TRD Gas System TIM Report

1
TRD Gas System TIM Report

• Peter Fisher
• MIT
• May 8, 2002

2
TRD Gas System
Box S
Manifolds
TRD 300 Liters
Box C
Xe 1550psia
Mixing Vessel 200 psia
17.6-20.4psia
CO2 940 psia
Schematic Arrangement of the AMS-TRD gas
system. All pressures are given at 25 C.
3
TRD Gas System

• Plumbing Design
• - A simplified circuit diagram of the TRD gas
  system is shown in the following figures
• - The gas supply system consists of Xe/CO2 in an
  8020 mix
• Structural Materials
• - Tanks Composite over-wrapped stainless steel
• - Lines and fittings stainless steel (welded
  connections)

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Outline

• Mechanical layout
• C. Gargiulo
• J. Burger (manifolds)
• Electrical layout and signals
• A. Bartoloni (this session)
• Components
• Operations
• R.Henning (slow control session)

5
TDR Gas System-Mechanical

• Box S/C are a single unit
• Mount on wake port side
• Design stabilized
• Layout from Robert Becker
• Finite element calculation from Corrado
• Magnetic field tolerable

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TRD Gas Supply Mounted to USS-02
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Box S Component Layout
Vacuum case
Box C
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Figure 2 Box S Diagram  
Xe
 
 
VG1a
RVG1a-2800psi
Ground Equipment
V17a
 
F3a
V1a
 
V3a
V2a
F2a
O1a
Xe Bottle 1550psia
P2a
F1a
60cc
30cc
V10a
V4a
O2a
V5
P1a
7 liters per day to Box C
V20a
 
RV3-300psi
O2b
V4b
V20b
V10b
D Vessel (Mix)

F1b
CO2 Bottle 940psia
 
O1b
V3b
V2b
30cc
F2b
15cc
V1b
F3b
P2b
V17b
P1b
Ground Equipment
RVG1b-1200psi
VG1b
CO2
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TRD Gas System (Cont)
RV4 29psig
P5
P3
To Manifold
CO2 Analyzer
Ground Equipment
CP2
CP1
V9a
Purifier
V8B
V8A
From Manifold
V6b
V6a
V9b
V18a
V18b
P4
RV5-200psig
From Box S (From V4a)
From Box S (From V4b)
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Magnetic Field at Gas System
Xe
Vacuum case
CO2
C
Marotta Valves
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TRD Gas System (Cont)
VMnA
VMnB
VMnC
VMnD
TRD Segment n
From Gas System
To Gas System
430 cu. in (7 liters)
PMnB
PMnA
TRD segment There are a total of 41 segments fed
in parallel from the manifold.
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TRD Gas System - Mechanical

• Fittings and Connections
• - All tubes in the TRD gas system are 1/8, 1/4
  or 1/2 outer diameter stainless steel tubes
• - Connections are made with welded joints (as
  an alternate sealed fittings will be used)
• - Connections between the gas manifolds and the
  TRD segments are made with 1 mm inner diameter
  PEEK tubing and metal connectors

13
TDR Gas System - Electrical

• Controls to Box S, C and manifolds via USCM
• All inputs, outputs and readouts have been
  specified
• Electrical simulator for Box S constructed
• Design by Rome (Borgia, Gentile and Bartolini) -
  separate talk

14
Box S Signals and Power
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Box S Electronic Simulator
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Box C Electrical Signals
Three GlenAir connectors 21-pin power 9-pin
high current 25-pin signal
24 V supply still unresolved!!
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Box S Pinout
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TRD Gas System Components

• Box S
• Composite overwrapped pressure vessels (COVP)
• High pressure valves
• GP-50 (gyppie fifty) pressure sensors
• Box C
• Pumps

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Box S Component List
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Arde Vessels
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TRD Gas System - Components

• Design and Operating Pressures
• - Xe Tank
• - Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 3000 psid
• - Min./Max. design temperature -60 F to 150
  F
• (-51C to 65C)
• - Relief valves setting 2800 psid
• - Normal Operating Pressure 1550 psid
• - Normal Operating Temperature 77 F (25 C)
• - Proof test factor 1.5 x MDP
• - Minimum burst factor 3.1 x MDP

