Development Testing of the Gateway Integrated Bipropellant Refueling Subsystem

The Lunar Gateway is a deep space orbiting outpost being developed by the National Aeronautics and Space Administration (NASA) in partnership with the European Space Agency (ESA) and other domestic and international partners. Because Gateway is a vital component of NASA’s Artemis program supporting long-term human exploration of the moon, it is designed for on-orbit refueling to allow for a longer life performance. The reaction control system (RCS) bipropellant refueling system onboard the station will have the capability to transfer propellants, monomethyl hydrazine (MMH) and mixed oxides of nitrogen-3 (MON-3), under controlled conditions and will span across three modules: the European System Providing Refueling Infrastructure and Telecommunication Refueling Module (ESPRIT-RM or ERM), the Habitation and Logistics Outpost (HALO), and the Propulsion and Power Element (PPE). These propellant transfers are complex operations with known hazards, and one of the risk areas is exceeding the flight system’s maximum design pressure (MDP) in priming and refueling pause/stop operations. In priming, liquid propellant is transferred from a pressurized source tank to evacuated transfer lines, which could result in excessive transient surge pressures and potentially damage hardware. In refueling pause/stop operations, fast-acting isolation valves (IV) are closed, which could lead to damaging water hammer. To mitigate these risks and develop the system, a collaborative NASA/ESA/Thales Alenia Space – United Kingdom (TAS-UK) test program was completed at TAS-UK on a simplified refueling breadboard representing ERM, HALO, and PPE bipropellant transfer systems. The objectives of the integrated breadboard testing were to (1) gather performance data to characterize and demonstrate critical refueling operations, (2) help inform flight designs, and (3) to validate numerical models that can be extended to predicting flight system performance. Integrated breadboard test data has shown the architected system performance is closing initial design assumptions. Further testing with propellant on a higher fidelity fluid simulator and analysis are planned.