and a TPS/tOst tank

10-29

sto

ISO

160

410

360

310

260

ZIO

160

110

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-50

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1 UUTKH FACE SIIKET - OIITEN UI.ANKET2 INNKI l V A C K .SIIKKT - UUTEH H I . A N K K T

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x

20 40 00 RO loo

TANK UM'ATMN.

10-7. Tt'St Tank M I . l Temperature Distribution at 2-40 and 'J90 Hours After 0-Tinit:

110

200

110]

ItiO'

.140-yH

i 100

80

410

•MO •

310

20

no

-100 -

-150 •

>• -200

-Z50

10

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80 100 120

TANK Lf iOATION,

re 10-8. Test Tank MI. l Temperature Distribution at 3-1-I anil 372 Hours After 0-Time10-30

220

. 2CO

ISft

120

100

410

160.

310

2CO

K. 210

ICO

no

60

20-'

-60

-too •

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-200

.-250

l-<:K•e -300

-350

-400

OUTKH FACE SIIKKT. - OUTER BI.ANKKT( N N K R FACE SIIKKT - 1NNKII BLANKfTOUTE'H FACE SIII:I:T- IKNI:H IH.ANKET

NOTE: NUM1IEH IN DIIACKKT INDICATESUK: A Ti<>.'j or TC: IK: TASK is DKGKKKS

240 260 280 300 320 340 3C" 380 TIME, hour*

Figure 10-9. Test Tank M l . I Temperature Distribution Between 210 and :|72 (foursAlter »-Time

spacing of 0.457m (18 in), 0.305m (12 Ln) and O.i52m (6 in). During this test threeMl.I blankets (Sec-lion ii) were installed on the surface of the thermal payload simulator,lioth inner ;uid outer test tank MLi blankets remained on the test tank. The detailedlest objectives and conditions are presented in Table 10-1. The "customized" Ml.Ithermal performance task was initiated on July 22, 197:") and completed on August in,19,'.1. The total' test time was 719 hours. This t ime included two null tests, one at thebeginning and one at the end of the test operation. All tests were conducted utilisingan 0. 2 wall power input to the test tank heater to promote fluid mixing within the tank.

The following sections present the test procedures, test specimen prepa. ation, testresults ;md evaluation of the test results.

10.3.1 (M'STOMl/ED MLI TEST PUOCEDURE - The procedure was as follows:- 1. Open the environmental chamber . .

2. Install the thice MLI blankets of the TPS (Section 6), utilizing three accessopenings Ln the cryoshroud.

3. Tank - TPS spacing 0.457 m( 18 Ln).

4. Close environmental chamber.

5. Pimp down environmental chamber to G . G 5 N/m^ x 10~3 (5 x 10~5 torr).10-31

G. Puri.-'chamber with GHe

7. Purge tun!; with hot GNo f»r (i hours at a temperature of 333K (GOOH) max.

• -4 2 -C8. Pump down environmental c lumber to 1.33 x 10 N/m ( i x ] 0 torr).

9. Cool baffles, cryoshroucl and TPS surface temperatures below 27. 8K (5011)and maintain these temperatures.

10. Fill test lank with lAlo-

11. Apply 0.2 \V (0. tiS3 BTU/hr) to the test tank heater :uid maintain this powerlevel during the null and eustomi/.ed M 1,1 testing.

12. Allow test t:mk fluid to reach thermal equi l ibr ium at a constant pressurelevel. Kqui l ibr ium conditions arc achieved when the temperature readingof thermocouples TC-29 (Figure 9-2). TC-38, -17,. :uid-5.1 (Figure 9-4)van' not more than • 0. r>fiK ( t l F ) during a 10 hour test period and the LH->boiloff rate .changes not more than 0. 5'V per hour.

—'1 2i:t. Maintain environmental ch:unl)er pressure at less than 1.^)3x10 N/m"

( i x i o torr).

II. Maintain baffles, cryoshroud, and TPS surface at less than 27. 8K (50H).

!;">. Conduct Initial null test. Check that the" boiloff rate at the 0. 2 \V powerlevel agrees wi th the previous boiloff rates obtained during the previous nu l ltesting (Section 1 0 . 1 . 3 . 2 ) . -

Hi. Heat up TPS to 2S9K (52010.

17. Allow test tank fluid to reach equilibrium using the same criteria as requiredin Step 12. Determine I.Ho boiloff rates for custom!/.cd MI I Test No. 1.

18. Adjust TPS/test t:mk spacing to O.oO.J m (12 in).

19. Maintain TPS temperature at 289K (52011).

20. Allow test tank fluid to reach equilibrium using the same criteria asrequired in Step 12. Determine I - H 2 b°iloff rates for customized M1.ITest No. 2.

21. Adjus t TPS/test l:uik spacing to 0.102 m (G in).

22. M a i n t a i n TPS temperature at 239K (520H).

23. Allow test tank f l u id to reach equilibrium using the same criteria asrequired in Step 12. Determine LIN boiloff rates for eustomi/ed Ml.ITest No. 3.

10-32

21. Conduct final null lest. Kepcat Step 15.

25. Shut down test facility.

10.3. 2 TKST SPECIMEN PHKPAKATTON - After cor-nlc.lion of the "Tank Installed MLI"thermal test (Section 10.2), the vacuum chamber was opened. Three pie-fabricatedMLI blankets (Section G) were installed on the TPS surface util izing thru I.- access open-ings in the cryo shroud.' These blankets were required for the "Customized MLI"thermal performance test. While the vacuum chamber was open, thermocouples TC-181 and TC-182 (Figure 9-3 and Table 9-1) were added 0.33 m (13 in) and 0.381 (15 in)from the outer edge of the cryoshroud ltd. Thermocouples TC-183, -18-1 and -185 wereinstalled 0.08!) m (3.5 in), 0. 23<J m (9. A in) and 0. 686 m (27 in) from the outer edge ofthe TPS.

The vacuum chamber was then closed and prepared for pump down. A series of purgingand evacuation oyeles were initialed to remove condensible Base's from the MLI andvacuum facility. During the initial pump down on July 11, 1975, the vacuum chamberwas evacualed from atmospheric pressure to a pressure of approximately 199. 5 N/m~(1.5 torr) u t i l iz ing two mechanical vacuum pumps. The chamber.was back filled withgaseous hc-lium to a pressure of 13.8 kN/m- (2. 0 psia) and left in this condition unti l July.1-1,1975. I'sing the mechanical pumping system, the chamber pressure was reducedduring that day to -4G.f>5N'/m- (0. 3:3 torr). Towards the end of the. working day, thechamber was back filled with gaseous helium to i:'>.3 kN/m- (2.0 psia). It remained ;'•.<th is pressure during the night. On July 15, the chamber was pumped down to a pressureof 0.53\'/ni~ (0. OO-l torr) u t i l i z ing both the mechanical and diffusion pumps. The chamber,was pressurized again to 13. 8kN/m- (2.0psia) and left in this condition u n t i l the morningof July 1 < > , )!)75. During this day the test tank was heated with gaseous nitrogen for aperiod of (i hours, at an inlet gas temperature of 33-1.-IK (G20R) and a gas flow rale of7. 09kg/hr (15. ( i lb /hr ) . The thermal payload simulator surface was kept at a tempera-ture of 337.2K (G07K). At the end of this day the chamber was evacuated to 7.38 • l<>- : }

(i; -. 10~'> lorr) and then back filled wi th GHe to a pressure of 13. 3 kN/m- (2.0 psia).•Chamber evacuation and back fi l l ing of the chaniber wi th gaseous helium was repeatedduring July 17 and 18. The chamber remained under a helium pressure of 13. S kN/m-(2. 0 psia) din-'ng July 19 and 20. On July 21 the chamljer was evacuated to 5. 32 •• irr-'N/m- (-1. > H. ' torr) ut i l iz ing the diffusion pump and cold trap.

10.3.3 CUSTOMIZED MLI TKST RESULTS - :

10.r!.3. 1 In i t i a l Nul l Test - The actual test activity starlet' m .July 22, 1975 wi th the i n i t i -a t ion of a null test. The; spacing between TPS and test tank was 0.-157 m (IS in) . A f t e rf i l l i n g Ihe cryoshroud, baffles, TPS,guard tank and test tank with liquid hydrogen the cryu-shroud vacuum pressure was approximately 5.32•• 10" : )N"/m~ (•! • 10"7 torr ) . I'ower inputto the lest tank was maintained at 0.2 walls. Forty seven hours after 0 - t i m e i t u a s deridrdto back f i l l the chamber wi th gaseous helium to a pressure of 2(i. <iN/m : ' (0 . 2 torr) in order to

establish :i high heat transfer rate to obtain a qu'ck chilldown of the MLI. The rapidtemperature drop indicated by the TPS-MLI thermocouples TC-38, -17 and -53 (Figure9-5) and the test tank i%iLI tlv .-mocouples '1C-29 is shown in Figure 10-10, Sheet 1.This, technique reduces the long hold time which is otherwise necessary to achieve thermalequilibrium. A vacuum pressure of 1.33x 10~^N/m2(l:- 10~ f>torr) was recovered after :!hours. The null test was conducted for 91 hours (Figure 10-10, Sheet 1 and 2) at which timethe boiloff rate was 0.00278 kg/hr (0.00612 Ib/hr) and dropping at the rate of 0.2'.i perhour. A1, that time the decision was made with the concurrence of the NASA COR toterminate the null test. Temperature changes of the selected thermocouples and thedecreaseof the boilof iate were within the lest criteria for the final 1<> hours of tes'ing(75 hours to 91 hours after 0-time). This period was therefore selected as thethermal equilibrium period. The IA12 boiloff data are shown in Table 10-15.The average boiloff rate during this time was 0.00283 kg/hr (0. 00(;23 Ib/hr).Temperature distribution data at beginning and end of the thermal equilibrium periodare presented in Table 10-1G.

10.3.3.2 Thermal Test No. 1, 0.457 m (18 in) TPS/Test Tank Spacing -.The tempera-ture of the thermal payload simulator was raised to the required 283.9K (5201?) onJuly 2(5, 1975 to start the first customized MLI thermal performance lest (Figure 10-10,Sheets 2 and 3) with the spacing of 0.457 m (18 in) between TPS and test tank. Thepower input to the test tank heater was maintained at 0.2 walls. The lesl was completedon August 4, 1975. The thermal equilibrium period !x-gan 238 hours after 0-time (Figure10-10, Sheet -1) and was conlinued for 73 hours (Figure 10-10, Sheet 5). The averageboiloff rate during Ihe equilibrium period was 0. 00355 kg/hr (0. 00730 Ib/hr). Liquidhydrogen boiloff rates and temperatures are shown in Table 10-17, 10-18, and Figure10-10, Sheets 1 through 5.

Table 10-15. Initial Null Test -0. 2 Watt Power Input, Boil-off Data During Ihe ThermalKquilibrium Period

Kqull.

Hour

0

1

2

3

4r,

t',

7

19

in1!

1?

1.1

I 1

10

1C.

Avcr:i;:<

1 -Ml Mil'*.-.! i

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7 j • u. '

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77 '».i

73 !•).'

70 ' O . C

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SI ' 0. l

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S4 |0.r

SO «.(•iu

fi7

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..r,-C.n««31b,-h,,:

10.3.3.3 Thermal Test No. 2, 0.305 m (12 in) TPS/TestTank Spacing - The TPS was moved from the 0.-157 m(18 in) to the 0.305 m(12 in ) position on 4 August 1975,315 hours after 0-time. Except for the TPS position,the test conditions were the same as those of thermaltest no. 1. The thermal equilibrium period began 429hours after 0-time, (Figure 10-10, Sheet 7) and continuedfor 51 hours until 480 hours after 0-time (Figure 10-10,Sheet 7) on 11 August 1975.

The average boiloff rale during the equi l ibr ium periodwas 0.00358 kg/hr (0.00788 Ib/hr). Boiloff rates foreach hour of testing are shown in Table 10-19. Thetemperature of MLI thermocouples TC-53, 47, 38 and2.0 and the TPS temperature (TC-183) -,rc- presented inFigure 10-10, Sheets 5 through". Temperature distr i-bution data at the beginning ;uul end of the thermalequil ibr ium period arc shown in Table 10-20.

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C O O O C-1 C

c o o cr c o

X '3MnJ.VJI3.IK3J.

10-41

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10-1'J

!-'„"' " !!' a ~{: pi • i • f - ' ! • j'H • j:n-:4 i£i7.-prn'TW;-j 4"^:Z?l*?r : '~ i "I""1'• "|'~rTT7n • "Jj >77- •!'Tr!TFTTFnT:T v. 7r" i" : r § i y.'~T:r::' :"uJrTiijjr H":^"izriOTjj? j j j p- TT; 23: -.::; :-n"TTrf"i~T: ;~T"ri^r 1 -:Hji . T m:s -rpT-nrprn-T r;'7:;T^>]-"iT:r. i 1 - 5

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10-43

f .

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U. uui:l:..:M!.y:.;.,:;;..:.:..:;.;.; :H2 TiJJ.L.lj.;.•:...: ..f |.L:.M;::. ::.:/. Ll3 •£; . . : • • : - • I - - - ^ J l ' - = • - ! - : • - • - ' - . - r - j -

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• V t £ $ S: c c o c o .? e» c" o o o

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10-11

cc'

r;c

r.

