National Conference on Cryogenics for Space

NCCS 2019
December 12-14, 2019, Trivandrum, India

Design aspects of a cost effective multipurpose PLC based thermovacuum

facility
Hafiz K R1, Suresh Kumar P T1, Rahul Kumar R R1, Murugesan V1 and Valsa B1
1
Vikram Sarabhai Space Centre, Thiruvananthapuram, Kerala, India -695022
([email protected])

ABSTRACT
A new thermovacuum facility of 1.1 m diameter and 1.3 m length has been designed, fabricated,
installed and commissioned at Quality Division-Vehicle systems environment test facility, Vikram Sarabhai
Space Centre (VSSC), Thiruvananthapuram. This facility was built primarily for conducting thermovacuum
tests of launch vehicle and spacecraft subsystems up to a maximum and minimum temperature range of
+150°C and -150°C, under a vacuum environment of 1x10-5 hPa. Provisions for conducting thermovacuum
tests and helium fine leak tests of pressurized subsystems was implemented to improve versatility. All facility
subsystems were designed indigenously and integrated in-house, which has resulted in reduced initial cost.
Vacuum chamber and thermal shroud was fabricated through local sources as an import substitute. Other
facility subsystems like vacuum feedthroughs and PLC based control system were realized in-house. This has
resulted in 35% cost saving in comparison with outright procurement along with simplicity in design and
maintainability. Vacuum pumping system comprises of a roots-rotary vane vacuum pump combination for
generating low vacuum and two turbomolecular pumps for generating high vacuum. Double embossed type
thermal shroud mounted inside the thermovacuum chamber is circulated with ethanol or liquid nitrogen for
simulating low temperature. Infrared lamps mounted inside thermal shroud are used for simulating high
temperature. PLC based control system permits remote operation which also avoids operator errors.
Standalone data acquisition system is provided for recording test parameters. This paper describes the
methodology adopted to realize a thermovacuum test facility with multiple capabilities and reduced testing
costs.

Key Words: Thermovacuum, PLC, thermal shroud, vacuum chamber, pneumatic tests

NOMENCLATURE ε Emissivity
PLC Programmable logic controller σ Stefan-Boltzmann constant
RS Roughing skid T Temperature
SV Solenoid valves k Thermal conductivity
TMP Turbomolecular pump M Mass
EP Electropneumatic valve Cp Specific heat
VG Vacuum gauge SCADA Supervisory control and data acquisition
PF Power feedthrough RTD Resistance Temperature Detector
TF Thermocouple feedthrough GUI Graphical User Interface
DAQ Data acquisition unit RCC Reinforced cement concrete
t thickness V Needle valve
p pitch PT Pressure transducer
P Internal design pressure RV Safety relief valve
S Allowable stress value RVP Rotary vane pump
TIG Tungsten inert gas MSHLD Mass spectrometer helium leak detector
GN2 Gaseous nitrogen R&D Research and development
LN2 Liquid nitrogen
IR Infrared lamps
Q Heat loss
F View factor between shroud and chamber
A Area of shroud

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 National Conference on Cryogenics for Space
NCCS 2019
December 12-14, 2019, Trivandrum, India

