Thermal analyses of power subsystem components

The hiatus in the Space Shuttle (Orbiter) program provided time for an in-depth examination of all the subsystems and their past performance. Specifically, problems with reliability and/or operating limits were and continue to be of major engineering concern. The Orbiter Auxiliary Power Unit (APU) currently operates with electric resistance line heaters which are controlled with thermostats. A design option simplification of this heater subsystem is being considered which would use self-regulating heaters. A determination of the properties and thermal operating characteristics of these self-regulating heaters was needed. The Orbiter fuel cells are cooled with a freon loop. During a loss of external heat exchanger coolant flow, the single pump circulating the freon is to be left running. It was unknown what temperature and flow rate transient conditions of the freon would provide the required fuel cell cooling and for how long. The overall objective was the development of the thermal characterization and subsequent analysis of both the proposed self-regulating APU heater and the fuel cell coolant loop subsystem. The specific objective of the APU subsystem effort was to determine the feasibility of replacing the current heater and thermostat arrangement with a self-regulating heater. The specific objective of the fuel cell coolant subsystem work was to determine the tranient coolant temperature and associated flow rates during a loss-of-external heat exchanger flow.