TRD Gas System CDR Report

1
TRD Gas System CDR Report

• Reyco Henning
• MIT
• May, 2003

2
Outline

• Functional Overview of TRD Gas System
• Mechanical Structure and Layout
• Components
• Functional Testing and Schedule

3
TRD Gas System
Box S
Manifolds
TRD 300 Liters
Box C
Xe 1550psia
Mixing Vessel 200 psia
17.6-20.4psia
CO2 940 psia
Schematic Arrangement of the AMS-TRD gas
system. All pressures are given at 25 C.
4
Xe
Box S Diagram
VG1a
RVG1a-2800psi
Ground Equipment
V17a
 
F3a
V1a
 
Va
V3a
V2a
F2a
O1a
Xe Bottle 1550psia
P2a
F1a
60cc
30cc
V10a
V4a
O2a
P1a
V20a
Burst Disc
RV3-300psi
O2b
V4b
V20b
V10b
D Vessel (Mix)
F1b
CO2 Bottle 940psia
O1b
Vb
V3b
V2b
30cc
F2b
15cc
V1b
F3b
P2b
V17b
P1b
Ground Equipment
RVG1b-1200psi
VG1b
CO2
5
TRD Gas System Box C
6
TRD Gas System Manifold
VMnA
VMnB
VMnC
VMnD
TRD Segment n
From Gas System
To Gas System
430 cu. in (7 liters)
PMnB
PMnA

• TRD segment
• There are a total of 41 segments fed in parallel
  from the manifold.
• Manifolds are mounted on the TRD octagon and are
  mechanically separate from the gas supply and gas
  circulation systems.

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TRD Gas SystemMechanical Overview

• Box S and Box C are mounted on wake port side
• Manifolds are mounted on the TRD Octagon
• Design for Gas System has been stabilized
• Layout from MIT.
• Finite Element Calculation and Modal Analysis for
  Box S from INFNRome.
• Vibration Tests of Engineering Versions for
  Mission Success

8
TRD Gas Supply Mounted to USS-02
Xe vessel
Mixing valves MV197
CO2 vessel
9
Fittings and Connections

• All tubes in the TRD gas system are 1/8, 1/4 or
  1/2 outer diameter stainless steel tubes.
• Connections are made with welded joints (as an
  alternate sealed fittings will be used). Welding
  as per MSFC-SPEC-560A (D. Rybicki).
• Connections between the gas manifolds and the TRD
  segments are made with 1 mm inner diameter
  stainless steel tubing and metal connectors.

10
FEA and Margins of Safety

• Performed my INFN-Rome
• Document enclosed in datapack
• Continuously updated
• Key Results
• First Mode 70.8Hz
• Positive Margins of Safety

Mechanical Analysis Doc.
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FEA Results (new)
First Mode 70.8Hz
Second Mode 81.4Hz
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Vibration Test of Engineering Version of Box
SMission Success

• Verify significant structural natural
  frequencies.
• Verify gas system functionality under vibration
  environment.
• Determine dynamical environment for the tanks by
  dynamic response.
• Performed at ENEA at Cassacia, Italy, March,
  2003.
• Detailed results in datapack
• Analysis ongoing

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Vibration Tests

• For All Axes
• Sine sweep test (0.25 G from 10-300 Hz, scan rate
  2 oct/min) .
• Random vibration test to the levels defined in
  (MWL).
• Sine sweep test to verify that there is no change
  when compared to the first sine sweep test.

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Test Fixture
Test fixture mat. Fe 360 weight 95 kg
Box S
Shaker Slip table
15
Characterization of Test Fixture
First relevant freq. at main beam 530 Hz
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3 Axis Vibration Tests
Y axis
X axis
Z axis
17
Preliminary Vibration Test Frequency Responses
30
25
20
70 Hz
15
Amplitude
10
5
180
90
Phase
0
-90
-180
20
50
100
200
Frequency Hz
FRF Acc. Responce X/ Excitation X
30
25
81,8 Hz
20
Amplitude
15
10
5
180
90
Phase
0
-90
-180
20
50
100
200
Frequency Hz
FRF Acc. Response Y/ Excitation Y
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Vibration Test Results

• Validates structural design All structures can
  endure dynamical environment applied.
• Verifies FEA analysis First natural frequency at
  70Hz. Test results in good agreement with
  calculation (70.8Hz).
• Validates functionality of the gas system
  Circuit and valves system checked before and
  after every random vibration test.
• Analysis ongoing.