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TRD Gas System Components

• Design and Operating Pressures (Cont)
• - Xe Tank (cont)
• - Outside diameter 15.37 in.
• - Volume 1680 in3
• - Tank weight 17 lbs
• - Weight of Xenon 109 lbs (max.)
• - External load test performed to 8.9 Grms at
• 0.08 g2/Hz all axes
• - Material is composite over wrapped stainless
  steel

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TRD Gas System Components

• Design and Operating Pressures (Cont)
• - CO2 tank
• - Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 3200 psig
• - Min./Max. design temperature -100 F to 300
  F
• (-73 C to 149 C)
• - Relief valves setting 1200 psig
• - Normal Operating Pressure 940 psid
• - Normal Operating Temperature 77 F (25 C)
• - Proof test factor 1.5 x MDP
• - Minimum burst factor 2.125 x MDP

24
Xe Vessel During Assembly
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TRD Gas System Components

• Design and Operating Pressures (Cont)
• - CO2 Tank (cont)
• - Outside diameter 12.42 in.
• - Volume 813 in3
• - Tank weight 9.5 lbs
• - Weight of CO2 11 lbs (max.)
• - External load test performed to
• - 8.9 Grms at 0.07 g2/Hz (axial)
• - 4.5 Grms at 0.02 g2/Hz (lateral)
• - Material is composite over wrapped stainless
  steel

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TRD Gas System Components

• Design and Operating Pressures (Cont)
• - Mixing Tank
• - Cylindrical Pressure Volume
• - Maximum Design Pressure/Maximum Expected
  Operating Pressure (MDP)/(MEOP) 300
  psig
• - Min./Max. design temperature -100 F to 300
  F
• (-73 C to 149 C)
• - Normal Operating Pressure 200 psia
• - Normal Operating Temperature 77 F (25 C)
• - Proof test factor 1.5 x MDP
• - Minimum burst factor 4.0 x MDP
• - 1 Liter Volume
• - Manufactured by ARDE (ARDE SKC
  13181)

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CO2 Vessel Prior to Overwrap
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Marotta MV197

• At storage tanks - 3200 psi
• Inline valves - does not leak out
• Based on MV100 design - same drivers
• Space qualified??

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Box C Components List
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Pumps

• KNF NMP30 Brushless DC 24 V pump
• Positive displacement - works in microgravity
• Rated for 15,000 hours at full power
• 30,000 hours (3.4 y) at half power
• Weak point- bearings - failure does not break gas
  integrity
• Two years under test at CERN

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Pumps

• 1.4 l/h across 3 psi gives 3 TRD volumes/day
• Tested in magnetic field, OK up to 500 G
• Enclosed in vessel to maintain integrity, reduce
  wear

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Gas system test setup
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Test system Results
1
0.8 psi

• 11 automated filling cycles
• Mix in Box S, transfer to C, monitor for 45
  minutes
• 1 pressure stability

Pressure (psia)
Time (h)
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CO2 Concentration test
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Component testing

• Marotta valves, GP-50 sensors under acceptance
  test
• Pumps
• on going long duration test
• vibration test next month at Aachen or MIT
• Magnetic field

36
MV100 Test 1 Doc
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GP50 testing

• Temperature compensated pressure readings
• Three kinds 0-25psi, 0-300psi and 0-3000psi
• 0.15 accuracy for pressure

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GP50 testing

• Susceptible to magnetic fields (under study)
• B sensitivity can be compensated by orientation
  or mu-metal shielding
• Working on acceptance testing

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MV100 Testing Status
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System Test

• Assembled flight system (Box SC) will be
  vibration tested according to Structural
  Verification Plan (JSC-28792, Rev. B)
• Functional test of commercial system with TRD
  test beam

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TRD Gas System Operations

• Ground operations
• Flight operations
• Normal data taking
• Normal filling
• Emergency response
• Startup, shutdown
• Scheme

