An intelligent, real time, fluid composition sensor for monitoring of helium purge processes

Rocket propulsion system development is enabled by rigorous ground testing to mitigate the propulsion system risks inherent in spaceflight. Helium is used in piping and engine purge processes to inert liquid hydrogen systems. The cost of helium is increasing as the supply diminishes, impacting testing of the rocket engines for space propulsion systems. There is an outstanding need within NASA propulsion test facilities for intelligent real time sensors that can measure hydrogen concentrations in a helium background during purging/testing to better understand the process and reduce helium use. In line with current NASA-SSC and Rocket Propulsion Test (RPT) Program Office goals, such a monitoring technology should be intelligent to enable the reduction in time and cost of propulsion systems development. The long-term objective of the proposed effort is to leverage Sporians prior work on smart, machine learning enabled, Raman spectroscopy-based sensing systems to realize the required intelligent H/He fluid composition monitor. Phase I focused working with stakeholders to define requirements; evaluating revised hardware designs; and proof-of-principle demonstration of technology feasibility. Phase II effort will include: 1) working with NASA and industry stakeholders to foster transition; 2) evaluating revised hardware/electronics architectures and designs; and 3) several rounds of full system prototyping and testing/demonstration to satisfy NASAs technical readiness level expectations. If successful, Sporian will be well positioned for the post-Phase II transition efforts with NASA and industry stakeholders. Work will be done through a collaboration between Sporian and the University of Central Florida (UCF). This concept was developed under a NASA-funded Minority University Research and Education Project (MUREP) Small Business Technology Transfer Research Planning Grants (M-STTR) award. There is a need within NASA propulsion test facilities for intelligent real-time sensors that can measure hydrogen concentrations in a helium background during purging/testing, to better understand the process and reduce helium use. The technology must be cost effective, able to perform in a cryogenic temperature/pressure environments, and comply with safety and quality standards. An ideal sensor would also simultaneously monitor for other possible purge line constituents (water, oxygen, nitrogen, etc.). Such a monitoring technology should be intelligent to enable the reduction in time and cost of propulsion systems development, supporting functions such as in-place calibration, outputting data in engineering units, time stamping, and digital bus/network communications. Sporian Microsystems has previously developed intelligent fluid composition monitoring systems based on Raman spectroscopy with embedded machine learning capable of simultaneous classification and quantification of fluid constituents. The long-term objective of the proposed effort is to leverage Sporian’s prior work to realize the required intelligent H/He fluid composition monitor. Phase II technical objectives and work plan tasks are: Objective/Task 1: Continue to work w/NASA and stakeholders to guide the development and facilitate transition Objective/Task 2: Develop detailed NASA and non-NASA commercial application specific system hardware designs to be realized in early Phase II Objective/Task 3: Develop total system electronics designs and associated full feature operational firmware Objective/Task 3: Prototype and test integrated (hardware and electronics) measurement systems and ML training data development Objective/Task 4: Revise hardware/electronics designs and fabrication processes based on testing results Objective/Task 5: Prototyping and high-fidelity testing/evaluation of final full-system hardware End of Phase II deliverable: A TRL 5 demonstrated working prototype of the proposed hardware, along with documentation of development, capabilities, and measurements, suitable to for subsequent NASA review and evaluation.

The proposed technology directly addresses a need identified by NASA-SSC for an intelligent sensor that can measure/monitor hydrogen concentrations in helium during the engine purging and testing processes. The technology is relevant to liquid propulsion systems development and verification testing in support of the Exploration Systems Development Mission Directorate and Space Operations Mission Directorate. It benefits test programs at SSC as well as other propulsion system development centers under the Rocket Propulsion Test Program Office. Commercial beneficiaries would be organizations interested in monitoring for hydrogen and other fuel gas composition signatures, including natural gas companies, oil and gas exploration/refining, utilities, government agencies, and large-scale energy systems who need to know the composition of delivered gas. The technology can also be used for DOD aerospace vehicles testing and operations

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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