3

Table 10-Ki. Tt-st Data at Mc^innin^ :uvl Knd c»l ' llu- 'I'lu-nnal Kqu i l i b r ium I ' t ' i - iml ufInitial N u l l Test During ilic Custom i/ed Ml. l IVrfurnianci: 'IVsiin.iv

llrclnalntf - 75 lluur* AlU-r 0-Tlmu

l l ' - lii.'-:ii-- . i•u'- 1iv-:.•ii--.;i r-7

•u--«

• r

•417.11

-121.0

- I2 l . i l

--..'2. u

•111.4

. ,'_•»!. 3

-•4VU. Ii

-r.-.-.oi'i:-'j i -U7 .S•IV- 10 •

'IV- II•n'.'i'jiV-13

r.-- n

-I ' J I .O

-12 1. 6•

-42 l . f i

•iv- 11 ] -r.-ii. i

'1C- 17

• i > ' - u-..'•-»IC-.V

'1 . ' • ~ 1

• 4 I - I . 7

•l. 'l.i:

-4..,.*

- 1. -.:..i- 1 1 • . 2

•I.' :•: ! 12...$i . - . - . - j j. i:". r.•H-- - . - I - I V I.I '

' l l ' -2 ' i ! • I . ' I . O

1 1'- i r • i : .. i1 i'-'.'H • *_.'. 3

i t * - .".i - 1 1 4; y

."."'"' ''. ' *U--.C i • i . - - . i

•i . • 1

•H'-.IS

•K'-J..

"1 *' »CJ7

"1 t ' »"H

-.11 1.0

• 11 .. 1• 1 1 7 . S

• •

"' ' '• '• '

1 t ''-';•! j • In i. it

T-..-.. -|..l:..

K U • I l l l . 7

1 l'. 1 ' 1 • !•< 1 71'U'- 1 t • 1" i. u

Ii '- II | -11". d•Ii'. l:.l i ' - l i .

K ' - i 71v'-Hli:-r.iI t ' - C O

H'-llTI--12

IV-!,I

- 1 1 1 . '„_

- I I J . I I-41 l.i...

• I I I . *

- I I I " . 1

• 1 _• 1 . t

• I I

r.'. i30. l*:h. a3H.li

II. S3:i. *39. 1

3.1. .1

4'.'. 2

3-J.O

J*. 1

3J. 1

3-.I..I

wit

T J 'K

•211.5

•251..'.

-21:. i-2.--0. 2

-211.3

•':•:. \-2 It*, f

-211.5

-211. »

-I-5I.9

-2M.2

-~:n .»-2M.9

.17 7 - ' j - . -4 1 . . 439. ':.T.I. 1rr.t. n

1:1. u:;-.. i.r *i i

in. it

:| : . 11:7.0u. -'12. r.

M . -J

.-

l ' . .4

:.:.. :ili.3O...H

19.2

-2a«. 0-711.4

-/."' 1. *l

-211.5

-.•1.1.0

•J ' . I .Z

- - '. * 1

•"•'ii' i

:S'o•:''•:. i- I '^t . ':

-219.0

-242. 7

.-12. 0

-212.0

-212. 1

-21'.. 9

»:M - 91 lluur. All«r o-TUiHJ B»|tlnf.ln - 70 11

• r

21.7

21.7

. ' I .I

2 1 . u

22. 1

2I . - J

21. 1

2.1. 1

21.721. :i

21. :'72. it

22. 121.3

2'L 92.1.221..)21.921.7

22. 020. •'

':'<,'.'.

"a. d'1.7

SI. 923. i:

^I'J. 0

nil. S:io. 7.Id. 7

.11. 127.3

-121. a-I2</. . t35. 2

11.5

•211. li i 11. i. i-:-il.3 i 21. » 1-252.0

-210.2

21.2 j23. ,. '

-.. a ... . . ... . :»».!• . -.'.I. 1 .'-.I ,

M. i i -211. :i31.4 -.'11.9

12. n

•J-i. 238.1

• 121.8 3i. 2-120.4 30. «

- 1 I'J. ' 40.3

• 1 2 1 . 4 3l.li

•411. S

-121.*

- IH. 1

• l.-o.i• l-'l'.b

•421 .2

.<:•:*• 1 '.*'). $,

• I ) * . 'J

- 1 1*» . 1- I^ 'H.O

-SI i .O

-Jli.2

- i i? . ; .•"

- ("4. 1!

•4.0.7

-:..|.0-I'll . 1- 1 'tl.3- 1'H. )

l.i. i -2li.. 3 ! .'•>. 9 j j - l i H . O

4*. II 1 - V I I " . '•> i -11-7 | -1.17.0

1-1.4

4 4 . 2

10.9

31.2

• I2-. .• i :>9. n• l l ' i . O

-in. i

-;•!•:. 3

-211.. 4

2MI. 0

-;.'•!. 1

I I I . 0 ! -210.7

2'i. 9 » - I'-i. S|-l"7.:l

2'i. 9 | - inn. 422.7 j j - 1 1 7 . 3

21.2 f -12 ' i . 0

22. 1 I - I I S . I22.5 |- I17. i l

HI. 1 ' .210.7 22.5 j j - i l ' . . 9

•|l'-S.. -I.'.-. J • .17. 7 ,-;'l2.3

II--:... • !

21'. 'J S - I I S . 1

t '

:<4.2-S. 2

-213.9

-2:.l. 1

•2i2.0

21.9 i2I..121. J '•

-1 J

21.2

-:•:.:. u si.:--211.2! 22...

•2-0.8 2-'. I

-211.1 21. 1

21.7

"•••"V-':*UNl-0

•U-- ..1Tt'-u.-

1C- ".3•ic-.-.iH'-i-O

'U'-O'.

IV u7ll'-i.-l

, I.. -71;. i i ' -72j ll -7.1

• IC-77

-V.'.2.W ! 2 I . 2 ! 1«'-7i

41.9 -219. 9 --3.:i

3v;::'». i

3-J.23'J. 2

41 .1Ii'. 14;.. 0

117. U41. A

42 .5

01. If

in. 3

-2:.l. 1

• 1* J 1 . "1

21. r.' 1 . 'i

-211. •: 21...

- V . I . 4 21."-2.1. 1

-I'lO. 1

-2111.7

21. li

22. d--

-212. j ! 20. 7

- I » I . O -1.7

-249. <i

• 2 12. 2

-211. -J

:.i..il ! -212. 1

:i.923.1.

^ 1. *'

31. 1

01. -J - 2 1 2 . 2 ! 11. t

Si'.." -211.7 a 1.1ii.a52. U

-21 1. 4 , 2i?. •»-214.3 l 2S. 9

53.0 -213. d ! 2'J. 1

01.2 -214. S

52.7

01. u

4 V . 7-

4H. . I

H.9

1 2 . 1

13. 1

I I . . :

-213.9 21.3

-211.5 2S.7

-719.5 23.7

- 2 M . O 22 .2-2 I'J. 9 2.1. 3

1.. --219.3 ! 23. -.1

-21U. 1 ' 2.1. 1i

! 1C 791 C - riO*l t "•• + I"

i i" -»i

i re- »ti ... ...: ' '•! I'C - "Jti

IV :<•!1 li'- 1"0

U'-l ' l l

j ri '-m:H'- IW

; n ' - in i

; IV -110

'K ' - l l l

'K- - I I - -

H ' - I I J

I C - I I I

tr-ir.I t ' - l i t :IV -117

•.'.•.,M

ll • l<2U -H3l l ' - l < l

-4.J.J

'•122. 3• •

••

• I2J. S

••

••

••

-421.0

•4"7.7

"

*•'• J

0-.. U

n i f f u ^ u M

l i t - •-.,].,

-32it.:7».»

• «

- M M

-4 | i>. V

-j ri l- 4 1 7 . 1

-12". II

- 4 1 .'. .1

-u.:."••

- 1 1-.». l

-i i*. ..-111 .2

• I I " . T- l l « . 7

- i i i . a- I I T . S

• 1 I - . 2

i»jr» AUcr O-TIII>» "| h'ud - 91 1! jur» Aft.?r C-Tlm»

• H [ ' I ' J - K ' K | - H i ' C j - K

i • i

37.7

3b 6

39.002.3

W5.3

•152. J-

•Til. 9

•Ui l .S; S3I . 1

23.7Mii.O | Jtl. I

l-ump

•""• ii

:o, i -r:o. o 4C.«

-172.4 37

20.3 -422.0 3<

••

••• •

21.7 -41 I. 1 It39. l -4i .r. i:

.107. <» t*?. 7 02-

JU3. 3 4^J. 3 12.

' jIS'J.l. • -1. 1^272. 0 • 29.6 ICJ

:.'.2.3 ! 39.G SIS.?! 103.4 ii-.:

li:i.3 J ?*.7 301. if 61.4 ! i2l

I39.1 '-19i.S

I1

.0 -251.0 I 77. 2-

.ii. .

i.c I - i . i - : - :7z .o. 4 39. S ' J1J.O :.0 1<!.1 ': -1.7 i

17.7J-320.0 i l l ' i.O ! -191.4 ! ." ."I

W9.S . 20.5 h^'j^j 07.0 ,117

* / '

12.2 j- 141. « i 23.4 i -4 11.0 i K

13:1 1-219.2 I?.. 9 ' - 1 17. 0 i:

12. 5 -24'J. t.

< r . .7 -217. H

4H. 2 -217.5

M.7 -711.2

4 7 . 7 I -2IC. .7

41.0 ! -211.8

4O. 9

71. 1 i- 151 .7 1C

2V. n j-r.-o. 3 •-:

.« 14. i jt>;.i; ;

! ii

.0 -21-J .P ' 2.1.3 ;1 j ...;>, ,. , J'). t. !

. , ' n 1 •_

.3 - 7 I S . U i :-.2 i

•> , 1 . .. , '

2 I . 4 J - 4 I 6 . 0 i 41." , --'IS. j 2 1 . 1

. \ \-2iO. 5 i 22.7 -4 IS. i i K

41 .1 -;..u.t .-•.E;-*!!!.! t'

11. 1 -'JO'J. 2 i 2.1.0 i-l!!.. 1 1 4«

.:. -.•>!. v !:-.-. ,

.». -.-...•. s ; :.-. :

.5 -j.-.n. 0 ' 2 J . 7

41.6 :-'.•;•) 0 | 23.2 '• 11*;. 1 j 11.1 .--•l'i.2 2 '. 0

4:i.3 i •::-.!. 2 j 21.0 . - 4 1 c , . 3 ; 4 3 . 7 . - 2 I - . 9 ; 2 « , 1

11.3 !--.'i!i.3 2 2 . 9 , - I I ' . 9 11.1 -?10.4 72. S

41. I -21-1.4 j V.'.d j-419. 1 41 .? • -rio. 1 . ;•.-. 7I--.2 - 7 1 ' . rt i 2:1. 4 ' -417 . B 1 12. 1 ;-•.':•!. C 2J. r.

i i . a j-:;«.ij 2 3 . 2 J - 4 1 1 . U , I . - .O I - V I ' . ' . K 2.1.3

- l l i i . S j 43. | -2(5.3 23.9 '- ; l f i .9 ' 43 .1 .-;•!?. 3 2:1.8

••...7..'.

"- H-'J. 2

• i.n.i;-it:.. «-m.»

.. .'.

• 2.5 -.-I9.H

i?3.ti ( -417 .1 • i 'J.S -I -'.'U. i; 12:1.1:

7i '

5J.R : -211-0 | ?s.2 ;-«.!9. l ' 5C

SI. 4) -214. C j 23. r. .'-4'1J.9 ! 51

4 4 . 2 -2||I. (l j 2 1.C .1-111. A . 1

45 .1 -2H.2 j 1'l.n j-110. 1 1 II

;

.9 i -211.5 25.3

. 1 i -711. -it 2-1. 1

.1 ' -7li . S 21. 7

.9 ' -.•>!. 3 21. »

10-45

0V l'v

Table Ui-17. Customm-d Ml . I Tlu-niKil Test N < > . 1, 0.<ir»7 m (IT. in) Tl'S/TcstT:ink Spacing Il»ii"fl DaUi During the Tln-nnal Kqu i l ih r ium Pi:riixl

Kquil.Hour

01o

3456789

101112131415161'181920212223242526272829no313233313530

TotalE lapsedTime, hrs

238239240241242243244?4524024724324925025125225325425525C25725325926020120220320-1205200207203209270271272273274

U(2 Bo

ktr/hr

0.00355.0.00355

. 0. 003000.003550. 003590.003550. 003500.003550. 00359

1 £,-11.Ib/hr Ji Hour

0.007300.007SO !

. O.OO'7'.CJ |0.007 .SO0. 007--9 .