1. INTRODUCTION PLC based control console

Spacecraft subsystems are subjected to

various environmental conditions throughout its
developmental and operational lifetime.
Environmental tests are essential to demonstrate the
ability of the system to meet the indented functions
and mission requirements when exposed to these
environments. Thermovacuum test is one of the
important environmental test which provides
assurance that spacecraft / subsystems meet design
requirements under vacuum conditions and
temperature extremes experienced as in flight with
adequate margins. It also detects problems related to
material, process, workmanship and other defects Figure 2 (b) PLC based chamber control console
which will respond only to thermal and vacuum Overall integration of facility subsystems including
environment. Thermovacuum tests are carried out in vacuum chamber, thermal shroud, vacuum pumps
facilities capable of simulating thermal and low were carried out and the facility was qualified for
pressure environments in a closed envelop. conducting tests of launch vehicle and satellite
Thermovacuum testing of pressurized subsystems for subsystems. In addition, this facility is capable of
satellite applications additionally requires evaluating leak tightness of pressurized subsystems
pressurization of test article during the test. Objective under simulated operating pressure. Overview of
was to establish a facility to meet the above thermovacuum chamber and PLC based control
requirements as well as to have versatile capabilities console is shown in figure 1. Design aspects of
for testing of different subsystems and thereby various facility subsystems are presented in detail in
increasing the facility throughput and cost following sections.
effectiveness. This was achieved by the indigenous
design of all facility subsystems and in-house system
engineering for facility establishment. Adequate 2. DESIGN OF VACUUM CHAMBER
technical and safety considerations were
implemented in the facility design for testing of
pressurized systems. Vacuum chamber and thermal Vacuum chamber was designed as per
ASME Section VIII Div.1-2017 [1] using material
shroud was designed in-house, pumping speed
properties as per ASME Section II Part D [2]. The
requirements of low and high vacuum pumps were
chamber was configured in cylindrical shape with
estimated. Sub systems like vacuum feedthroughs
horizontal orientation with a double hinged
and PLC based chamber control system was designed
torispherical door in front and a rear dish welded to
and implemented in-house.
the main chamber body.
Vacuum chamber Chamber size of 1.1 m diameter x 1.3 m
length was optimized based on present test
requirements and space for mounting thermal shroud.
Test requirements of pressurized subsystems for
future missions was also considered in finalizing the
chamber size. Rotational movement of the door
about vertical axis perpendicular to the chamber axis
was limited within ±5° to ensure proper alignment of
door flange with main chamber flange while the
doors are closed. Location, quantity and size of ports
were finalized considering the requirements for
Thermal shroud Vacuum pumps mounting vacuum pumping systems and other
chamber accessories like vacuum feedthroughs.
Figure 1 (a) Overview of thermovacuum chamber Material for vacuum chamber, flange nozzles, door,
and shroud supports was selected as SA-240 SS304L
due to low outgassing properties, corrosion resistance

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NCCS 2019
December 12-14, 2019, Trivandrum, India

and superior weldability. Door seal was configured as 3. VACUUM SYSTEM

trapezoidal groove of inverted dovetail design on the
main chamber flange [3]. Surface finish for all Vacuum system comprises of vacuum
vacuum exposed surfaces was controlled within 1.6 pumps, venting system, vacuum measurement and
microns (Ra value) and emissivity was limited within monitoring system. Various types of vacuum pumps
0.15 to reduce heat transfer from thermal shroud to were considered to achieve a vacuum level of better
chamber wall. Full penetration weld was done for than 1x10-5 hPa.
long seam weld joint of main chamber body,
continuous welding was done from inside the Rotary vane pump has superior pumping
chamber for all ports to obtain leak tightness and speed at atmospheric pressure and there will be
stitch welding from outside for strength. Individual reduction in pumping speed as the pressure is
and total leak rate of chamber was limited within lowered. Roots pump has superior pumping
1x10-9 Pa.m3/s and 1x10-6 Pa.m3/s respectively. performance in comparison with rotary vane pump
from 100 hPa and is capable of generating a vacuum
better than 1x10 -3 hPa. Hence a combination of roots
pump backed by a rotary vane pump was selected for
reducing chamber pressure from ambient to 1x10-3
hPa. Pumping speed of roots- rotary vane pump
combination was estimated considering the
theoretical pumping speed of the roots pump, the
maximum compression as a function of fore vacuum
pressure and the pumping speed characteristic of
backing pump. Considering shorter startup time in
comparison with cryopumps, turbomolecular pumps
was selected to generate high vacuum. Pumping
speed of turbomolecular pumps was estimated
considering desorption rate from the surface of
chamber and shroud, permeation through the
chamber seals and leaks from various interface joints.
A schematic of vacuum system is shown in
Figure 2: 3 D Model of vacuum chamber figure 3. Roughing skid RS is isolated from main
chamber using electro pneumatic valve EP2. Nominal
3 D model of vacuum chamber is shown in pumping speed of the roughing skid RS is 220
figure 2. Thickness of cylindrical shell is estimated as m3/hour at 1 hPa which is capable of evacuating the
8 mm for cylindrical shell and torispherical dished chamber up to 0.01 hPa in 40 minutes. An air
ends with adequate margins with respect to external admittance valve EP5 and a low vacuum gauge VG3
pressure. Adequacy of design to withstand internal is also integrated in this line for venting the inlet port
pressure during pneumatic pressure test was also of roots pump to prevent back streaming of oil from
verified. 3D model of vacuum chamber is shown in rotary vane pump. Evacuation from 1x10-3 hPa to
figure 2. 1x10-5 hPa is achieved using two turbo molecular
pumps TMP1, TMP2 with a total pumping speed of
Bolt load for door flanges at operating
conditions and gasket seating was calculated. The 4100 L/s. Turbo pumps are isolated from the chamber
total required bolt area was estimated from the bolt using electro pneumatic valves EP1 and EP3. Fore
vacuum pumping of turbomolecular pump is
loads and bolts were designed with a higher actual
total cross sectional area. Flange moment calculation achieved by connecting the turbomolecular pump
for external pressure was done and flange stresses exhaust port to inlet line of roughing skid through
solenoid valves SV3, SV4 thereby avoiding the use
were estimated. Considering the above, thickness of
of separate fore vacuum pumps for turbo molecular
main chamber flange was estimated as 50 mm, which
pumps. Sequential operations of all vacuum pumps
is higher than the minimum required thickness. ISO-F
are achieved with the help of PLC system to avoid
vacuum port flanges and ISO-KF flange connections
human errors.
for mounting pumps and other chamber accessories
was selected as per ISO standard [4, 5].

