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Challenges in Cryogenic Development Present & The Future: Twentieth National Conference New Delhi April 10-11, 2006

The document discusses cryogenic challenges in developing engines for India's GSLV Mark III launch vehicle. It describes the engine cycles under consideration, ongoing development of turbopumps and engines using liquid hydrogen and liquid oxygen propellants, and testing of components such as gas generators, thrust chambers, seals, and turbo pumps. The long term goal is to conduct integrated engine tests and qualify the cryogenic upper stage for the GSLV Mark III.

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Gopala Krishna
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69 views36 pages

Challenges in Cryogenic Development Present & The Future: Twentieth National Conference New Delhi April 10-11, 2006

The document discusses cryogenic challenges in developing engines for India's GSLV Mark III launch vehicle. It describes the engine cycles under consideration, ongoing development of turbopumps and engines using liquid hydrogen and liquid oxygen propellants, and testing of components such as gas generators, thrust chambers, seals, and turbo pumps. The long term goal is to conduct integrated engine tests and qualify the cryogenic upper stage for the GSLV Mark III.

Uploaded by

Gopala Krishna
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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CHALLENGES IN CRYOGENIC DEVELOPMENT PRESENT & THE FUTURE

Presentation by NK GUPTA Project Director, C25 LPSC-ISRO, Trivandrum

Twentieth National Conference New Delhi April 10-11, 2006

SATELLITE C25

L110 (ES)

S200(2 Nos)

GSLV MARK III VEHICLE

Fig 1. STAGE FLOW DIAGRAM

Fig 2. ENGINE OPERATING CYCLES

Expander Cycle

Staged combustion Cycle

GG Cycle

PERFORMANCE COMPARISON OF VARIOUS CYCLES (Comb. Chamber Pc=60Ksc, MR=6.4, AR=200)


Gas Generator Cycle LH2 Pump Outlet Pr. (Ksc) Engine lsp. (s) Engine Mixture Ratio Engine Thrust (T) Engine Weight (Kg) Thrust/weight Ratio #Incr. P/L from GG Cycle (Kg) 99 453.39 5.441 20.468 587 34.87 Staged Combustion Cycle 129 459.45 5.872 20.212 606 33.35 215 Expander Cycle 155 459.45 5.872 20.212 604 33.46 217

Fig 1. ENGINE / SUBSYSTEMS GAS GENERATOR LOX TURBOPUMP LH2 TURBOPUMP INTEGRATED TURBOPUMP THRUST CHAMBER FLUID COMPONENTS INTEGRATED ENGINE (SL)

Fig 3 STAGES OF COPPER CONVERGENT INNER SHELL DEEP DRAWING

STAGES OF COPPER DIVERGENT INNER SHELL DEEP DRAWING

3 3 4

Combustion chamber helical channel milling

C20 INJECTOR BODY

GAS GENERATOR

Fig 6. IGNITORS FOR CRYO ENGINES


54

EBW

2
EBW

3
110

4
17

Electric igniter

Pyrogen igniter

INJECTION VALVES GG LOX

EXHAUST GAS DUCT LH2

GG WITH FEED CIRCUIT FOR TESTING

CE20 GAS GENERATOR MOUNTED AT TEST BED

Fig 5. GG HOT TEST SEQUENCE


To
HELIUM PURGE VALVE LH2 VENT VALVE (HVV1)
OPEN To-20 CLOSE To-3.3 CLOSE To+ 1.5

Tf =To + 50 s
OPEN Tf+0.2
OPEN Tf+2.5

CLOSE Tf+10

CLOSE To-3

OPEN Tf+1.5

LOX VENT VALVE (OVV1)


CLOSE To-5

LOX VENT VALVE (OVV2)


OPEN To CLOSE Tf + 2.5

LH2 INJECTION VALVE(HIV1)


CLOSE To-6.5 OPEN To+ 1.5 To+ 2.7 CLOSE Tf CLOSE Tf - 4

LH2 INJECTION VALVE(HIV2) IGNITER LOX INJECTION VALVE(OIV1) LOX INJECTION VALVE(OIV2)
ON To+0.2 OPEN To+0.3 CLOSE To-10 OPEN To+ 2.7

CLOSE Tf + 1

Fig 7. PERFORMANCE OF GG IN HOT TEST


40
G G 02H T02 TEST

3 7 .8 +

30

s)