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TRD Ground Operations

• TRD testing
• Verify system operation
• Filling
• Transfer Xe, CO2 from standard 25 l gas bottles
  to Box S storage vessels
• Recovery
• Trasnfer Xe from Box S to standard 25 l gas
  bottles

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TRD testing at KSC

• Need to fill 350 l TRD straws from standard 25 l
  bottles for testing
• Circulate through external filter, remove O2
• Recover gas after use
• Standard procedure, will be carried out many
  times during construction

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Recovery System
To box S
Regulator
VH8
PH4
RVH0
VH0
2800 psid
VH5
VH2
VH3
VH4
VH1
VH7
PH3
PH1
PH0
PH2
RGA
VH6
30cc Bottle
1 liter Bottle
Rotary Vacuum Pump
10 liter Bottle
25 liter Bottle
Sorption pump
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(No Transcript)
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Recovery System

• Xe in TRD
• stored in Box S at high pressure - 1550 psia
• Expensive 10/l
• Need to be able to
• Transfer into Box S vessel from standard bottles
• Recover from Box S vessel to standard bottles
• Monitor gas composition in detail (Residual Gas
  Analyzer, RGA)

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Recovery system operations - filling Box S vessel

• Open standard 25 l bottles to Box S vessel,
  pressure equilibrates 1000 psia
• Seal Box S vessel
• Condense Xe from 25 l bottle to 10 l bottle, seal
  25 l bottle, open to Box S vessel
• Repeat with 1 liter, 30 cc bottle

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Recovery system - recovering procedure

• Seal TRD straws
• Open Box S vessel to cold 25 l standard gas
  bottles
• Xe condenses
• Seal storage vessels

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Box C OperationsNormal on-orbit
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Gas Mixing Procedure

• - Mixing Program On Ground and JMDC
• - Following Sequence
• Start with Known Mixture in D Vessel. Vent D if
  mixture unknown.
• Fill required partial pressure of CO2
• Fill required partial pressure of Xe.
• Vent to Box C when required.
• - Minimize ground communication
• Prototype system completed 500 mixing cycles
  under computer control.
• Timing of Valve operations performed by UGBS, not
  USCM!

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Box C daily filling procedure

• Shut down CP1.
• Close V8a and V8b.
• (Confirm TRD manifolds are open)
• (Box S opens V4a)
• Open V6a.
• Read all pressures every 1 sec
• (Box S closes V4a)
• Close V6a.
• Wait 5 seconds
• Open V8a.
• Start CP1.

Black UGBC control Blue UGM, UGBS
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Box S Emergency Response
Under review!
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Box C Off-Nominal Responses
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Box C Startup Sequence

• Confirm V18a, V18b, V6a, V6b, are closed.
• Open V8a, close V8b.
• Power up CO2 analyzer, send initialization
  commands
• Read all P, T, and query CO2 analyzer.
• Turn on CP1.
• Turn on high voltage to Tube 3 and Tube 4.
• Read all P, T, pump current, and query CO2
  analyzer.
• Begin normal operations.

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Box C Shutdown Sequence

• Shut down CO2 analyzer.
• If on, shut down MCA.
• Stop HV to Tube 3 and Tube 4.
• If on, stop HV to Tube 1 and Tube 2.
• Stop CP1.
• If on, stop CP2.
• Shut V8a and V8b.
• Confirm V18a, V18b, V6a, V6b all closed.

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Assembly schedule

• Box S
• Schematic prototype built, 500 cycles
• Electrical dummy built, shipped
• Commercial version complete at CERN Sept.02
• Flight version from Arde Feb. 03
• Testing Rome or Munich Fall 02

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Assembly Schedule

• Box C
• Prototype C1B at Aachen
• Prototype C1C at MIT, operations studies
• Design for C2A nearly complete, assembly Sept.
  02
• Flight C2B March 03
• Testing MIT or Aachen - Fall 02, integrated test
  Fall 03

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TRD Gas System Weight Estimate (unchanged)
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TRD Gas System Issues

• Where is gt24 V?
• Need thermal environment designed around 20 C
• Dallas temperature sensors
• where?
• How many?