ALBERT

Description: An orifice element is commonly used in liquid rocket engine test facilities either as a flow metering device, a damper for acoustic resonance or to provide a large reduction in pressure over a very small distance in the piping system. While the orifice as a device is largely effective in stepping down pressure, it is also susceptible to a wake-vortex type instability that generates pressure fluctuations that propagate downstream and interact with other elements of the test facility resulting in structural vibrations. Furthermore in piping systems an unstable feedback loop can exist between the vortex shedding and acoustic perturbations from upstream components resulting in an amplification of the modes convecting downstream. Such was the case in several tests conducted at NASA as well as in the Ariane 5 strap-on P230 engine in a static firing test where pressure oscillations of 0.5% resulted in 5% thrust oscillations. Exacerbating the situation in cryogenic test facilities, is the possibility of the formation of vapor clouds when the pressure in the wake falls below the vapor pressure leading to a cavitation instability that has a lower frequency than the primary wake-vortex instability. The cavitation instability has the potential for high amplitude fluctuations that can cause catastrophic damage in the facility. In this paper high-fidelity multi-phase numerical simulations of an orifice element are used to characterize the different instabilities, understand the dominant instability mechanisms and identify the tonal content of the instabilities.

Description: Simulations of cavitating turbopump inducers at their design flow rate are presented. Results over a broad range of Nss, numbers extending from single-phase flow conditions through the critical head break down point are discussed. The flow characteristics and performance of a subscale geometry designed for water testing are compared with the fullscale configuration that employs LOX. In particular, thermal depression effects arising from cavitation in cryogenic fluids are identified and their impact on the suction performance of the inducer quantified. The simulations have been performed using the CRUNCH CFD[R] code that has a generalized multi-element unstructured framework suitable for turbomachinery applications. An advanced multi-phase formulation for cryogenic fluids that models temperature depression and real fluid property variations is employed. The formulation has been extensively validated for both liquid nitrogen and liquid hydrogen by simulating the experiments of Hord on hydrofoils; excellent estimates of the leading edge temperature and pressure depression were obtained while the comparisons in the cavity closure region were reasonable.

Description: A generalized multi-phase formulation for cavitation in fluids operating at temperatures elevated relative to their critical temperatures is presented. The thermal effects and the accompanying property variations due to phase change are modeled rigorously. Thermal equilibrium is assumed and fluid thermodynamic properties are specified along the saturation line using the NIST-12 databank. Fundamental changes in the physical characteristics of the cavity when thermal effects become pronounced are identified; the cavity becomes more porous, the interface less distinct, and has increased entrainment when temperature variations are present. Quantitative estimates of temperature and pressure depressions in both liquid nitrogen and liquid hydrogen were computed and compared with experimental data of Hord for hydrofoils. Excellent estimates of the leading edge temperature and pressure depression were obtained while the comparisons in the cavity closure region were reasonable. Liquid nitrogen cavities were consistently found to be in thermal equilibrium while liquid hydrogen cavities exhibited small, but distinct, non-equilibrium effects.

Description: An assessment of four spacecraft pyrovalve anomalies that occurred during ground testing was conducted by the NASA Engineering & Safety Center (NESC) in 2008. In all four cases, a common aluminum (Al) primer chamber assembly (PCA) was used with dual NASA Standard Initiators (NSIs) and the nearly simultaneous (separated by less than 80 microseconds) firing of both initiators failed to ignite the booster charge. The results of the assessment and associated test program were reported in AIAA Paper AIAA-2008-4798, NESC Independent Assessment of Pyrovalve Ground Test Anomalies. As a result of the four Al PCA anomalies, and the test results and findings of the NESC assessment, the Mars Science Laboratory (MSL) project team decided to make changes to the PCA. The material for the PCA body was changed from aluminum (Al) to stainless steel (SS) to avoid melting, distortion, and potential leakage of the NSI flow passages when the device functioned. The flow passages, which were interconnected in a Y-shaped configuration (Y-PCA) in the original design, were changed to a V-shaped configuration (V-PCA). The V-shape was used to more efficiently transfer energy from the NSIs to the booster. Development and qualification testing of the new design clearly demonstrated faster booster ignition times compared to the legacy AL Y-PCA design. However, the final NESC assessment report recommended that the SS V-PCA be experimentally characterized and quantitatively compared to the Al Y-PCA design. This data was deemed important for properly evaluating the design options for future NASA projects. This test program has successfully quantified the improvement of the SS V-PCA over the Al Y-PCA. A phase B of the project was also conducted and evaluated the effect of firing command skew and enlargement of flame channels to further assist spacecraft applications.