37

33

. 3940

41

0.00780 •'-0.00771 j! 430.007SO I 4 '

0.007 S3 ii 45

TotalElapsedTime, hrs

27527 S277273279230281282

. 283

0.00350 j 0.00783 J! . 46 2840.00357 0.007SG 470.00359 0.00789 430. 003G7 j 0.003H3 : 190.00300 0.00792 500.00350 0. 00733 ' 510.00352 ' 0.00774 !0.00355 0.007-500.00319 I 0. 0070S0. 00352 0. 007740.0034!) 0.007080.00319 0. 00703

5253

2852802S7288

Lll,

kR/hr

0. 003590. 003500.003500.003550. 003550.003470.003570. 003500.003590.0035G0. 003530. OU3530. 003000. 00359

23!) 0. 00302290 0. 0035(5

Dolloff

Ib/hr

0.007S90.007350.00783 .0. 007800.007300.007640.007860.007710.007390. 007830.007770.007890.007920.007890.00790 10.00783

291 0.00359 i 0.007S954 ; 292 0.0035755 293 0. 0035350 29457 295

. 0. 00350 0. 0077 1 j 530.00350 0.007710.00317 0. 007'M0.00;t55 0.007SO0.00355 0.007300.00359 ; 0. 007390. 003570. 00359

59• (iO

01

0.007360.00777

0.00350 0.007710.00345

290 0. 0033G297 0.003-12298299

02 300«3 I 301

0.007SO | 040.007S9

0.00355 0.007300. 00353 0. 007770. 00353 0.007770.00357 0.007300. <10;»03 0. <)07;l'J0. oi.»3or.o. on:tr,70.00305

0. OOS050. Oo7St;0. OOS02

050007Oft

302303304305300

09 ! 30770717273

305309310311

0. 003590.003520. 003520. 003520.003520. 00353

0.007580.007390. 007520. 007 S96.0077-10. 007740. 007740.0077-10.00777

0.00350 ! 0.007710.00352 0.007740.00350 0.007710.003152 0.007740.00349 ! 0. 007080.00350 0.007830.003G2 ' 0.007900.00357 0.00786

Average lU. l lof f : 0. 00355 kn/hr (0. 007SO Ib/hr)

Table 10-18. Test Data at lieginninj; and Hnil of Uio Thermal !-. '<|iiilil>riuni Period ofTest No. 1 During the Custom!/.cd Ml.I Performance

,„*«„

rv-iTf-STi'-3Tf -4If -5If -•.l f -7Ii -8l f - i»IV -10Tf -IIl f -12II -13

I f I IIf -15

If 16I I - 1 7

If IS

If -|iIf -.--Irf .-I'if •-'u .•:!If 21If :•:.1 1 -.'i:

i l f :7['IV .-1

•If _"l1

I I I ' -.'.I

1 f - M

•If :lTl ' ..'.1'. -.'..U -..7If -..1

I f -

It • '. -I

If- : 1I f - i 2

!V- 1 1

nt - 2.14 ll-uf. AfHT 0-Tlme

•I

- I I I . S-4K..7-U':. 7- 4 M . 4- I I I . 8• II'.. *-Hi:, i- :IT. i-41 1.0

•- 4 1 i:. 2- 11'. 2•

- I I . u

-Hi-. 21 .' - . 1

- 1 12. 1

-117. 'J

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III. 543.34.1.3II. 648.24 1 . 2

43.5.

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43.8

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41.6

4 7 ^ 5 >

42.7

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4rl. .'.

41.5

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4:1. r>11.2

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210.2- 2 I J . 6-213.0,

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• 210. d

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91.1

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219. 1•-M9.8«'.M. H.51.1.:<'.«. a.11:1.7.1'.'.. rt

117.7

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- 222. 8-.'22.8•222.5

222. 4-222.3•222.4

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- 7«. 2•73.8•i.'.'J-75.5

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2»;.924.24.23.26.

21.2 4 . 223.727.2

24.323. 2

23.921.323. 126.423.723.7

23. 12.;. 3

Kiul - 111 Hours Aflar 0-TUnc

•v-110.3-411.2- 4 1 1 . 7- i 1 1'.. 9

-410.5

-411.0

-411.1

- 116.3

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•

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•

- I I I . 7- I I I . O-416.2

- 4 I U . 3

-4U.S

-415.6-416.9

-410.3

2 4 . 2 j! -411.2[j24.3 -411.523.4 1 -41'i. 52'.. 9 ,, -410.821.2 j -411. 3

21.1. I -411.1-4 ,7 .8

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• H

49.744.845.343. 149.516.044 .943.750.3

45.743.8

45.346.0

43.849.745. 14 4 . 443. 149.7

44 .845.543. .'.

49.245. 145.5

41.249.341.3

21. 7 | -413.7 I 46.323. 1 jj -116.1

il '2ll. 3 j| -411.0

21. 1 Ii -413.0

-iO. 4 |! -369. 0

50. 4

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50. S50. ;i10. fl

SI. 7

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121 .4

121.9

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197.0

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197.7

19.1.2

249.9

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•.T.I. 1

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-239.C,-I ' l l .O-l"9. 5-111. 5-I'll. 1

,'|(VI 4

i.l. 5

4.1.5

49.047.0

91.091.091.491.991.991.8

93.221S.7219. 122'1. 4

:'!:*. i.'.".'0. 4

221. 4

350.0

310.5

:i 1 1 . 1:IM. 9

350. 6524.1

•c-245.6-•48.3-248.0-249.3•246 .7-217.6- 2 4 H . 3

219.9

-215.3

•247.8

-248.9

-243.0

-247.1'.

•241.9

-245.6

•241). 1

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-219.3

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-219.0

211.9

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-217. 1

-:'ii.o

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-217. 1

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-222.4

-222. 1

• 222. 1

• 222. 2•221. 1• 15,1. 5

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27. C24.925.223.927.525.621.924.327.9

25.424.3

2S.225.624.327. r,25.124.723.9

27.*

' '25.3

Heglnntnx - 231 lliniri Afli-r 0-Tluiu

lf-67Tf-11IV- 59.IX' -60

TC-611C -62

rc -S3If -f.4IX' -MrC-66TC-671C -68to -7.1

n'-72IC-73TC-741l>75IV-76TC-T7TC-7STC-79If -BOIV.-8I

21.2 j j lo -9127.3 | TV -9225. 125.321.427.425.2

21. 724.2

TC-93TC-94IV-95TC-H6Tf-'J?

TC-S9

1

lire -i»o27.22<i. 1

r.o. 610. 6:.u. a51. I51. 111.051.8

121.6-151.5 1 2 1 . 7

1C- 101

1- F - H

1 c

57.662.661.463.t>2.f - \ .

611.

59.C2.

- S I S .

117.11

122. 6

12 1 . 4

122. 4

12 !. 1

j2 1 . 4

12". 0

ll'j.i.

WJ.i

:: i i . 6••

i62.9

63.6

6J.4

122.9!.:M. «,5..-J.4

LHIIu^l.m l'.:n.]i

29.7 1 I--J.7

101. fl ' l':f,. l>

11 ii

-.120. 1

:.II.G1:19. 9

61.0 j . .21.11

*•

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16. '.'

14.4

17. 1

IL. 5

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23(1. 1

2S7 . 6

2'JU. 3

2»9.72'10.J2t'0. 1.'.-9.7

i. 7 2SJ .9

5.1 | J J r . 7

7. 1

- l i l . H

'.•ail. 3131. 1

17.3 j J9U. 1

17.7

17.0

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29u. 2

- I . I 1 272.1

40.7 3 13. 914.9 i 28). 1

- I H S . 5 77.719. 'i 232.2

1

•411 .7 I/..3 - 4 J . O

- 4 1 4 . 7

- 114..'

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11.3 i - 4 J . U

i:.,au. ii

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1^ .4I , •'

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• 4 1 2 . 5

'IX" -102 i -397.2TC-I'I3Tf-!'H

TX'-l'lSTt;-I0..

1C -107TC-1HSIf -109TC-110

Ti'-lll

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11. '-114TC-111

i--:i.o |TV-\IIJ1/17.2 ETC- 117191.7191.41'.'7. 7

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72.1*

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4 1 . 0

I I . 0

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-412. 1• •

- ,07.0

-41.'.:. 9

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4 7 . 2

44. 4

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l.'nd - 311 IK.ur« Alli-r o-TlmV I

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64.561. 1('•5. 161.561.461. 16:1.462.4

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64-. S-111.9

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77.978.577.6

29.7105. 277.3

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2 ; . 4 | - 4 , l . l- i6.o. :•.•..•.';; -413. ii

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521.5

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5..17.9531.5.537.6

4*9.75.::,.2537.3II'.. 0

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11.91 »>. 2in. i

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41.6 1 •:•!;.?41.5

45.1

41.5

4i}.3

4?. '4

41.8

- v 1 7 . y-:'|7. 'j-217. 9-217. 1

-'/i':. .1- 2 i 7 . i

4C.1 i -21". . 147.5 i -:i.:.f4S.O -24 ' . . 5.

MJ.6 -2 I J . 1

4S.2

54.7

IU. 4 M.64 1-0.4 120.4

-.'.rj.lt .-.••..7-.-*,.; v.*.:

520.7

5,20 7I

- 2 4 1 . 'j

il.:'25-. j......25.3

21.3

25.3

21.- 726.925.4.'1. H:•.:. i"'.. 7

:=. i

2 .' . 3

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li.9 .-•>. I]'.. 1 j.'-'J. :iIi'.. I ;.T9.3

e

10-47

Tahlc'10-19. Customised MLI Thermal Test No. 2, 0..'JOG in (12 in)TPS/Test T:mK Spacing, Itoiluff Data During the Thermalt'.quilibrlum Period

Equll.Hour

01234S6789

10111213141516171819202100

232425

TotalElapsedTimc.hrs

429430431432433434435436037<•»<»

439440•141442443444445446447448449450451452453454

LH-j ]

kK/hr

0.003590.003600.003600.003590.003620.0035G0. 003C20. 003GO0. 003630. 003650. 003650. 003590. 0035fi0.003570. 003550. 003590.003570.0035G0. 003530.003560.003530.003560.003520.003550,003470. 00352

Jollotf

Ib/hr

.0. 007S90. 007920. 007920.007390.007960.007830.007960.007920. 0-17990. 008020.003020. 007890. 007330. 007860. 307800. 007390. 007860. 007830.007770.007830.007770. C07830. 007740. 007800.007640. 00774

EquU.Hour

26272829303132333435363738394041424344•154647•18•1950

51

TotalElapsedTimc.hrs

45545645741,459460461462463464465466467468469470471472473474475476477

.478479480

Lllo Bo

kK/hr

0.003550.003570.003590.003620.003GO0.003560.003550.003650. 003620.003620. 003630. 003620. 0035y0. 003590.003590. 003GO0. Ot 3560.003590.003590.003600.003560.003590. 003550.003590.003620. 00.166

loff

Ib/hr

0.007800. 007860.007890.007960.007920.007830.007800.008020.007960. 007960.007990. 007960.007890. 007S90.007890.007920. 007830. 007390.007890.007920.007830.007890.007800.007890.0079G0. 00805

Average Boiloff: 0. 00358 ke/hr (0.00788 Ib/hr)

10-4S

Table 10-20. Test DataDuring the C us torn i/.-.

-End of the Thermal Kquilihriurr. Period of Test No. 2!L1 Thc>:::u! Porfomiiuice Testing

, „ r H . . . -IVeinnlniC - 429 Hour* A f t e r 0- Time 1 r..1 - 4.-<

TC-1TC-2TC-3TC- 4TC-S

- »

-4-1.3• 4 I K . S

-416.5

-418.5

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li;-c i -us. 2

TC-»TC-9

- 4 1 1 9

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T C - l l i -4!C.iTC-12! -4i«. 1•IC-13TC-1 4 -417.0TC-15 -41H.2TC-lii .-111.5

T i ' - l » i - 4 1 7 . 3TC-2'| - l l ' i . 5 l 19.1 -2I.'..74.1.5 - V I ' ! . 0 21.! • -415. f ' i .2 - 2 1 - . u43.5 - 2 4 U . O .'1 2 -415. '.j 4 1 . 4 -21-.. i

41.5 I -21u. 1 J2 I ' -417.6 4

4 S . 2 -2il.. 4 •-•-•.•> - 4 1 1 . 0 ) 4

43." - 2 I S . H -I 3 ii - 1 1 4 . 9 1

45. 1

49 .2

43.54 I . C

43.0

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-219. &-250. 1

-219.343.9 | - 2 H . 9

41.5 -25'1. I

*' 1 • ''

42.7 -243 .5ll.r. -250.1

TC-2! -412.0 41.0! -2IS. 5

TC-23

•. • ; --us. 5 42.;. : '• - 117.3 4

•

).« ' -245. -1

1.5 j -24-1. '•

.'.'• - 2 4 K . 5

23. 'J ' !•;.« 4 4 . 0 -21".«21. J •'• -U.-. 1 12.T. 1 - 4 ' 7 5 4

1.9 -21 -.3

23.7 j -!!•.. 7 . 4

23.1 j - 4 1 S . O J 4

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2U. 7 -111. .l! 4S.7 - 2 I & . 0

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TC-25 -412.3 47. 7 J -.'«.. 7 :'(.. 5 'i -.111.5! 4TC-2-i -4'.r.. 2

! 'IT -27i TC-2*

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^TC-29|' -412.0BlC-30

TC-02

TC-3.'.