CE20 GAS GENERATOR HOT TEST VIDEO FOOTAGE

Fig 8 CE20 ENGINE- TURBINES ARRANGEMENT

LH2 TURBINE

LOX TURBINE

TURBINE EXHAUST NOZZLE

Fig 4. DOUBLE LAYERED RING

SINTERED BRONZE SEALRING

DETAILS OF DOUBLE LAYERED RING Major specifications :


Property

External layer

Internal layer

Composition Cu-10%Sn Cu-10%Sn-5%BN Porosity(%) 30 Max. 20-35 Hardness(BHN) 50 Min. 35 Max Bending strength 250 min(MPa) 100 min (MPa) UTS 150 min. (MPa) 50 min (MPa)

Present status of Technology :


The technology of processing double layered seal rings of all 3 sizes has been established through powder metallurgy route for application in C-25

Bronze Sealring(YMB-22)

OD 53 x ID 44 x 11.3 mm OD 110 x ID 100 x 12 mm OD 126 x ID 118 x 9.5 mm

C-25 Turbo Pump

CE20 TP DEVELOPMENT TESTS


A. Cold Flow Tests with water/GN2 1. Pump tests, driven by Electric Motor. 2. Turbine test driven by GN2 absorbed by Dynamometer. 3. Integrated Turbo-pump test with GN2 & water. B. Tests with Cryo Fluids LN2,LOX,LH2 4. Turbine driven by GN2 & Pump working with LN2. 5. Turbine driven by GG & Pump working with LN2. 6. Turbine driven by GG & Pump working with LH2/ LOX C. Integrated Turbo-pump Tests 7. GG-LH2TP-LOXTP integrated tests.

LH2 PUMP COLD FLOW TEST

Proto LH2 pump at test bed for testing with water & driven by electric motor

LH2 TURBINE COLD FLOW TEST LH2 Turbine tested with GN2 at design pressure ratio and low power level. Cd & efficiency as expected. Speed= 8300 rpm
Pi = 8.1 bar, Pout =1 bar, Ti = 284K, Flow =1.1 kg/s PR = 8.1 , U/Co = 0.15 Power= 80 KW Cd value = 0.91-0.93 Efficiency= 47% at U/Co=0.15

LH2 TURBOPUMP LOX TURBOPUMP

LOX TP Development tests with LN2

CE20 LOX TP test with GN2-LN2

Speed: 13000 rpm LN2 Flow: 28 lit/sec Pump Head: 6 MPa

Fig 9. LOX TURBOPUMP TEST DATA WITH LN2


LOX TURBO PUM P TEST
14000

12000

10000

LH2 TANK

ITSc LOX TANK

ENGINE

Fig 10

SPECIFICATIONS OF ENGINE & STAGE


Propellant Combination Total propellant loading Operating Cycle Thrust, Nominal (Vacuum), kN Engine Specific Impulse, s Engine Burn Duration (Nom), s Chamber Pressure, (Nom), MPa Engine Mixture Ratio LOX Flow Rate, kg/s LH2 Flow Rate, kg/s TP speed : LOX/LH2 : 25790 kg : Gas Generator : 200.7 (3.0%) : 443 3 : 550 : 6.0 : 5.05 (1.5%) : 38.546 : 7.638 : 38000 rpm(LH2) 15000 rpm(LOX)

Fig. 11 CRYO TANK THERMAL INSULATION


Anti static coating Heat shield coating Vapour barrier coating

PUF Adhesive Tank wall

Fig 12 Thrust Chamber Test Facility

Thrust Chamber Test Facility

CE20 ENGINE SUBSYSTEM TESTS


SINGLE ELEMENT HOT TESTS GAS GENERATOR DEVELOPMENT TESTS TURBO-PUMP BEARING TESTS WITH LN2; LOX/LH2 LOX TP SEAL TESTS WITH LN2 & LOX LH2 TP SEAL TESTS WITH LN2 & LH2 LOX TURBO-PUMP TESTS GN2 & LN2/LOX; GG & LN2 /LOX LH2 TURBO-PUMP CRYO TESTS GN2/GG & LN2/LH2 INTEGRATED TURBO-PUMP TEST (Pr Fed / Boot Strap) SUB SCALE CHAMBER (19 ELEMENT) TEST INTEGRATED SEA-LEVEL ENGINE TEST

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