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NCCS 2019
December 12-14, 2019, Trivandrum, India

Figure 3: Schematic of vacuum pumping system

4. THERMAL SYSTEM allowable stress value given in ASME Section II, part
D [2] in kPa.
Thermal system is used to simulate required
thermal environment in a thermovacuum chamber. = √ (1)
Thermal system comprises of a thermal shroud which Thermal shroud assembly has a cylindrical
is a thermally controlled envelop and associated section of 0.89 m diameter and 1.25 m length, with
cooling / heating system. Thermal shroud panels of two flat disc end shrouds of 0.82 m diameter. 3 D
double embossed configuration were designed as per model of thermal shroud is shown in figure 4.
ASME section VIII Division 1 [1] and fabricated Cylindrical shroud is designed as two ‘C’ shaped
through local source as an import substitute which segments. Each ‘C’ shaped segment is further
has resulted in reduced initial cost and lead time. separated into five regions by a long seam laser
Each shroud panels consists of two SA-240 SS304 L welding. Inlet and outlet piping to each segments are
sheets welded together by laser welding on identified welded to a common manifold at bottom and top
spots. Continuous TIG welding on edges are provided respectively. This ensured complete filling of coolant
for better leak tightness. Panels are inflated by medium throughout the shroud for uniform
hydroforming to obtain a predefined path for coolant temperature distribution along the length and
circulation. avoiding hot spots.
Thickness of sheet was calculated using The thermal shroud is configured as
equation 1, where t is the minimum thickness of plate optically tight envelop by closing all gaps between
in mm, p is the maximum pitch measured between the segments using passive copper plates. Partition
adjacent seam weld centre lines in mm, P is the welds are provided in the disc shrouds to prevent
internal design pressure in kPa, S is maximum

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direct flow of coolant medium from inlet pipe to shroud to the chamber was estimated using equation
outlet. 2.

Qrad = F. A. εtot. σ. (T4amb − T4shroud) (2)

Where F is view factor between shroud and
the chamber, σ is Stefan-Boltzmann constant, A is the
area of shroud, εtot is the total emissivity which was
be estimated from equation 3.

εtot = (3)

Where εs is emissivity of shroud and εc is

the emissivity of chamber.
Conductive losses through insulator
mounted between chamber wall and thermal shroud
was estimated from equation 4.