Description: A flow conditioning device for incrementally stepping down pressure within a piping system is presented. The invention includes an outer annular housing, a center element, and at least one intermediate annular element. The outer annular housing includes an inlet end attachable to an inlet pipe and an outlet end attachable to an outlet pipe. The outer annular housing and the intermediate annular element(s) are concentrically disposed about the center element. The intermediate annular element(s) separates an axial flow within the outer annular housing into at least two axial flow paths. Each axial flow path includes at least two annular extensions that alternately and locally direct the axial flow radially outward and inward or radially inward and outward thereby inducing a pressure loss or a pressure gradient within the axial flow. The pressure within the axial flow paths is lower than the pressure at the inlet end and greater than the vapor pressure for the axial flow. The invention minimizes fluidic instabilities, pressure pulses, vortex formation and shedding, and/or cavitation during pressure step down to yield a stabilized flow within a piping system.

Description: An improved computational model for simulating flows in liquid-propellant injectors in rocket engines has been developed. Models like this one are needed for predicting fluxes of heat in, and performances of, the engines. An important part of predicting performance is predicting fluctuations of temperature, fluctuations of concentrations of chemical species, and effects of turbulence on diffusion of heat and chemical species. Customarily, diffusion effects are represented by parameters known in the art as the Prandtl and Schmidt numbers. Prior formulations include ad hoc assumptions of constant values of these parameters, but these assumptions and, hence, the formulations, are inaccurate for complex flows. In the improved model, these parameters are neither constant nor specified in advance: instead, they are variables obtained as part of the solution. Consequently, this model represents the effects of turbulence on diffusion of heat and chemical species more accurately than prior formulations do, and may enable more-accurate prediction of mixing and flows of heat in rocket-engine combustion chambers. The model has been implemented within CRUNCH CFD, a proprietary computational fluid dynamics (CFD) computer program, and has been tested within that program. The model could also be implemented within other CFD programs.

Description: A computer program implements a numerical model of thermal effects of cavitation in cryogenic fluids. The model and program were developed for use in designing and predicting the performances of turbopumps for cryogenic fluids. Prior numerical models used for this purpose do not account for either the variability of properties of cryogenic fluids or the thermal effects (especially, evaporative cooling) involved in cavitation. It is important to account for both because in a cryogenic fluid, the thermal effects of cavitation are substantial, and the cavitation characteristics are altered by coupling between the variable fluid properties and the phase changes involved in cavitation. The present model accounts for both thermal effects and variability of properties by incorporating a generalized representation of the properties of cryogenic fluids into a generalized compressible-fluid formulation for a cavitating pump. The model has been extensively validated for liquid nitrogen and liquid hydrogen. Using the available data on the properties of these fluids, the model has been shown to predict accurate temperature-depression values.