TC-37! TC-3S

TC-39TC-401C-41TC-12TC-13

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-370.fi-.170. 2-j.5.7-:ti;9. 9-3n9.9-3i'.ti. 4

TC-44 ! -210.4TC-15

. '1C - 17

TC-13TC - I'J

TC-51•ll'-S-.'TC-MTI:-MTC-55TC-5H

,

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4 d . O -2 l t i .5 i 2'i.7 jl -411.8 4

,

41. 1 •25,. 4

45.3 - 2H.O

89.5*9.499. ^90.3;io. i

-22J.5-::'. 1. 5•:.'3.:t-223.0

-223. 1

90. J •: -223. 191. li -:.'2.3

219.fi -l.r.:.221'J.'-. -151. 2

-2:i9.li 220.1 -ir.0.8

-239. 0

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•

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'.'21.0 -I£.0. 1221; 8q. .J..... ,

- 150.0- - r

3.-.O. g i -7-.. 33*ri. 3 -:? ' . . ' .J5''.. 1

:u7. ^51?, ?

22.1 !| -4!S.(l | 4

25.2 :' - I 1 3 . S 4

49.7 -370.2 i49.7 -37". 2 *49.9 -3-19.C fi50. 2 -3i,'1. 3 500. 1 ' -3il?. 4 <t:•<•: i • -3...?. 3 i «50.9 ; -:n;7.9 i -j22.0 -2HI. 2 ! 21

?2. o' -2:19.7 i 2:p

22.4 i -:.-j.:i 22

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•}!.* ! - lOi . ' J ' 3.'.

•M ? ': -n i.''. ' M-75.2 ! ;H. o !j -1-1:1 4 s;

lj •' i-»".0 • 19.-I.2 'i -111. I' 31

15. 1 i 2:t(!. 3 ii.'. 9 .'.-•!

•i.s •:•••• i!.2 -2-IS. fi1.2 -213. (1

j.2 -2!fi. 4

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r.. 1 -2I7..1

J.S -223. n

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).3 - i jO . 3

i." -i:.u. s.:i | - l i ' i . 3

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24.1. ,

2 4 . 7 •

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2' .2 'j

20. 1 •,

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21.7 '

TC-::'

.•C-51

1C-591 C - ilO

'IV-"1TC-i-2

: - ' .«

TC-H723.7 j iTC-iH

2 4 . 4 1

21.9 ,

li' -71TC-72TC-73

23.0 1JTC-74

2 i . l !"2.1.3 ;27.- , '•

"i c !

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•2 f i . S :2 4 . 3 .

"•''!3 ^-

49. » ;49.9

50.2

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TC • > t ~TC--I.:' IC- ' j l

TC-;.r.TC-Sli

1C- I"''•i '.•-!..•:•TC-l ' i l•ic-i.v.TT-lf tC

50.4 ' JTC-l l i?50.3 :50. 151.2 !

122.1 '.122. 4 !

1JJ.123. '

l'1'..'J\:-".. 1

1 •••>."-•Jy. j

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n:-]')3I f - l l f JTc-m10-1111C- 112

i ' l . ' - l l 1ir •!•:.IT - in :1 1 ' - i 1 7

i" -127I C - l - ' ii »'• 1-2

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60. 7 520.7 ! lli. 1 2SD.3

57.4 517.4

f.0.7

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f.9.2

521). 7 ifi. J -JJ9.3 !, C3.0CO. 1 1 :.:.•/. 7 n.. 11 1 . 9 '.21.9•11.3 M 1.3(.0 »i '/'o G

K.72?9.3 j t.2.7289. 9

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f.5. 4CO. 9

525.4525. <J

B4.5 024. i

1^4.4

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18. 113.913.2

tif!.4 40.4CI.8 521.8 13.4

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1-

192.4

291.3292. 1

59. ?

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74.?75.5

291.4 j 74.9

022.1O I ' J . 2521.0r.22.75.2 2. t!L22. 1

£.20. 5li-.S

3 1C. 3

17."

15.:

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200.1

2.-.-I. 417. 1 ' 29H.617.2 230.417. 1 290.3!ti.3 ?.•'!. I

IC.O J2 ; ' J . 215. .i 2JM

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534.9 24." 1297.2035.852 1 . ;»

24.5 1-J7.724.0 • 2)7.2

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--:: ' r. 4 1 . 4 | 2 ;^ . o 21.7• •: .;..•: 44. '- ; -24.1.4 i 24.8- ! i - . . f i 1 44. 4 ' -21?. 5-11.7. « j 4 4 . 4 -2I6 .0

21.724.7

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103.7 j S13.772. r.

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-219.9 2.T.3 j j - l l R . S

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10. 3• •>

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23.921i. 723.9

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-107.5

41.3 -21». 3

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2,. 91

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52.2 j - 241 .2 29.0.'2.5 -243. P : 29. 4

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i-0. 0

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115.2 -192.? | ?il.7

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45.1Ji 2

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72.5

4 4 . 241.0

43. S

44 .0

41.9

47.0

4 4 . 540. 146.0

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-;49.6-218.8-24S.9-24S. 8-216. 3-217. 1-24S. 5

25.225.6 J24. j j

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23.9

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24. i l

2 4 . 421.3L ' 4 . 4

24 .9

2 4 . 7-2H. 1 i 25.1-217.C 25.6

4. .5 -24;. 7 27.5

4S.2

51.951.0

520. 0

52". 4

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11.7 !2 ;H.?15.9 ! 9. 1

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• 1 ' I _

PAGE

10-

10.:L3. I Thc-rmal Tost No. 3, O..153r.i (Gin) TI'S/Tcst Tank Spacing - The TPS wasmoved from the 0.30.~> in (12 Ln) to the 0.1.03 ni (G in) position on 11 August 1:»75, 45;0:hours a l te r 0- t jme. Except for I he TPS position, the U;st conditions wore the s:une asthose of thermal test No. 1. The thermal equi l ib r ium period began 501 hours after 0-t ime (Figure l 't-10, Slieet 3) and continued for 101 hours hours un t i l (102 hours afterMime (Figure 10-10, Sheet !M on 10 August 1075. Tlie averageIxuloff rate during the

equilibrium period was 0.0035!) kg/hr (0. 0071)1 Ib/hr). Hpiloff rates for each hour oftesting are shown in Table 10-21. Tin: temperatures of M l . I thermocouples TO.~>3, 47,38, :md 29 and llie TPS temperature (TC-18.'!) are shown in Figure 10-10, Sheets 7through 0. Temperature dis t r ibut ion .data are presented in Table 10-2/2.

10.3.3.5 Final Null Test - The TPS was left at the 0.153 m (G in) position and wascooled to liquid hydrogen temperature starting 003 hours after 0-timc on Ki August1975. .

Except for the TPS position, the test conditions were the same as those of the in i t ia lnull test. The thermal equilibrium period began (>88 hours after 0-time and continued .for 31 hours unti l 710 hours after 0-time on 11 August 1975, (Figure 10-10, Sheet 10).

The average I oiloff rate during the equilibrium period was 0. 00330 kg/hr (u. 00727Ib/hr). Boiloff rates for each hour of testing are shown in Table 10-23. Thetemperatures of thermocouples TC-53, -17, 38 :uid 29 and the. TPS temperature (TO183) are shown in Figure 10-10, Sheets 9 and 10. Temperature distributions arepresented in Table 10-21.

10.3.4 EVALUATION OF Cl'STOMIZED MLI TEST RESULTS - The thermal i ->rform-ance test of the customi/ed MLI had two major objectives: The first objective was toconfirm the results of the previous nul l tests described in Section 10-1 or to establisha new nul l point. The.second objective was to determine experimentally the thermalperformance of the customised MLI at 0.'T.7 r.i (1C- in), 0.303 in(12 in) and 0.152 in.((i in) distance between test tank and thermal payload simulator. All tests wereconducted ut i l iz ing a 0. 2 power input to the test lank heater to promote f lu id m i x i n gwithin the tank. The results of hot! experiments are discussed below.

10.3.4. 1 Initial and Final Null Test - Table 10-25 compares the resu l t^ of the i n i t i a land final null test obtained during the customi/ed MLI performance test wi th the resultsof the previous null test No. 2 and No. 4 obtained at the beginning of the icsi program(Section 10. 1). It was assumed that the I . I M boiloff rates of the previous n u l l testsNo. 2 and 4, and the in i t i a l and final nul l tests conducted during the customized MLItesting would be approximately the same after a true thermal equ i l ib r ium wasachieved. This assumption should be valid oven with the add i t ion of three TPS MLIblankets and changing the spacing between TPS ami test tank f jvn i 0..;.";7 in (1°- in)0.152m (G in). A re turn of the the rmal payload s imula tor f n n n the 0.152 in ((! in)position used dur ing the customized' MLI thermal performance test t» the originalO.'157m(r.i in) position was n t recommended because of a possible f a i l u r e of the TPS

10-50

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Tab'e 10 22. Test Data at BeRinnini: and End of liv rii"rin:i; l .quil ibrhun Period of Test No. 3 Durini,'the Customized Ml.I "Iht-mrji PcrK-r«i:iKCO Tesiini:

' [IW-RU.nlng - Ml llu«ir» Af l r r 0-TUne Knd - 1:02 th,uri A!t,?r 0-Tlir.o

TC-lTC-2TC-3TC - 4TC-5TC-».TC-7TC-8TC.-9IT- 13T C - l lTC-12TC-13

• V

-411.0

-416.5-416.7- 4 It. 9

-111.3-Sit. 2-417.3

•

-410.2*

-41G.T

-4U.7

TC-14 -417.31 C - 1 .'TC-1STC-'.T

TC-H1C- 19TC-20TC-21TC-:J

•* (O. 9-41s. 1

-111.8-417.0

T 4 I 7 . 5-4H.9-411.5-416.7

TC- 23. , -416.2TC-21 I -413.5TC-25 -4 : i .GTC-°»> -41.'. 1

tc-27 -*•'" £

•rc-2e -419.-| TC-29 -411. 8

1C -JO

TC-31

-41,;. 9

-41',. 6TC-32 -4H.O

1X.--3JTO 731

TC-30TC-36TC-37

-Jl'.'.'l

-M3.S-41.-,. 1

••

-J71.9TC-33 -371.9

TC-31 -371.4TC-40

TC-UTC-42TC-43TC-14TC-15IX -40TC-47

TC-19TC-4*TC-50

TC-01TC-52'1C -531V.--5I

-37 u. 9-370.9-370.9-3S9.4

-210.7-240.3

•233.9-233.7

-2J3.G

-233.2-in 1.0

-103.9- I I I . 6

-!«-J .3•

TC-55 -11J.2TC-f-; j ,0 .01C-.S7 1.1.3

• H

49.0

4 J.341. 14J .743.842.7

••9.8

43.341.3

12.743.540.945.243.0

42.541.1.48.513.343.641.513.441 739.440.743.2

•c-24i:. 0-24^.0-249. 1

-248.9-249.5

-24.'.. 5

-249. 1-230.3

-249.5-249. 0-240.5-216.4-249.3

-249.6-250. 4-246.3

-219. 1-243.9

-250. 1-216.3

-21a 9-251.3-230. K-216.4

43.1 • -249.3

41.440.5

H7.G

46.54.4.9

as. i98.163.639. 1

39.189.130.6

219.3219.7221. 1220.3220.4

2? 1.8JSb.o'

3S1.1.145.43S6. 7

34,7.855,1.6

i! 1 . :>TI-O-! , ;-..(. |-.jr.i

•K

27.2

J7.124.323.7

27.7

24.122.9

23.724. 227.726. «23. »23.622.626.9

• F

-110.7

-416 .2-41i:. 2

-<10. 8-4 10. 6

-410.4-413.0-419.5•

-416. 1

-4 I9 .5.

-417.3

1•II - f

f.'.J. '--1M1..-I

4.1. J I -.'I:.'.'

41.2 j -1-10.9

•1:1 6I.'.O

O'l. 0

-2H.5-;i9-2IJ.9

4,-i.O -249.041.5 -240.1

12. ; -1-49. 5

- 4 1 j. S •*•«. j ; - j-i -. ••-4H.9 4 I. I | -2il). 1-111.5 43.5 -2-.''..3

-416.9-417.5

43. 1 -24'j. 3

42 .0 -21:1. «-413.7 ' ; 1.3 -'JOn. 3-411.0

24.1 -110.524.3 * -416.323. 1 t -419.4

26.9 S -411.3

"4 '1 | -416 3

21.9 5 -416.5

•„•;.<! , -419.3

20.!) f -411.S

23.9-243.5 J4.7

-250.7

-191.2

-Z47.-4-248.3

-21-1.3-224.3-221.0

-22J.7

-223.7-223.7-222.9

-:'•!. i

-151.1-101.4

-150.8

-1S0.8-100.0

-75.4-78. 1-SI . 3-70.0

-S9.010. o!•;.<11.4

22.5S.'.O35.924.9

45.9

-4 1H. 7

•49. 0 -!'!«. f>.43.5 - 2 I 9 . 0

43.7 -1-1J.9

41.0 j -2r.il. 1

4 J . 7 ! -'.'!'.. !

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' • - . . .