Qcond = ∫ ksup dT (4)

Where Qcond is the conductive loss, A sup

and Lsup is the area and thickness of support
respectively, ksup is the thermal conductivity of
Figure 4: 3 D model of thermal shroud assembly support material provided by the manufacturer.
Transient heat load for cooling shroud from ambient
was estimated using equation 5.
Outer surface of the entire shroud was h
polished to obtain average surface finish better than Qtrans = Mshroud Cpss(Tshroud). (5)
1.6 microns to minimize outgassing and emissivity
was limited within 0.2 to reduce thermal losses. Based on the above equations, the required
Inside surface of the entire shroud assembly was heating and cooling power were estimated. To meet
painted with two coats of thermovacuum compatible this requirements, different combination of thermal
paints for improving emissivity to 0.8. systems was selected for different temperature ranges
considering reduced installation and operational cost.
Various options like closed loop GN2 An IR lamp based heating system consisting of 32
system, closed loop mechanical refrigeration system, numbers of IR lamps was selected for operation from
IR lamp based system and open loop LN2 system for ambient to +150 °C. An open loop LN2 based system
cooling and heating of thermal shrouds were was selected for operational temperature range from
considered. Closed loop GN2 system has advantage ambient to -150 °C considering the test articles with
of precise control of temperature ramp rate and lower emissivity, higher heat loads and tests with
allows operation in wide temperature range. Initial higher ramp rates. A standard thermal circulator with
and operational cost of closed loop GN2 system is mechanical refrigeration system was selected for
higher. Closed loop mechanical refrigeration system operational temperature range from ambient to -70 °C
has limited temperature range and heat load considering long duration tests of test articles with
capacities, primarily depending on the cooling lower heat loads. The above combination will result
medium. To finalize the cooling system architecture, in a reduced overall operational cost due to optimized
the required temperature ranges and the power and LN2 consumption. LN2 loop consists of
corresponding heat loads from the system were inlet solenoid valves for cylindrical and end shrouds,
assessed. which are controlled by PLC system based on the
Total heat load comprises of heat load from temperature feedback from thermal shroud. When the
test article, radiative losses and conductive losses inlet solenoids are closed after attaining specified
from shroud, transient load for cooling or heating of temperature limits, LN2 in the line between LN2
shroud. Maximum thermal load from the test article storage tank and inlet solenoid valve will be
is estimated as 500 watts. Radiative heat losses from vaporized due to heat in leak. In order to avoid hot

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 National Conference on Cryogenics for Space
NCCS 2019
December 12-14, 2019, Trivandrum, India

gas entering the shroud during subsequent openings chamber subsystems through a user-friendly graphic
of inlet solenoid valves, a vent valve is provided in user interface (GUI) on a desktop computer. The
the loop which will be actuated for 40 seconds prior software is also capable of real time monitoring and
to opening of inlet solenoid valves. archiving of complete test data. Individual screens are
provided for accessing the chamber system, pumping
system, thermal system and auxiliary systems and is
5. INSTRUMENTATION AND CONTROL provided with complete status of all equipments and
sensors in each subsystem. SCADA screen for
SYSTEM instrumentation and control system is shown in figure
5.
A PLC based system has been designed and
realized in-house for remote operation and control of The SCADA software is also capable for
all facility subsystems. The control system has been providing real-time warnings, errors and alarms in
designed to operate in two modes, allowing users to case of unexpected behavior of subsystems. Provision
operate the system in PLC mode using the PC based for setting temperature limits, warning limits etc. are
SCADA software and also in manual mode using the available. It is also equipped with an expert mode of
control consoles. The PLC based system is designed operation for trouble shooting and maintenance of the
with all the required sequences for automatic facility.
operation of the facility subsystems and the required The SCADA software is also interfaced with
safety interlocks to eliminate chances of human error an additional standalone data acquisition unit for
while operating the system. The PLC system monitoring and recording of the test data from test
monitors the sequences and interlocks in real-time article / thermal shroud instrumentation. The
and is designed to initiate shutdown sequences to instrumentation capabilities of the system include
reach fail safe mode, in case of emergency situations several channels identified for temperature
like power failure, equipment malfunction etc. measurements using thermocouple / RTD, strain
The PLC based system is interfaced to the measurements using strain gauges and other voltage
operator through in-house designed SCADA and current measurements.
software. This enables the user to control all the