Description: A comprehensive numerical framework utilizing multi-element unstructured CFD and rigorous real fluid property routines has been developed to carry out analyses of propellant tank and delivery systems at NASA SSC. Traditionally CFD modeling of pressurization and mixing in cryogenic tanks has been difficult primarily because the fluids in the tank co-exist in different sub-critical and supercritical states with largely varying properties that have to be accurately accounted for in order to predict the correct mixing and phase change between the ullage and the propellant. For example, during tank pressurization under some circumstances, rapid mixing of relatively warm pressurant gas with cryogenic propellant can lead to rapid densification of the gas and loss of pressure in the tank. This phenomenon can cause serious problems during testing because of the resulting decrease in propellant flow rate. With proper physical models implemented, CFD can model the coupling between the propellant and pressurant including heat transfer and phase change effects and accurately capture the complex physics in the evolving flowfields. This holds the promise of allowing the specification of operational conditions and procedures that could minimize the undesirable mixing and heat transfer inherent in propellant tank operation. In our modeling framework, we incorporated two different approaches to real fluids modeling: (a) the first approach is based on the HBMS model developed by Hirschfelder, Beuler, McGee and Sutton and (b) the second approach is based on a cubic equation of state developed by Soave, Redlich and Kwong (SRK). Both approaches cover fluid properties and property variation spanning sub-critical gas and liquid states as well as the supercritical states. Both models were rigorously tested and properties for common fluids such as oxygen, nitrogen, hydrogen etc were compared against NIST data in both the sub-critical as well as supercritical regimes.

Description: A computational fluid dynamics (CFD) model that includes representations of effects of unsteady cavitation and associated dynamic loads has been developed to increase the accuracy of simulations of the performances of turbopumps. Although the model was originally intended to serve as a means of analyzing preliminary designs of turbopumps that supply cryogenic propellant liquids to rocket engines, the model could also be applied to turbopumping of other liquids: this can be considered to have been already demonstrated, in that the validation of the model was performed by comparing results of simulations performed by use of the model with results of sub-scale experiments in water. The need for this or a similar model arises as follows: Cavitation instabilities in a turbopump are generated as inlet pressure drops and vapor cavities grow on inducer blades, eventually becoming unsteady. The unsteady vapor cavities lead to rotation cavitation, in which the cavities detach from the blades and become part of a fluid mass that rotates relative to the inducer, thereby generating a fluctuating load. Other instabilities (e.g., surge instabilities) can couple with cavitation instabilities, thereby compounding the deleterious effects of unsteadiness on other components of the fluid-handling system of which the turbopump is a part and thereby, further, adversely affecting the mechanical integrity and safety of the system. Therefore, an ability to predict cavitation- instability-induced dynamic pressure loads on the blades, the shaft, and other pump parts would be valuable in helping to quantify safe margins of inducer operation and in contributing to understanding of design compromises. Prior CFD models do not afford this ability. Heretofore, the primary parameter used in quantifying cavitation performance of a turbopump inducer has been the critical suction specific speed at which head breakdown occurs. This parameter is a mean quantity calculated on the basis of assumed steady-state operation of the inducer; it does not account for dynamic pressure loads associated with unsteady flow caused by instabilities. Because cavitation instabilities occur well before mean breakdown in inducers, engineers have, until now, found it necessary to use conservative factors of safety when analyzing the results of numerical simulations of flows in turbopumps.

Description: The safe and reliable operation of high pressure test stands for rocket engine and component testing places an increased emphasis on the performance of control valves and flow metering devices. In this paper, we will present a series of high fidelity computational analyses of systems ranging from cryogenic control valves and pressure regulator systems to cavitating venturis that are used to support rocket engine and component testing at NASA Stennis Space Center. A generalized multi-element framework with sub-models for grid adaption, grid movement and multi-phase flow dynamics has been used to carry out the simulations. Such a framework provides the flexibility of resolving the structural and functional complexities that are typically associated with valve-based high pressure feed systems and have been difficult to deal with traditional CFD methods. Our simulations revealed a rich variety of flow phenomena such as secondary flow patterns, hydrodynamic instabilities, fluctuating vapor pockets etc. In the paper, we will discuss performance losses related to cryogenic control valves, and provide insight into the physics of the dominant multi-phase fluid transport phenomena that are responsible for the choking like behavior in cryogenic control elements. Additionally, we will provide detailed analyses of the modal instability that is observed in the operation of the dome pressure regulator valve. Such instabilities are usually not localized and manifest themselves as a system wide phenomena leading to an undesirable chatter at high flow conditions.