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Manifold Vibration TestMission Success
Vibration Test Mounting Block

• Tested at RWTH Aachen, Germany, on 7/18/2002
• Six-fold Manifold was vibration Tested
• Along each axis Sine sweep, random vibration
  (6.8g rms), sine sweep.
• Functional and leak test completed successfully
  afterwards

20cm
Manifold
20
Magnetic Field at Gas System AcceptableImportant
for Component selection and placement
Xe
Vacuum case
CO2
C
Marotta Valves
21
TRD Gas System - Electrical

• Controls to Box S, C and manifolds via USCM
  (Universal Slow Control Module), soldering as per
  NASA-STD-873.3 w/Change 2
• All inputs, outputs and readouts and electrical
  connections have been specified
• Electrical simulator for Box S constructed
• Designed,constructed by INFN-Rome
• Vibration, thermal vacuum test with rest of TRD
  gas system

22
Control Electronics Overview
TRD
Xe CO2 tanks
pump
manifolds
computer USCM
UGBC
UGBS
UGFV
Electronic-control
INFN Roma
Command Monitor Signals
Gas Lines
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Electronics Status
Requirements (power, connectors, pinouts, etc.)
defined.Flight Boards ready summer 2003.
Engineering Electronic Boards ready and tested
Box S Simulator
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TRD Gas System Components

• Box S
• Composite overwrapped pressure vessels (COVP)
  manufactured by Arde
• High pressure valves, Marotta MV197
• GP-50 pressure sensors
• Box C
• Pumps, KNF NMP 30 KNDC B, brushless, DC diaphragm
• Flip valves, Burkert 6123

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Box S Component List
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Pressure VesselsArde Inc.

• Xe Tank
• Used on ISS in PCU
• Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 3000 psi
• Min./Max. design temperature -60 F to 150 F
  (-51C to 65C)
• Normal Operating Pressure 1550 psi
• Normal Operating Temperature 77 F (25 C)
• Proof test factor 1.5 x MDP
• Minimum burst factor 3.1 x MDP
• Leak Before Burst (LBB)

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• Xe Tank (cont)
• Outside diameter 15.37 in.
• Volume 1680 in3
• Tank weight 17 lbs
• Weight of Xenon 109 lbs (max.)
• External load test performed to 8.9 grms at 0.08
  g2/Hz all axes
• Material is carbon fiber composite over wrapped
  stainless steel
• Qualification by similarity report Arde EG10330,
  N/C, July 6, 2001.

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• CO2 tank
• Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 3200 psig
• Min./Max. design temperature -100 F to 300 F
  (-73 C to 149 C)
• Leak before burst
• Normal Operating Pressure 940 psi
• Normal Operating Temperature 77 F (25 C)
• Proof test factor 1.5 x MDP
• Minimum burst factor 2.125 x MDP
• Qualification by similarity report Arde EG10331,
  N/C, July 6, 2001.

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• CO2 Tank (cont)
• Outside diameter 12.42 in.
• Volume 813 in3
• Tank weight 9.5 lbs
• Weight of CO2 11 lbs (max.)
• External load test performed to
• 8.9 Grms at 0.07 g2/Hz (axial)
• 4.5 Grms at 0.02 g2/Hz (lateral)
• Material is composite over wrapped stainless
  steel

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TRD Gas System Components

• Design and Operating Pressures (Cont)
• Mixing Tank
• Cylindrical Pressure Volume
• Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 300 psig
• Min./Max. design temperature -100 F to 300 F
  (-73 C to 149 C)
• Normal Operating Pressure 200 psia
• Normal Operating Temperature 77 F (25 C)
• Proof test factor 2 x MDP
• Minimum burst factor 4.0 x MDP
• 1 Liter Volume
• Manufactured by ARDE (ARDE SKC 13181)
• Fracture and stress report Arde Inc., EG 10348
  N/C, Nov. 6, 2001

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CO2 Vessel Prior to Overwrap
Main safety leak before burst
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Marotta MV197

• In Box S ? High Pressure
• Hermetically sealed
• Designed for 170,000 Duty Cycles. We anticipate a
  max. of 20,000 duty cycles during AMS-02 mission.
• MEOP 3 000psi
• MDP 6 000psi
• Proof 12 000psi

5cm
33
MV197 Acceptance Test Records from Marotta
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Box C Components List
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2 Pumps

• KNF NMP30 Brushless DC 24 V pump
• Positive displacement - works in microgravity
• Rated for 15,000 hours at full power
• 30,000 hours (3.4 y) at half power
• Weak point- bearings - failure does not break gas
  integrity
• Two years under test at CERN, MIT -gt works over
  -20 to 60 C

