Validation of Transient Spacecraft Refueling Model with Gateway Breadboard Test Data

The ability to refuel spacecraft on-orbit is a key enabling technology for deep space human exploration. On-orbit refueling requires priming a pressurized liquid propellant from a source tank into fluid transfer lines at vacuum conditions, which could result in excessive surge pressures beyond the system’s qualified operating limits and potentially damage hardware. Another source of potentially damaging surge pressures is the water hammer transient that occurs when the isolation valves are closed to pause or end the refueling operation. Therefore, it is imperative to employ numerical models during the development of flight hardware to parametrically characterize system performance over a wide range of operating conditions to minimize the risk of exceeding pressure limits during flight. Since rapid pressure transients can be difficult to model accurately, it is important to validate those models with test data. As part of the Gateway bipropellant refueling system development, a simplified fluidic breadboard system was created using water as a simulant for fuel to support early program risk reduction of refueling operations. The objectives of breadboard testing were to gather performance data to characterize and demonstrate critical refueling operations and to validate numerical models that can be extended to predicting flight system performance. A description of the breadboard test article and the results of numerical model validation is presented. The model is shown to have very good agreement with test data.