24.:; 1 TC-M).2,..-. i IT-.:I

27 . . 1 | H.'-'.3

2 4 . 7

24. 2

23.3

29. 1

24.233.1

TC-ii4TC-'.O

•K | -llj

01. i ! O- ' l .Of-0. 4 j O.iu, 4C l . O j 0."..0

61.2 ! '- • ' -1

Cll .O O.'.i. jS'.I.O 513.0

OS. 7 ! 51-i.TTC-l.j; i L' 5 i 521,4

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l» -7i1C-7-J

i -K--7-:23.7

- l l ' J .9 3:0. !»• 1

ti

•i3. 1 023. 1

63.7 1 :.2.'l.7

TC-71 I 62.4•>•.•* , i -

22.3 |j TC-7,;•J.i. t 1 TC-77

23.9 1C-73

23.6 i; TC-7'J

22.9 i! '1C- 5127.2 ! IT-1!!

022. 4

29.01C.'.. 6

l-.'J.l,

IT (l-Tln,o F.wl - f.,"2 Hours AlUrr 0-Tlir.e

•c 1 -,; j -Kt

16.6 1 i«9.810.9 2»9. 1

16.0 2-9.7

1C. 0

15. 110.)

1S9. 22S3.3

IMS. 216.0 2*11.7

-84.3 I3J .9t

:17.4 J9U. C17.7 2:V>. 317.0 i ;'..f). 2

1

-1.3 i 271.3OsO.li 41.0

i:l.S j Ol ' l .O

-31',. 2 111.859.3 . :.1-J. 3..

Jl . ' i '•' '" ••••': \i'4.3 ; '{C-9". •; -111'.. 2

M. 1 ij "C-:-J ! -4'.6.o27. 1 IT--: ; -nr . .6

4'1 7 - ' '43 9 "4 1 d TC-'JJ -417.04.1.0 ! -2.9. u 21 .2 r! TC -•-'•• ]-41''.. 2

4I ' .748.2

-20". li

-I'm. 413.3 -219. 1

-410.0 44 .0-429.0 4'J. 0

-311.5 l-4 IV 3 j 41.?-410.1

«•

-371.24J.9 1 -371.2

.49 .2 j -37il.849.5 S -370. 5

Q49.5 ,-3.0.349.5 j -.170. 25U.3 S -.169.4

U'1.8 S -210. fl

122. 1 « -2:i9.7

12J.S122.3122.4

123.2197.8IDS. 1

101.9'193.2

193.2299.22J9.6257.6

-233.5

-239.2•

-237.7-ll.l.r.

-109.5- l i t . 3-103. 0

•-113. 1

44.9

88.9

-2 IS. 3-251. U-190.7

-25H.3-243.3

-21':i.9

22.0 j J T f - 9 7

2'.. J R:-:H21.1 TC •--.*'.•

2-4. 1 ji TIM09

•41.1.8

13.814.044.4I'1 0

43.310.2

-112 .0 47.0

-116 .4 i l l . f i

-41/J.7 0'). 3

22.2 1 TC- '"l | -41.1.I) j 4,:. 2

62.3 j T';- ' .'! -3:?. 3l^J. 9 1 TC- I' .!

2i . a' •

1 C - 1 . -110.9jj TC-110 -417.0

49.3 ;; TC- lU ' i j -.417.8 .is. 3 -11-3.9 13 3 1 TV-M7 -417 .0

f'J. • -2":i 6r9. i89.7

S9.89D. 6

-•20. o221.3

2"l.5220.3

'.22. 335'.. 4?0l .£3I5.7

307.0

34T..O

61.7 i 020.7'10. i;

or., e£20 . s5 1C. S

-223.5

-223.4-323. J-222.9-151.0-1511.8

-ir.o. i-150.5

-119.7

-75.2-77.9-81. 1-71.9

-30.510.1K..O13.?

49. w l! yC-H: I -416.1'4-».7 TC-1U9 - 4 1 4 . 0

49.3 |j TC-l 10 -4ir,. 749.3 j T C - l l l -41''.. 2

1,1.3 'j TC-li;1 •.:•.•. 4 !; Tr - i i a

- 115. G-411.7

122.3 | TC-l 14 - 4 I J . O

123. 1 || TC-110122.7 ! TC-110

•

-413.2!| T i : - l l 7 j ••

123.1 l! lo -127

193.1 ] i f-131I").',. 3

192. I1H3.3

132. 723H.3

TC-H2

TC-133

T C - l - 1; T C - I = ;

2"f. 2 .:-.-.! i

-407.8-407.6

CO. 1ro. r,60. i:

71.7

43.1

42.542.2.43. 0

4.1.34C. 0

43. '3 .43.941.440.348. G

40.6

52.2

02.45:;<l. i520.6

520. 6

10. 5 i 2S9. T-i?:.8

10.3

80.4

2i3.0

-248. 9 i .3-1-49.6 21.4

-218.',-249.3-24S.1

-247.5-246.8-200. 1

-240.3-2-17.0-233.4.

-249.:

-249.0-249.8-219.3

-243.9

' -247.6-249. 1-249.9-IMS. 5-24". 0

-240.0

-24?. 2

-24-1.2-244. 1

15.71C. 016.0

24.723.92 4 . 320.720. 123. )27.925.7.19. H

23.923.623. 423. <j24.320. 024.124.321.720.226.7

26.0

61.2<;o. 6GO. C

:-,9. 3

S3.057.5-.0.5

-11-3.5• »

77.373.377.3

29.9101.3

74.5

• R

Ml. 2520. C5:0.40*'0 1019.3:,\i.o017.5LliO. 6

33'.. 5

537: 3038.3537. 3

489.9064.3

521.5-3!5.0 l i O . O

71.0••

-416.0-416.0

-410.6-110. 7-415.8

-113.3-412.5• 113.0-409.7

-413.7-333.8

•-117.0-417.3

-417.8-41G. 9-116.5-111.5

-416.9- HE: 5-•'. ;G. o-414 .9-412.3•

-4:3.3

••

29.0 -403.4

23.)2fiS.il239.2

299.21

1

-4U8.059.6CO. 2

GO. .6

534.0

44.044.044.443.344 .446.747.541.550.345.3

71.2

•13.042.742.243.143.540.543.143.544.045.147.7

46.7

51.602.0

519. C52C.2520.6

I

•c18.415.611.9

11. 311.611.316.1

-3-1. 3

25.325.925.3

-1.0100.3

•K

293.6239.0

239. 123S. 9

257.92r7 .5249.3

1-6.9

299.5

299. 1299.5

272. J313.5

23.7 29C.9-192.6

23.5

-243.8-248.8-213.5-?4S. 1

-24?.. 6

-247.3-246.8-250. 1-245.3

-247.5-233.6

-219.3-249. 5

-249.8-_ . i. '-249.0-247.9

-249.3

-?">. 0-213.8-248. I-24';. 7

-247. 3

-244.5

-244.3ir,. 515.816.0

i?0. (,

296.7

21.424.424 .7

24. 124.625.926 .423. 127.925.739.6

23.923.723.''4

23.92«.:25.3

23.924.224.4K. 1?'o.5

25.9

29.72 S . 9 .

235.7239.0

259.2

Or

Table 10-23. Final Null Test, 0. 2 Watt Power Input-Boiloff Data During theThermal Equilibrium Period

Equil.hour

012

345G789

101112131415

ToUi .ElapseJTime, hrs

(>33G89090

' G D IG92G93094G95G9GG97698G99700701702703

LII9

kg/hr

0.003300, 003300. 003300. 003290. 003280.003290. 003300. 003330. 003330. 003350. 003320.003320. 003350.003290.003360.00342

Boiloff

Ib/hr

0.007270.007270.007270.007240.007210.007240. 007270. 007330. 007330.0073G0. 007300.007.1100. 0073G0. 007240.007390. 00752

.

Equil.hours

1617181920212?232425.202728293031

TotalElapsedTime, hrs

704705 .706707708709710711712713

714715716717718719

LH2 B

kg/hr

0.003420.003330. 003330.003350.003320. 003320. 003290. 003300.003280.003260.003280.003260.003250.003250. 003320. 00332

oilcff

Ib/hr

0.007520. 007330.007330. 0073G0.007300.007300.007240. U07270.007210.007180.007210.007180.00714

.0.007140.007300.00730

Average Boiloff 0. 00330 kg/hr (0.00727 Ib/hr)

10-53

Table 10-24. Test Data at Beginning and End ot the Thermal Equilibrium Period of Final Null TestDuring the Custoim.'.sd oil.I Thermal Performance Testing

Btgtmittflt - 688 Itoms After 0-Ttroe

| .F ' -H

TC-l

•ci i

-415.6 4-1.4 -24(f. 5TC-2 -418.4 41 . f i

rC-3 ! -U3.0 ! 41.0

TC-4TC-5TC-6TC-7TC-8TC-9TC-10

TC-llTC-12TC-13TC-14

-418.7 41.3-41.1.7-417.8-413.5-419.0-4K..O.

-418. 1-413.5-417.3"-419.5

TC-15 -413.0TC-16 i -418.9TC-17 -419.-4TC-18 -413.7TC-19TC-20TC-21

-419.7-418.9-417.0

43.342.441.542.041.0

41.641.542.7'1.542.041. 141.641.3

-250.1

-210.9

-250.3-249. 1-249.6-110. 1-249. 9-243.8

-250. 1-250. (

-249.5-250. 1-240.9-200.3-250. 1--'30. 3

41.3 -2i». 341.1 1-250.3J3.0 1-240.3

TC-22 -J!1.S J I . 5I TC-23 i 417. « I 42.4

TC-21 -414.3 ! U.7TC-25 -417.5TC-1'i-: 1 -4H. 1TC-27 1 •

42.5

11.9

TC-28 ! • i

-250. 1-210.6-'.! 00. 0-24.''. 6-249.9

TC-I-J ! -417.3 12.7 -249.5TC-30 -413. :t j 47.7 -246. 7TC-31 - IK.5 | 12. 5 -243.6TC-3J j -4 ' ,9 .5 | 10. i -250.7TC-33 | -311.5 it lS.5 -19". 7

i TC-3-1 : -4l : i .2 i i o . * i -247 .2! TC-3f, -:!,.7 IS. 31

! TC-37 j -117.3 12.7TC-33 ; -1 17.8 ' 4 2 . 2

-249.0

•240.5-249.8

TC-J9 -416.3 13.1 -249.3TC-10 i - 110.5 I 13.5

.' TC-41 ! 117.0 13.0• TC-42 ' - 117.0 43.0i TC-13 -116.0 41.01 TC-41 -417.8 j 12.:

TC-45 .!' -413.0 j 12.0TC-16 -41G.3 43.7TC-47TC-49TC-49TC-50TC-01TC-02

-419.5 41.5*•

-413.0-419. 1-421.9-419.9

IT -53 -412! 31C- 54TC-55 -417.3

42.041.938. 110.1

-240.0-243.3-249.3-243.8-243.8

-240. 'J-243. 9

-250. 1

-219.9-219.9-202. 0-200.3

17.7 -240.7

12.'

__.

-2-19.5

•Kf

24.7

23. 1

23.3

22.924.123.6._,-,.,

23.324.4

23.123.123.7211.123.322.3

Rnd - 719 llouj-3 /.f>r O-Tlme |

-F PR "C _1K_.-1

-415.2 j 41 .3 i -i:S. j J-I.9 ,-417.8 ! 42.2 -210. f 23. t

-417.8 I 4?.l!

-413.4 j 41. B

-410.2 i 4J.3

-417.0 43.0-413.0-117.5-410.4

-417.3-417.8-416.5-419.0-117.0-4U.4

23.1 I -417.022.922. 9?•-'. 9

-415.1-419.4-413.4

23.3 |, -416.923. 1 t -413.023.623.223.623.3

-417.3-417.8-417.3-417.3

42. u42.544. 6

42.7

-I-i?. 5 23.1

-250. 1 23. 1-21S.3 . 24.3-249.3 23.9 !-249.9-1'43. 6-24 S. 4

-249. 5

23.3 |

S3. 6 I11.8 1

23.742.2 -249.9 j 23.443.5 -219.0 24 .2

•rc-ftoTC-O:ix:-'-3TC-C3TC-f.OTC-61TC-02TO -63

rc-'ViT«:-6iTC -06TC-c-TC-r-s

l'.b' - C89 llcxira After 0-Ttme 1

•F 1 -R1

•c

-421.8 33.2 i -212.0-423.3

••

-116.0-117.1

-421.9-420.3-113.0-1U5.4

42.0 -1SJ.O 'J3.3 i to -'' i "43.0 -219.3 23.3 Tt-72

41.6 -2.'.ii. i : 23. 141.0 -249.3 23.341.9 -213.!) ?3.3U.C ! - •-•!,'). 1 23. 141.043. 142.04:>.7

-J.'.O. I-210.3

23. 123.0

-249.9 23.3-•.'10.0 23.7

4 2 . 2 i -219.8 U3.-;42.7 -240. 5 23.7•12. J - 2 I S . B 23.4

3 -420.0 -10.023.72H. 523.622.582.5

-417.0 4.!.0j -4 17. i 4:!. 2

-410.9 | 43. 1-4IS.7-3,2.0

26. 0 j! -4 13. 325.2

23.723.4

23.9

-411.01 -j -417.0

-117.5' -410. £.

