Liquid hydrogen and liquid oxygen feedline passive recirculation analysis

The primary goal of the National Launch System (NLS) program was to design an operationally efficient, highly reliable vehicle with minimal recurring launch costs. To achieve this goal, trade studies of key main propulsion subsystems were performed to specify vehicle design requirements. These requirements include the use of passive recirculation to thermally condition the liquid hydrogen (LH2) and liquid oxygen (LO2) propellant feed systems and Space Transportation Main Engine (STME) fuel pumps. Rockwell International (RI) proposed a joint independent research and development (JIRAD) program with Marshall Space Flight Center (MSFC) to study the LH2 feed system passive recirculation concept. The testing was started in July 1992 and completed in November 1992. Vertical and sloped feedline designs were used. An engine simulator was attached at the bottom of the feedline. This simulator had strip heaters that were set to equal the corresponding heat input from different engines. A computer program is currently being used to analyze the passive recirculation concept in the LH2 vertical feedline tests. Four tests, where the heater setting is the independent variable, were chosen. While the JIRAD with RI was underway, General Dynamics Space Systems (GDSS) proposed a JIRAD with MSFC to explore passive recirculation in the LO2 feed system. Liquid nitrogen (LN2) is being used instead of LO2 for safety and economic concerns. To date, three sets of calibration tests have been completed on the sloped LN2 test article. The environmental heat was calculated from the calibration tests in which the strip heaters were turned off. During the LH2 testing, the environmental heat was assumed to be constant. Therefore, the total heat was equal to the environmental heat flux plus the heater input. However, the first two sets of LN2 calibration tests have shown that the environmental heat flux varies with heater input. A Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA/FLUINT) model is currently being built to determine if this variation in environmental heat is due to a change in the wall temperature. During the third set of calibration tests, a faulty reference junction was found. Based on this anomaly with the reference junction, the heat flux calculations from the first two calibration sets are now considered questionable.