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Pumps

• 1.4 l/h across 3 psi gives 3 TRD volumes/day
• Tested in magnetic field, OK up to 500 G
• Enclosed in Volume to maintain integrity, reduce
  wear

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Prototype gas system
Mission Success (Functional, 500 automated
mixing cycles)
Monitors
Box C
Box S
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Box S Commercial UnitVibration and Functional
Tests
Daily volume
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Component testing

• Marotta valves acceptance test complete
• Pumps
• on going long duration test, low temperature
  cycling
• successful vibration test Aachen
• Magnetic field ? Acceptable.
• Flip valves ? under test, Acceptable over
  operation range, 0-40C

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GP50 Pressure Sensors
Manufacturer Acceptance Testing
5cm

• Temperature compensated pressure readings
• Three kinds 0-25psi, 0-300psi and 0-3000psi
• 0.15 accuracy for pressure
• Magnetic Susceptibility under Study

41
System Test

• Assembled flight system (Box SC) will be
  vibration tested according to Structural
  Verification Plan (JSC-28792, Rev. B)
• Functional test of engineering system with TRD
  test beam at end of this year
• Thermal vacuum test of flight hardware

42
TRD Gas System Operations

• Ground operations
• Flight operations
• Normal data taking
• Normal filling
• Emergency response
• Startup, shutdown

43
TRD Ground Operations

• TRD testing
• Verify system operation
• Filling
• Transfer Xe, CO2 from standard 25 l gas bottles
  to Box S storage vessels
• Recovery
• Transfer Xe from Box S to standard 25 l gas
  bottles
• Procedures same as PCU - working with AMS Mission
  Management to procure existing equipment from
  Boeing.

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Box C OperationsNormal on-orbit
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Box S Gas Mixing Procedure

• Mixing Program On Ground and onboard AMS
• Following Sequence
• Start with Known Mixture in D Vessel. Vent D if
  mixture unknown.
• Fill required partial pressure of CO2
• Fill required partial pressure of Xe.
• Vent to Box C when required.
• - Minimize ground communication
• Prototype system completed 500 mixing cycles
  under computer control.

46
Box C daily filling procedure

• Shut down CP1.
• Close V8a and V8b.
• Confirm TRD manifolds are open
• Box S opens V4a
• Open V6a.
• Read all pressures every 1 sec
• Box S closes V4a
• Close V6a.
• Wait 5 seconds
• Open V8a.
• Start CP1.

47
Box C Off-Nominal Responses
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Box C Startup Sequence

• Confirm V18a, V18b, V6a, V6b, are closed.
• Open V8a, close V8b.
• Power up CO2 analyzer, send initialization
  commands
• Read all P, T, and query CO2 analyzer.
• Turn on CP1.
• Turn on high voltage to Tube 3 and Tube 4.
• Read all P, T, pump current, and query CO2
  analyzer.
• Begin normal operations.

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Box C Shutdown Sequence

• Shut down CO2 analyzer.
• If on, shut down MCA.
• Stop HV to Tube 3 and Tube 4.
• If on, stop HV to Tube 1 and Tube 2.
• Stop CP1.
• If on, stop CP2.
• Shut V8a and V8b.
• Confirm V18a, V18b, V6a, V6b all closed.

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Assembly Schedule

• Box C
• Prototype C1B at Aachen
• Prototype C1C at MIT, operations studies
• Design for C2 complete, production to start as
  soon as possible
• Box S
• Schematic prototype built, 500 cycles
• Electrical dummy built, shipped
• Engineering version complete at CERN Sept. 02
• Flight version from Arde Apr. 03
• Thermal vacuum test Aachen Summer 03

51
Box S Assembly

• Arde Corp., Norwood, NJ
• MIL-Q-9858, NHB 5300.4 and ASME Qualified
• Vessels used for PCU and NSTAR space engine
• Construction to start April 2003

52
Box C Assembly

• Marotta Corp., Montville, NJ
• Valves, fluid control systems
• Major valve supplier for ISS

53
System Test

• Assembled engineering system (Box SC) will be
  vibration tested according to SVP-JSC-28792, Rev.
  B
• Thermal vacuum test at RWTH--Aachen
• Functional test of system in TRD test beam

54
Summary

• TRD Gas System design is complete
• Assembly, vibration test of Box S engineering
  model successful
• Flight version of Box S to be built at Arde
  starting April
• Engineering and Flight Box C to be built at
  Marotta
• Combined thermal vacuum test on Hardware
• Engineering version of control electronics
  complete and undergoing testing.