24.2 J -416. 223.92.1.924 .4

i-4 (7. o

•ir 3! *'i -4i:,.c23.4 -i -417.3

23.3 :: -- i i7.f i21.3

23.1

::>. 323.321.222.3

26.5

-410.2

-413.0t

*

-417.8-420.6-113.7-413.9

41.3113.0

-231.0 22.2-219.3-21.1.8-•J-IO. 3~?ilO. 3

-191.0

41,. 7 -217..!4C,. 0 -217 .0

I3.(l -U i J. !l

42.5 -2-1-J.6

23.023. 12-'l. H

22. 032.2

25. 925. c>

P3.323.0

4.X 5 ! -210.0 2 4 . 24.1.8 -243.043.0 j •'.••10.343.1 -210.34 1 . 1 - 2 I S . 54 2 . 7 -L'13.5

24.3

23. 323.921.7LVI .7

41;. 2 j -213.^! 23.4•U.9 -^13.942.0 -219.9

42.2 -210.342.2 -24 'J .S33. 1

4 1 . 3

21.3

::<. 3

23.423.4

-20 1.3 :*:.9.or ( ) ^ .... y

4 1 . 1 -:::, j. 4 1 22.8

23.7 1! -111. S 43 .2 -2 in. 4

i

26.8

;

. _. . .

TC-73TC-74TC-70

1 TC-70TC-77Ti>78

: TC-7:)TC- 30TC-?-.to -DlTC-S2TO 93n.C-D4TC-05TC-OS'1C -97

• TC-3:

j TC-M1TC-l 00

• r>;.-iOii 1C-1C-2i TC-I03

TC-KI1TC-U-:,TC-l OuTC-l 07TC-lOj•|.;-:0<1

TC 1 ! DTV-IMTC-112TC-l 13TC-l 14T'.'-ilSr r - i i i ;

•TC-l 17

!.J - 1?7

Tt'- i- : i•\v.-\i-:

I TC-1 J3T'. ' -1H1

< '1C- lii

f.3. 0C3.9G2.7

:iti.7 i -252.8

43.142.9

33.139.7'.7.0•4 .6

523.0523.9522.7

-249.3-243. 3

-252.0

•K '

21.220.4

23. »23.1

:i.:

End - 719 Hours After 0-Tlme

•F

-414.7-411.5-413.5-410.3-M9.3-411.0-412.0-413.9-411.8

-251. 1 *2.1 ' -411.8-247.1 | 26. 1-242.9 30.3

jI

17.4 ' 250.617.9 f 201. 117.2 230.4

UiCT-i.ilon pump23.0 4M.O

102,0 ;5 t i2 .5CO. 1 i 523. 1•

- 3 I O . r . 111.4<,:.; SIM. s

'

-1.16 272.030.3 3U.510.7 2»j .9

-193.0 SO. 216.7

•* i-.-115.0 . 41 .4 -248.5

-415. «i 14.4 -j -243.5-410.S 14. S-410.0 43.5

! - 4 1 l . 2 45.8-ll:'..2 40.6

-243.3-249.0-247.8-217.2

26H.9

24.7

24.72 i .9

24.225.426.0

' - 411 .3 -10.2 i -•_'••,•;. 4 1.6.8j -413.0' -111 . 1

: 1:1.7

42.0 : -2(9.9 23 .148.5 -2l ' i .O j 2 7 . 210.3 ! -247.5

•• ' i-. *:-...i.7 -13.3,-•117.0.-417. 3-4)ti. »

, -4 |T, .C,

1-4 1.1.5

-IK,. 5

-11C .O

43.0iJ.7-13. 14 4 . 44i;.s

-249. 1

-z-i9. 3-24S.5-719.3-243.5-•/I7.4

43.5 -210.043.7

-410.2 41 .8-415.6 4 1 . 4

'-111.4 ta.b1

-415.2 41. 8

-2IS.9-I4«.3-243.0-2-17. 3

-213.3

" i

25.7

24.123.923.723.924.7

-400.6-393.5

63.6C9. 570.4

29.6103.265.7

-315.064. Z

••-114.5-414.0-414.2-410.6-41-1.7-411.5-411.0-417.3-410.5-413-0

t

.-414.3•416.0

i -416.3-415.8-415. 1

25.8 ij -412.724.224.3

24.723.3

24.9

- I f i 3 . : 51. .9 -244. 4 ] 23.8- : n 7 . 4 C2.6 -241.0 .'9.2-113.2• 1 S L - . . 1

40.8 -M7.2 ; 26.04 7 . 7 -:-!<-,. 7 f 2u. 5

- 11:1.9 ! 40. 1 j -217.6 j 25.6

1 -4 K,. 2, -410.41 -411.2

-414.7-413.3

1 ••

| -414.2 •

1 ••

-41/7.0i -40B.5! -413.0', -411.5

•R

45.343.546.549.740.749.048.01C. 1

45.248.253.461.5

528.6529.5530.4

459. 6000.2025. 7145.0524.2

45.546.045.844.445.348.549.042.749.547.0

40.7

44.043.7

44.244.947.3

43.84 4 . 640.845.340. 7

4".. 9

•c-248.0-246.3-247.4-245.6-250.6-246-0-246.5-247.6-246.4-246.4-243.5-239.0

20.521.021.5

-1.1640.8!8.8

-192.6IS. 0

-247.9-247.'-247.8-24S.5-248.0-24H. 3

- U 4 C . O-249.5-245.7-217.1

-247.3-248.8-24S.9-248.6-248.3-216.9-24S.S-213.4-247.8-24%. 0-247.3

-247.8

53.0 ; -213.853.5

•K

25.2

26.925. R27.622.6

27.226.7

. 25.6

26.826.829.734.2

293.7294.2294.7

272.0314.02M.O60.6

2M.2

25.325.625. <24.720.226.927.223.727.52fi. 1 |

1

25.424.4

24.3

24.624.9 •2n.3 :

• 21.3 '24.8

K. 425.225.9

25.4

29.4

-243.5 29.74 7 . 0 -2-17.1 i i'-. 149.0 I -240.3 ' 20.9 '

. -112.5 47.5 ! -?!•..? , 2S. 4

• Incurred ]•• Si r ^L-citof 9.2.1

PAGE ISOF POOR QUALI'lT

10-54

N.! ! . ; . ! . ' i i

Table 10-20. Comparison of. Null Test Results

Nolu: All data include the oxtrruiuous lie:iL lloxv into "•>:• I !U fn]-- 'rvpower input. - 2 . . . . .

i......1.4.

S.

li.

8.

0.

10.

11.12.

1.1.

M.

15.[

15.

'

1C.

17.

IS.

19.

21.

22.

f-3.

VM.

• Xo

Null TWl j No. 2

Klii|i:.i-il Pinio llailjlu (Kipuvs 10-1 1 10-10) i 1." - 121

TlitTiiial i:-iullllirlum I'm uxJ.IIrs 10

TI'S lilunl.i 13 ! •'»'""-I

Tl'S-Ti-;t Tank Distance, t»:i (in) 45.7 cm (1

r.stiiimlri! ISoilnn l(al(.-.K£/l,! (!!•/'!:!•) i i . O O l i; (n

Ax-craisc Mirasurud UoiioII .Kivln (iu/hr) U.UOl .M (0

Measured Ik-al U-a!.af.e, wa i t s lllTl.Yhr) 0. 1S7 (0

7j UfVlal i iui belnvro pnilicti:i] and measured -15.3

koUofl l-lili-s

Avcvai;e Chruuber Pressure, N/m" (Torr)

Average Sliruuil I'rcssurc, H/m" (Torr)

9.65X10'5 (5

2.0*;0'S (I.

Average- Aml.ienl Temp, (luring EyuU.1'crioil. K (°l<) 267.0 (511

O 1Arrragu Tl'S-Surlacc Ttscp. K i i<! 1 20. 0( 37

Average TPS-MI.I Top I'acc K i n - i t Temp."K (°K) No MM HI

Vil.I-Oaler I-'arc Sheet-Outer ll!.i:J:cl Ave. 'Trrop. °A(°H), sue figure !>-^

1C-1 . 23. i ( 42

TC-5 22.1 ( 26

TC-0 22.4 ( 40

TC-13 . 22.-'- ( 40

TC-17 .'.2.S ( 11TC-21

TC-25

23.3 ( 42

if..< ( •::TC-29 S2.S i 4i

Average 22.'- ( '.It

M l.i -Inner Far': Sheci-l.ir.iii1 Ulinkci Avc.Temp. °K i°H), sec fisuro 'J-2

TC-I

TC-8TC-12TC-K.TC-20TC-24TC-2S'.'C-32

Average

• o , o

Uail'lc -i'.c-tujm Avui-jpc Ton:p, "K (UR)

Sluou'-i - I.uJ A\\-i-ag... Tt-mp. '••'. t. K)

s c . i . - 'V "[,.

Phrfud i.k».tyni A\t-raû Tt-nip. K ( R)

21.4 ( 3S

•>1.3 '. 3-.

2!. 5 ( 33

21.3 ( 35

21 .4 ( .1-:

21. 'J ( 39-

21.1 ( 35

21.4 ( .15

••

••

••

'-•

* *

Sh«>uJ-Top-V«.(it Avcrarc Temp. K( II) ! 22. 7 ( 40

Shir-u(I-!la(lU-Vi:nt Avi-i-agt; 'IV-.np. LK (°!t) 2?:. 1 ( -17

TI'S - V.-nt AVCIMRC Tcm;>. °K ("iij 27. S ( 49

'

IhoiTna! ..•quililî.-ui, u-a» ul>uJiu-.!. »,:c Section iO.3.3

- 17'-

1 11

.S in)

.0033.1)

6387}

. Ox IT7)

5-10-'')

; ".»

- 217 0 -

16

:

i.

Nom: 3

43.

o.<

7 Ci. i (IS li.) 4.1.7

i

! 0.^ \v:,U t

i.:i::il J

t. i

j

j.-:,| (!:. 1:1) -

o;o; .,<-•. of j ; 2 o | o. 00213 <o. or 0231 i

C.2J'J (0.6170) 0.3

t 4

10.6'

.4 «52

so.C

io-5 is.oxio'7; 10. ex

2.;3xic-5(i.8x;o-''.) 5.3»

.7)

. 1)

.>nkct3

-1!.7)

285

JbL

No

23

22

.4; 23

.3) 22

.3) 22

.1*1 22

.:•> 23

.1) . i 22

.1) 22

.D) i 21

• -i)• 7)

• H)

.C)

.4)

.")• C)

21

2j

2 j

21•Jl

21

Jl

*•

»*

t»

• •••"

.=) I =2

.0 (513iO)' 293

.<H -'7.0)' | 2»

Ml'.l liijr.la-li j ro

I

.1 ( 4!.'i) 2:j

.9 ( ••;.:•.) . ! 23

.3 ( 42.f.| JJ

.e ( 40. •:.)

.^ ( 3'j. t) j 22

.3 ( - l l .o l ' 23

.0 ( 41.4) j 23

.6 ( 4H. C) 22

.i( •!!.!! ' i 23iI

.3 ( 3S.4) 1 21

.3 ( 3S.3) : 21

.4( ut.c, ' j n

.3 ( .•!=.: :ii 21

.4 ( .Id.C) i 2^

.9 ( :iy.5i 21-

.1 ( iS.D) 20

.4 ( 35.5) j 21

22fi 23

2:1

25

i24

.5 ( 41.0) . 211

.0) • 2r,. 3( 47.3; 23

.5) 24 .0 ( 44 .2 ) 2*

.6

.7

.a

.c

. !

. ^

.4

( 1 . I*'501 iii. . *.O"5 t'S.O'.'.O" "<

iO-5(A.O"'iO-5}[

1

(526.0)

1 -H- -0

( Dr,.,-,

• •>-'.-:,! il.'.;t *- . ))

( -lo.ai

i.

uru-: !u::itijj'

M:u: * "'- — . — I

C0.1 • T.'j

'•'• ' :.3 |

1 r,. 2 nr. (ti \a;

C. 001 65 (;, . i;i* ;•' -.-, ;

O.OOJ30 (0. (.•(.•.•.•.)[

0.40S ( i . : i j - l i ) !

• 76.0 »

s.a. io-SM.-i- io-7}3.32«10'5.;.'J,-io-"J

1!

290.6 (S:!2.0i <

2G.3 i > ; .2 ) ] '

i

24. u ( 43. S, |

1

: '».<! t 4-t.e; . :2 4 . 2 1 .vi.q '

24. f. ( -i; ::\ \ •2j.!< i •:'!. ; i2:1 . i ! ; . . i

.3(.4i.!;) 2:t.n i •;.,.:. 1

.:

.r

2

.2

.3

.0&

.C

.5

.2

.7

.2

.6

.4

-7

.7

.i

.6

. 4

( 41. j)

( 41.:;.( 41. C,

.( 3F..D( 3 = . r i .( 3!-. 3)

( 37..')( 37. M

( 3S.!i)-

( 37. 1)

( 3S.1)

( 40. S)

( 41- S)

( 42. .V)

( o l . I )

( 42.7) '

( 44.-!)

