FY18 IRTD Instrumentation Ring (IR) for Cryogenic Operations

Cryogenic systems are required to store and transfer cryogenic commodities. Kennedy Space Center (KSC) ground operations (GO) are primarily involved with cryogenic systems that store and transfer liquid hydrogen (LH₂) and liquid oxygen (LO₂), and are used for propellant loading of launch vehicles. Propellant loading operations are complex activities. Operation and maintenance (O&M) of these cryogenic systems account for a sizeable portion of the life-cycle costs in any program.

At the present time, cryogenics systems at KSC incorporate many individual transducers and sensors (to measure pressure, temperature, flow, etc.) in and around the systems’ components (such as tanks, pumps, radiators, etc.) and along the connecting transfer pipes. These sensors are used to command, monitor and control the flow of cryogenics while maintaining the required conditions of the propellants. These sensors and transducers are monitored by LH₂/LOX system engineers, console operators, and subject matter experts (SME) to determine loading operations modes and the quality of flow along the system during transfer operations, among other things.

Several inefficiencies are identified with present approach. Among them are (a) the number of sensors utilized by the systems (not necessary optimized for sensor placement and coverage, primarily located around main components such tanks and pumps), (b) the number of individual penetrations and welds (required to house these sensors) with the potential for thermal and propellant leaks, (c) the number of associated power and signal cables to these sensors, (d) the inability to accurately determine in real time the quality of flow (by-phase, gas, liquid) across the system (which translate in longer loading activities), (d) the labor-intensive activities associated with operations and maintenance (O&M) of these systems (such as sensors’ remove and replace (R&R), calibration of sensors, system retesting, etc.)

The primary objective of the Cryogenic Instrumentation Ring (CIR) is to improve the monitoring and control capabilities of cryogenic loading operations when compared to traditional approaches. The CIR Improvement objectives are to:

• Optimize the number of required sensors and their locations across the cryogenic systems, which in turn
  • Minimizes the number of penetrations and welds required for sensors
  • Reduces the associated power and signal cabling required
  • Reduces the amount of calibration, R&R activities, re-testing, etc.
  • Reduces the number of potential propellant leaks in the system
• Improve the understanding of cryogenics flow throughout the system
  • CIR units at specific locations of the system together with a real-time physics-based simulation of the system provides a holistic view of the overall process versus a fragmented series of partial assessments (tank, pumps, transfer lines, etc.) which in turn
    • Reduces/Optimizes propellant usage during the different modes of the loading operation
    • Support real-time decision making and contingency actions if needed
• Improve instrumentation and process health management activities
• Overall, reduce the O&M costs associated with these systems

The CIR approach seeks to demonstrate the benefits and feasibility of a localized instrumentation scheme that provides improved understanding of the cryogenics flow dynamics by measuring constituents at specified locations throughout the cryogenic system. By positioning these CIR units between adjoining sections of cryogenic pipes (such in ), it reduces the number of penetrations required throughout the length of the pipe.

The CIR system could incorporate various sensing elements to measure temperature, pressure, flow rate, density, humidity, vacuum, oxygen, hydrogen, and helium concentrations among other parameters. Other desired parameters may either be derived from these fundamental parameters (by sensor fusion) or quantified by a hybrid instrumentation approach (such as flow quality, two-phase flow regime determination, liquid level, etc.)

The CIR concept was previously investigated under the Autonomous Cryogenics Loading Operation (ACLO) project, funded by the Space Technology Mission Directorate (STMD), Game Changing Development (GCD) program. CIR was one in a series of intelligent instrumentation concepts designed to support autonomy through the use of intelligent sensors and actuators, sensor fusion, and embedded health management capabilities in cryogenic operations. Under the ACLO approach, CIR units located at specific points (interfaces) of a cryogenic system would supports the evaluation of flow performance and system/components health, among other things.

The ACLO project combined a real-time high-fidelity physics based model of the targeted cryogenic system with real-time information obtained from the sensors in the system to assess and determine the optimal loading of cryogenics. CIR units would provide real-time snapshots (views) of the flow along the system at predetermined locations to determine the evolution over time of flow regimes and heat flow characteristics. Integrating and fusing the data received from each CIR with the physics based model provides a complete and in-depth understanding of the performance and condition of the system.

Due to budget limitations, the ACLO project was cancelled when the CIR task was in the formulation phase. This IR&TD project continues the development of the CIR concept, algorithms, and it prototypes a sample of instrumentation ring as proof of concept.

• Optimize the number of required sensors and their locations across the cryogenic systems, which in turn
  • Minimizes the number of penetrations and welds required for sensors
  • Reduces the associated power and signal cabling required
  • Reduces the amount of calibration, R&R activities, re-testing, etc.
  • Reduces the number of potential propellant leaks in the system
• Improve the understanding of cryogenics flow throughout the system
  • CIR units at specific locations of the system together with a real-time physics-based simulation of the system provides a holistic view of the overall process versus a fragmented series of partial assessments (tank, pumps, transfer lines, etc.) which in turn
    • Reduces/Optimizes propellant usage during the different modes of the loading operation
    • Support real-time decision making and contingency actions if needed
• Improve instrumentation and process health management activities
• Overall, reduce the O&M costs associated with these systems

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