( ••'•-.- -J)

( 4::. 6)

i :.2..'.i

211.7 ', -IZ.O.i :

2:«.S ( -12.0. :'-••:.! { 4:1. ij i

i22. : ( -i :.-:.-.2.1.0 i - i J . - :>'-'-. :} ( (• , 0. ' ;

23.0 ( -;..;;2.-..0 ( it .4)

23. 2 ( - l . ' .Oj :;

2 2 . 7 1 .;,...,,. :2.'..i-( • ; ; . • ; ) •• 124.31 43.7) j

j

2i .3( :/:.î \

i

K.'JI !•••.-,) i

Ju.a ' •:•;. '•>; 1

,3.4 «,- , . : , !a.'.'J ( :•-.(•: j

i. J

" Scr Si-L-tlun 9.-1. 1

10-55

positioning mechanism. The deviation from the previously estimated bolloff rate of<). <n>|S.-| K^ lir < < > . i H H U S |l... hr| (Section 1<>. 1) was -!«.:)', and • I. - I 'T for (he previousnul l tests No. 2 and I. The deviation of the in i t i a l ;md f ina l nu l l test dur ing thecustomi/cd Ml . I testing was •">'.:. i; :uul -78.0' . . In order to explain the large deviationof the last iwo null tests the temperature variat ion of t in- components surrojnding thel . l l j test tank were studied. The temperatures are shown in Table lo-2f>. There areseveral reasons whv the K.lloff rates of the in i t ia l ami final nul l test were higher thanthe previous null points.

I. The ambient temperatures were higher causing a higher heal leakage intothe test tank from the outside plumbing such as the leakage evacuation line.

:l. Higher ambient temperatures could increase the thermal acoustic oscillationsresul t ing in increased heat ir:uisfer into rhe tank.

::. deduction of TPS. Test Tank tiistance resulting from the addition of threeMl. I blanket.- ..nd the adjustment from O.'1.r>? m (!>'= in) to 0 . l G 2 m ( C In)caused tin? radiation view factor to increase. The I . I I - . lank viewed a largersurfac:;- area of higher tcmpcr.it cres (Tl'St than ii» the previous null lest No.'_'am) I (Si-e Table !<!-•_'",. Step I d ) . - i i igh 'T temperatures oi" the T1JS duringl l x - i n i t i a l and f i n a l r u t I I u-sts are verified bv the higher TI'.S vent gasteiiiperalinvs. Step 2 i.

I. S l ight lv higher radiation shield temperature.

It is uii-ortunatc that it is impossible to compare temperatures of the baffles and shroudbecause of the fa i lu res of thermocouples TC 31 through 1'_'7 (Section 9.2. 1) dur ing nulltest No. •_' :uid. I at th i - l icgtnning of tin- test operation. Comparing component icmp'Ta-turcs of the i n i t i a l nu l l test w i t h thi isc ol the f ina l nul l t e s t during the customi/ed thermalperformance test it is shown in Table lO-li.! .that the temperatures of the final nu l l testarc h igh . - r therefore causing' higher l . l lo boilot'f rales.

l i i -v tewing the various reasons for higher heat t r rutsfer into the ci*\'ogenic t:mk resultingin higher boilolf nites than estimated it c:ui be ciinciiided that only the occurrence ofthermal acoustic osci l la t ions could have caused the excess hr.at flow. Since pressure11-;e i l l . - i t ions were obseivcd dur ing all tes t ing an addit ional sinknown amount of heat hasbeen transferred through the f i l l and vent lines from the warm end outside of thechamber to the cold end o;~ the lines into the cryogenic l iquid . Invest igat ions (Kef.I ' l - ' J i have determined that addit ional heat leaks due to oscillations c:ui be severalorders of magni tude larger than the normal penetra t ion lu-a t leaks. The effect may beeven ni"iv s i u n i f i c a n t for a ervogt-nic test tank ope idl ing in ;m extreme low temperatureenvironment w i l l ) very small boiloff I'ate.s.

10.:}. I . L ' Cu^snmixcd M l . I Thermal -Per formance Test - A comparison of the results ofi l i c tank ins ta l l ed M l . I test iScc i i> ' i i 10.2) anil the three customi/ed Ml.I thermal

10-00

performance tests is shown in T;iblc JO-2G. The expert menl;d tail of I' :uid heat leakageil:it:t shown in the table include the cxtnuieous heat flow mto the LIU tank :uui a jiowerln|Kit of 0.2 watts (O.GJ»:s UTU/hr) into the t;u\k heater. Subtracting l!ic u\vr:ige hi-atflow value of the initi:d and final mill tests (table 10-25) from the total measured healleakages obtained during customized MLI tc.sl No. 1,2 :ml .'/, the n-Mil ting heattlow through the MLI is 0.050 watts (0.2013 UTU/hr), O.OG3 watts (0.21G7 UTU/hr):uid O.OG5 watts (0.2224 UTU/hr), res)>ectivcly. The thermal peifonuance of thecustoniiy.cxl MLI is plotted in l-'ijjure 10-11 versus the spacing di.staix-e between thetlnrnnaJ .pnylo:ul simulator and test tank. The Increase in heat transfer through theMLI, resultuog from the Tl'S |K>silion change fiom the 0.457 m (18 in) position to the0.151' 1:1 (G in) position was approximately !#;.

The c.V'crimental heat tr:uisfer Uirough the U'tnk insUilled MLI was 1.204 watt.s (4. 11UTU/hr). This value was obtaine<l by substrncUng the a\er:ige null test heat flow v:ilueof mill test No. 2 and Mo. 4 fiom the total heat Qow into the LHv t;uik obtained duringthe tank Installed MLI test. 'Hie exivrlmental hoat How through the t:mk i installedMLI :tl the 0.457 m (IS m) Tl^S-lcst t:uik sp:«;i;?g :UK( wiU? tto MIA blankets on the:theniuil paylorul simulator was approximately 20 tunes higher than the hoal flo'.v v rdueobtained for tlie. customised MLI during test No. 1. Tlie TPS was covervd \viUi UireeMLI blankets during the customised MLI test No. 1. It should I) .- re:di/.ed hoxvevei', U^atthe boUoS'f rates were still dropping at a rate of 0.15!."i per hour <hiring the fuia! 25'hours of the tank installed MLI test. The :ibsenre of the Tl'S insulation blanketscaused the- average lcni|x?ralure of Liu: outside t'aee sheet of the outer bl.'Uiket to risef'X)m 27.2K (4^.01*) to 11.",.-IK (207. 7R). The average temperature of the inner facesheet of Uie iiUK-r l)l:uiket lose only 7.0K (12.CR).

An attempt was made to estimate the heat transfer through the customized MLI testNo. 1. No consideration was given to heat le:iks through MLI attachments or healli-;iks caused by thermal acoustic oscillations of the hydrogen gas within the fill andvent l ine . The estimate was based on ut i l isat ion of tlie MLI heat transfer Equation10-1 (Sec-lion 10.1.4). The average temperature of 27.2K (48.OK) (table 10-20) atthe outer bl:uiket, outer face sheet of the test tank MLI was used to calculate theinsulation performance. The. estimate resulted in a heat transfer rate of 0. 0114watts (0.0:;00 13Tl.Vhr).

No attempt was made to calculate, the heat transfer rates of customised tests No. 2and '•'• due to the similarity of the average outer face temperatures indicated In table10-20.

Table 10-27 summarly.es :dl test results and the prediction of the results. Discrepanciesbetween prediction.? :u-.d experimented results were thoroughly discussed In tlieappropriate previous sections.

10-57

,', I aims III -'.ill. C

CNoli-: All Data Include UK- Kxtr

f • • " ' " " . - • -T.-nl

i~.i . »" J '»•••• " "iT- il'B«" > • i"-6 -"•' •'"•• '^

j j_ ft"*- I'"'"' T.nil Pi.sUmv cm (Hi)

| :.. >li-:.-.-i"l l-'il-il lljif Kc/l.r ill'/hr)

i t. >i. . .in. .1 ii. 1 i.. j-iki »Miit, iin L 'i-ii

j 7. A.^i--!> ' f l ,H. iUr 1-im.ui... H/mi(Torr1

| «. A, , - iuK , -Sh,>M.l t .....ur.-. T«rr

• \ ' r i v\ . IVl'HAj "K ("it)

. 0 . 0

)l Avi-i-Ji;v Tl 'S-Ml 1 T..,. Fico Sh. .-*•• ' lt::ur«' 9-.'

! T C - I1 TC - '.\ TC-1.'i TC • l :ii IV- 17' '1C-2I

TC-2ij IT -29

i I .I . Ml 1 li:..,T 1 .'• •• ^ • ' .>•• ' • lt.niT IM.nu.,-1 A\v.

oinpansun iSctvUistoiui/cd M 1.1mcous lleuUlow

~->, '. -nT '-Nuno

45.7 (18 in)

0.011 «t. (O.l..",2l)

1. .7 .(4.HJJ3)

e.«4-to-»(5*io- ' i

i.ea«io-.5(»»»o- ti

Z»4.J (52U.e)

,n ,

SoTI-S MI.IHl9lJ.fl.'1

64.0(111.2)69.9 (120. S)

vec'n thu I aiik Installed MI. I andTc'sl KcsullsInto the Ml., Tank. JUKI 0.2 Watt Power bjj>. . ^^ t- M 1 I i

No 1

IO - 111"»•*•I J

J -

4S.7 t-m (IK in)

o.woss <«.«,:«•,

U. 43S3 (1.4KW)

U - O X I O - S U O O - T ,

•J.6S«10-»(S*io-')

293. C (S28.1)

Z en i j',>/> (T»^y. * (•'Av. v/

M>.v | 91.6)

27.3 ( 49.1)27.1 ( 45.*)

76.9 (IX". 4) 27.6 ( 4:>.C)101.2 (U2.I )13.1. 1 1^.3'j.f)153.2 (27i.7|

. . i t t i r ^ c i ' i i

Nu / . No .1

~3~I~T«0 "4^0 - 'uut

S t |f^l

» '30. i mi (12 In) I5.2iii . (l, in)

j •

0.442S ( i .nn> 0. 4141; d.:.i-

e.6SX!0-s(5 <10-T) 5.3 . lO-^^x

i.J «10'5(«xnr'1) 1.6«xio'S(2-<

. 293. .1 (027. S) 2fJ2. C (S»f.'. *i)

2^9 { (S *0 31 269 * Ci''if '11

10. 1 ( 90.1) 411. C. ( ^'J. -')i

1t27. 3 ( 49.1) 57. 3 ( 4v ; l )27.0 ( 48.6) 27.2 ( 4r.'.-j27. S( 4!>.C) 27. S ( lu. 1)

'2 7 . 0 ( 4 S . C ) 2C.7 { 45.0) ; 20. M l - . 3)27. J( -"<.l) . i 2B.E ( 46.3). 27.1 ( 4 J . "

1(13.1 (2'.i:l.i) 27.1 ( 4 f . S ) ! -2i'..7 1 45.1) 20.'. 1 J' '•102.1 ,21>1.7> 27.1 ( 43.7)

1 1.1>.4 (2u7.7)

T C - Il TV-;.

•IV- 1.!\ TV -!<ii Tr-.-.ji 7r-.'4

TC-.'rTC- I.:

24.4 ( 43.9) 23.5 ( 42.3)

?4.1 ( 43.3) j 23.9 ( 4.1. 1)

24.4 ( 4.1.!)) i 23.9 42. f,

21.6 ( 44. C) j 23.7 42.7)24. S ( 14.71 J 23.i 42.3,?i. 3 ( 45. O 2:1.8 42.-)32. f. < 18.7) 2.1.4 42.. •>32.4 ( OS. 3) 23.6 42.:'.)

1 AVIT.I.X- . 30. 6 ( f.5.2) | 23.64 42. C,(

l . ... V . O i

o o! ^ v .._

. f

O . C

IS. Sh.«.-S,.l. /o.-.'.^T,:,,,,. " K i ' - K .

Cl. SI,i%.u.lll..(l.'. :,i.\i.-i:i.-.:T.iii i.. "K<"l«|

;'i>. .••.i.n-uil 'li.|> V.i.i A-.ir.ii:>' Ti'm|>. UK (°H) 2J .7 I 42. t)

21. Shiwi- l H . l . l - V.-iil .\v.v..;.r'loiii>. °K (°H> 2i;.:( 4-:. 2)

1-J. Yl* - V.-nl A.,-1.1,;.- IVii!;.. °K ("it) 1*7.4 (337.3)

2 . . 8 < 44.7)

2 j. 4 ( 4i. t)

20.7 ( 4S. 1) 1 2». - ( 4-. .')27.0 ( 43.1) -. 27.1 ( 4 - .^ )

1

23.2 ( 41.6) j 22. S ( 4 : . l )?:*. :i ( 42.",

j23.4 ( 42.1) ; 2:i.O ( 41.1)23.3 ( IJ.OJ 22. S ( 4!.i!>23.2 ( 41. S) 22. » ( 41. J)23.. 'I < 42. U| 2.1. 1 ( 4 l . : . j

22.6 ( 4C..-)23.1 ( 41.S) 22.4 ( !•>. :)23.3 ( 41.11) 22.:* ( !!.-)

t24.1 ( 43.4) j 2.t. 7 ( 12.1.)

?J Q t JJ =| i Vi A 1 J t '.I

27.0 ( 4-*.r.| 20.4 ( 47..',) ' 2". .9( H . C )

30.1 ( 1-i. 1) 2a.7 ( 13.4) ' 2S . ' j ( :.2.>j.

25. S( «<".. 4) 2 j . 2 ( 4S.:<) '• 24. 0 ( 44. j)

29.0 ( 53. «! 2 K . 2 ( f ,2.C) .j 26.: '>i :-,!.:i)

2f..3( 45.2) 20.4 ( 47.5) | 21. J( -11. <-.i .

2 i , 3 (41 .S ) 2 5 . 4 ( 4 0 . 7 ) ^ i . ' J l l l . V ,

192.4 (.140.4) 1-J2.4 (316.3) j l '7.>Ji:i .-!-, . l '

l i t .

'

j

•1

I) '

io-7;

IO-T.

i

!

' '

•

1

j

j'

10-58

r-t O

EMIn

s

Ou:

ITSooo

ooo

ooo

O oot* *c*o oo oo o

«rta •

rt*o

to"

uH

2 3

•spw

aao

•aea.CHOQ

O>•

a•co

Ii3i*-iooy

1/1

5 H

isH H

no nG •§ti ^o 3

td I

o1-to

w

O <Po o o

o

0o

ooo

10-50

Table 10-27. Sumnuuv of Tost He.suH.s

Test No.

Null Test No l

Null Test' No 2

Null Test No 3

Null Test No -1

Tank Installed MLI

Customized MLI

Initial Null Test

Therm:Q Test No 1

Thermal Test No '2

Thermal Test No 3

Fin:U Null Test

- 'Hea t FlowExperimental\V:ilts(lMu/hr)

0.06S (0.2. 'VJi)

0.137 (0. G::K7)

o.:;G7 (1.25L-.1)0.239 (O..S170)

1.204 (-1.1100)'

O.;350 (1.19r>0)

o.osa (0.20i;;)"

0.063 (0.21fi7)- '

0.065 (0. 2.22-1)' •

o.4oa (i.:io-vi)

IMvf i i e i ix l•\V;ilt.« (U'M/\u-)

0.020.'! (0. 1000)

0.2293 tf.TWi)

0.-120." U - ' » G r > 2 )

0.220:; (0.7C-2G)

o.: ;r , iO ( 1 . 2 0 1 )«

0.2203 (0.7320)

0.011-1 (0.0300)

.'

.

0. 2203 (0. 7f('2C)

' Value was determined ny subtract ing the average- heatof N u l l Test No. 2 and No. 1 (Table 10 -2 f> ) I'rom the lu t a lmeasured heat flow (Table 10-2IJ, Tank Installed >.!!.!).

*• Value \vas detemiined b\ .subtracting the average heal flim-of the i n i t i a l and f i n a l null test ('1'able l f ) - 2 o ) from live t o t a lmeasured heal leakage (Table1 10-2*;, Cuslomi/ed M L I ) .

10-60

11 • • •

CONCLUSIONS AND m-:COMMKNDATlONS

11.1 CONCLUSIONS

The successful completion of the program entitled "Thermal Performance of a Custom-ized Multi layer Insulation (MLI) , " has provided a significant advajicemenl of the staleof the art in cryogenic storage systems which are designed to exchange heat direct ly .with outer space. All of the components of the system were designed ami successfullybuilt to meet the objectives of the program requiring the demonstration testing of thehigh performance customized. Ml.I jjystcm.

The conclusions reached from this study are summa.-i/cd in five.categories: (1) design:uul fabrication of test tank modification and tank suppjrt system, (2) cryosl.r'.udmodilicalion and thermal payload simulator, (:5) test lar.k and thermal puyload simulatorMI.I, (I) test facility, ;uid ( f » j testing.

(1) Design and Fabrication of Test Tank Modification :uul Tank Support System

• A test article was designed and fabricated by modifying a l . f » 2 m ('I" in)NASA-furnished tank. The modifications established the required smoothcontour over most of the t:mk surface for ease of fabrication and instal lat ionof a multi layer insulation system.

« The structural capability of the modified test tank was verified by analv-s is .

• Manufacturing problems were encountered during the preparation of the .tankwelding. These problems, including an excessive amount of trapped v.-eldingstresses, a variation in parent metal thickness, the presence of porosi ty,weld folds, inclusions and cracks, were directly attributed to the in i t i a l

•fabrication of the l..r)2 m (i>0 in) tank.

• H was decided to change the proof pressure level from JJG^.G kX/m~ v"'^-^'psig) to 276.0 kN/m2 (40 psLg), because of the defects reve:iled by x-raysin areas untouched Ijy the modification operation.

» Double conoseals were successfully used to reduce tank door leakage.

. • The tank leakage measured at a pressure dif ferent ia l of 1->S kN/m~ (20 psig)was 2 . v S -. 10~7 SCC/sec. This amount of gas leakage was les^ t l ian Un-allowable leakage rate of 1 v I0-(>scc/sec.

11-]

• The test tank support system design, consisting of Ihrei: adjustable turn-buckle struts had a minimum effect on the ML1 blanket design :uid offeredpractically no interference during ML.I Installation. The attachment of thestmts to th'i Lllo guard tank resulted in a minimum heal leakage to the testtank.

(2) Cryoshroud Modification :md Thermal Payload Simulator

« The modified cryoshnmd design provided a near LU? hydrogen temperatureto simulate the environment of deep space and minimized cryoshroudhydrogen usage.

e The cryoshroud baffle thermal analysis was correct in determining that threeliquid hydrogen-cooled baffles are' adequate to intercept and absorb bothdirect and reflected thermal radiation within the cryoshroud.

• An aluminum honeycomb baffle configuration bonded wi th APCO 1252 urethaneadhesive and additionally bolted lo the baffle baseplate produced good thermalcontacts, allowing all bailie surfaces to attain almost the same temperatureas the cryoshroud walls.

. • The thermal payload simulator design provided a constant temperaturesurface for the insulated test tank lo view during the test operation.

(3) Test Tank and Thermal Payload Simulator MLI

• The MLI design and fabrication effort resulted in an insulation system of highstructural strength and constant layer density.

• The system was rapidly installed and removed. Handling of individual blanketswas easily accomplished due to the load carrying, protective, a luminum/Mylarlaminuled cover shields which also acted as radiation shields.

• Shcldahl GT-755 material was used to fabricate the cover shields. Thematerial was shaped by u t i l i x ing a vacuum forming aid. Vacuum forming thismaterial at room temperature prior to exposing it to ;!!HK (710R) temperatureallows the part to be formed as a laminate, whereas heating it first wouldsoft :n the adhesive awl allows slippage to take place between the Mylar andthe aluminum.

• Silk net material was easily stretch-formed by moistening it f i rs t with waterto provide the necessary drape characteristics.

• Forming of the a lumini /ed Mylar radiation shield material was readilyaccomplished by. pleat ing it to shape on the blanket manufacturing lay-up aid.

11-2

The pleats were held in place w i t h ahtmmi/.ed Mylar tape. The plea t ingmethod resulted in excellent contour ai-d densi ty control.

• The manufacturing aids required to fabricate t h e ' M L I were fabricated bvut i l i / ing the test tank surface and fiberglass/epoxy material, therebyavoiding the high cost of plaster molds.

(I) Test Facility

• During the total test operation of 100! hours, the faci l i ty performed except-ionally well . No leakage was experienced \ v i t h i n the vacuum chamber.

• The MRS Baratron d i f fe ren t i a l capacitance manometer maintained the testtank pressure wi th in the required • 1.3S N'/m- (0.0002 ns i ) of the set pointduring the entire lest operation.

• The guard i:mk pressure was controlled at the beginning of - the test opera! ionby the NBS developed Barostat. Device to mainta in a constant back pressurew i t h small variations in vent gas flow rates. Dur ing the n u l l tost, i t wasfound that the guard l:uik boiloff varied from a high of greater than l>. Ou!7mpt ''sec (10 scfm! immediately after filling to a low'oT less than n. 0002 IID /see (0. 5 sofm'i a l t e r the temperature had slabili'/.ed. 'I'his resulted inthe need for a constant ad jus tmen t to main ta in a narrow pressure band. ';':.-.-Barostat was tlierefore replaced with a pressure transducer/closed loopcontroller/flow control vah'C.

• A water displacement flow device was successfully used to measure L i l jboiloff rates.

< " > ) Test ing

• Precondit ioning of composite MLI systems while exposed to a high vacuumenvironment pr ior ' to loading the tank wi th a cryogenic f lu id is of utmostimjx>rt:u)ce to minimix.e outgaasuig during testing.

• Outgassing can IK- accelerated by repeated (several days') flushing of thevacuum system w i t h gaseous helium and by heating of the MLI.

o The approach to thermal equilibrium dur ing tes t ing was a long-t ime processdue- to the 1.112 temperature environment in which the MLI was tested.

o Majo r r-'asons for the discrepancy between predicted and measured boiloffrates we. re (1) the extended out gassing process, (2i the rmal e q u i l i b r i u m wasnot completed, (, ' i j additional uncontrollable heal t r a n s f e r t h rough the- f i l l amivent line existed. This heal transfer was caused by thermal acoustic:oscillations. (Kef. ]0-2).

13-3

• It was found that the LH;> test fluid was capable of storing incomingfrom, extraneous heat leaks and the test tank heater tor a period of eighthours. This period was followed by a sharp increase in boiloff ralescaused by a sudden onset of convective currents.

•• Healing of the uninsulated thermal payload simulator caused a:i increase in

temperature and pressure of the trapped gases within the test tank M1..I,resulting in higher heat conduction and LHo boiloff. A combination of higherconduction and lateral heal transfer through the ML.I layers forced theinsulation temperature to drop again.

• After 372 hours of null and thermal performance testing, boiloff rates weredropping at a rate of 0. 15(;; per hour indicating tha t the insulation was stilloutgassing. .

• The change in distance between the TPS and test tank from 0.457 m (18 in.)to 0.152 m (G In.) increased the heat transfer through the MLI by 10%.

« The experimental heat flow through the tank installed MLI .at the 0.457 m(18 in.) TPS-test tank spacing and with no MLI blankets on the thermal paylondsimulator was approximately 20 times higher tlirtn the heat flow value obtainedfor the customized .MLI during test No. 1 utilizing 3 MLI blankets on the TPS.

11.2 RECOMMENDATIONS

(1) MLI

• It is recommended that the final MLI gore section of each blanket layer betr immed at assembly. M this time, the final gore blanket can be altered toensure that there are no gaps or overlaps at the seams. Out-gassing of all theblankets in a vacuum chamber at a temperature of 339K (GlOR) is recommendf 'prior to tr imming of the final inner and outer gore sections.

(2) Test Facility

e The use of double Conoseals is recommended at locations where dissimilarmetal flanges are connected to reduce pipe leakage.

2• A tank pressure control of ---.I. 38 N/.". (0. 0002 psi) can be accomplished by

using the MKS Baratron differential capacitance manometer.

• Reference junct ion of thermocouples should be outside of the vacuum chamberin a l iquid nitrogen oath to avoid operating failures:

11-4

(::) Testing

It is recommended to oulgius the MV..1 1'or :i minimum oi' one \\vck by heatingand flushing the .MLI. with gaseous he-Hum.

Steady Lllo boil off L-:m IJL- promoted by f luid mixing wliich can bu sicconiplishwiby nuicluuiica] means or by a constant application of a minimum power levelof 0.2 watt lo :ui interned heater.

11-5

12

REFERENCES

1-1. W. H. .loimson ;md G. R. Cowgill, "Thermal Analysis of Customized Mul t i layerInsulation on on Unshrouded Liquid Hydrogen Tank," NASA/Lewis ResearchCenter Report NASA TN D-0255, March 1971.

2-1. -I. E. Dyer, "Stress Analysis of Liquid Methane Test Tajik," Contract NAS3-l-lior,, General Dynamics Report PD70-019H, 25 November 1970.

2-2. Anon., "Metallic Materials and Elements for Aerospace Vehicle Structures,"MIL-HDBK-5A, 3 February 19<JG.

2-.'». Convair Report 27-091-11, "General Requirements for the Design andManufacture of Fusion Welds, 2 January 19tiO.

2—1. Raymond J. 'Roark, "Formulas for Stress and Strain," Me draw Hill Book Co. ,N. V., Fourth Edition.

5-1. General Dynamics/Astronautics Report DDB64-003, 10 April 19G-4, Computer .Program to Evaluate Radiation Exchange Factors for Grey, Diffuse Surface(Script F Program P32-83).

-8-1. A. B. Walburn, "Design and Development of Pressure and Repressuri/ation.Purge System for Reusable Space Shuttle Multilayer Insulation Systems,"General Dynamics Convair Division Final Report CASD-NAS-74-032, ContractNAS8-27419, February 1975. .

10-1. C. W. Keller, G. R. Cunnington and A. P. Glassford, "Thermal Perform-ance of Multilayer Insulation," NASA CR-134477, LMSC-D3 198(iU Final Report,5 April 1974.

10-2. L. \V. Spradley, W. H. Sims and Chien Fan, "Thermal Acoustic Oscillations,"Lockheed Missile and Space Company, Final Report No. LMSC-HREC TRl)390(ii)0. Volume n, March 1975.

12-1

nasa cr-13505lx casd-nas-76-018 final report - core

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