Figure 5: SCADA screen for Instrumentation and control system

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 National Conference on Cryogenics for Space
NCCS 2019
December 12-14, 2019, Trivandrum, India

A manual mode of operation is also A schematic of provisions included in the

designed to enable user in the event unforeseen thermovacuum chamber for conducting pneumatic
failures of PLC considering the safety critical test is shown in figure 7. Needle valve V1 is used to
pneumatic tests conducted in this facility. Essential connect rotary vane pump RVP to the test article for
safety provisions are provided in manual mode also evacuation of hardware prior to test for ensuring
using relay interlock wiring. Manual mode permits purity level of test gas. Needle valve V1 can be
operator to carry out all functions remotely from the closed and V2 can be opened after evacuation of test
control console. article to connect pressure inlet line from pressure
control system for pressurization of test article.
Pressure transducers for measuring test article
6. ADDITIONAL FEATURES pressure, safety relief valves and an electropneumatic
valve is also connected in this line.

Various provisions are incorporated in the Test fixtures for holding pressurized
facility design to improve the versatility of the subsystems inside the chamber was also designed and
thermovacuum test facility to meet customized test fabricated. This test fixture is capable of holding the
requirements. Some of the features are described test article; preventing the same from rotation, lateral
below. movement and at the same time permits axial
movement due to dilation during pressurization /
testing.
6.1 PROVISIONS FOR PNEUMATIC
TESTS
Thermovacuum facility is located inside an
RCC test bay, which is designed to withstand
inadvertent failure of pressurized subsystems during
tests. A dedicated system for automatically
pressurizing the test articles meeting all safety
requirements was realized. This system consists of an
air loaded regulator coupled with an electronic
regulator. A pressure feedthrough was designed and
realized for providing pneumatic pressure line to the
test article located inside the vacuum chamber.
Schematic of pressure feedthrough is shown in figure
6, which consists of a DN ISO 40 KF adaptor (1), a
gland nut with knurled head (2) which can be
tightened to push a collar (3) to compress the O ring
(4) between external surface of tube and internal
surface of adaptor to achieve sealing. Figure 7: Provisions for pneumatic test
An additional solenoid valve SV1 (in Figure
3) is connected to turbomolecular pump exhaust port
which connects the pump to a mass spectrometer
helium leak detector (MSHLD) for conducting
helium leak tests of pressurized satellite / launch
vehicle subsystems by global hard vacuum method.
All vacuum pumps will be disconnected except
tubomolecular pump TMP1 during leak tests.
Automatic control sequence of all pumps for
conducting leak test is implemented in SCADA.

5.2 INDIGENISED FEEDTHROUGHS

Testing of avionic packages and functional

Figure 6: Pressure feed through tests of aerospace mechanisms under thermovacuum

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NCCS 2019
December 12-14, 2019, Trivandrum, India

environment requires vacuum feedthroughs for 7. REFERENCES

routing power, thermocouple and signal connections.
The feedthroughs were designed and realized
[1] An international code- 2017 ASME Boiler &
indigenously as an import substitute. Qualification
Pressure Vessel Code, Section VIII Rules for
and acceptance tests like vacuum tests, leak tests,
construction of pressure vessels Division 1.
outgassing properties evaluation and electrical
properties tests were carried out. The indigenized [2] An international code- 2017 ASME Boiler &
feedthrough has several advantages like faster Pressure Vessel Code, II Materials Part D, Properties
manufacturing time, capability to meet custom R&D (Customary).
requirements, avoiding schedules slippages and
[3] NASA preferred reliability practices- Vacuum
thereby increasing facility throughput. Indigenization
seals design criteria, Practice No. PD-ED-1223.
of feedthroughs has also resulted in substantial cost
savings when compared to imported feedthroughs. [4] ISO 1609 Vacuum Technology - Flange
dimensions.
[5] ISO 2861 Specifications for- Dimensions on
quick release coupling of the screwed type used in
vacuum testing.

Figure 8: Vacuum feed through

6. CONCLUSION

A new PLC based thermovacuum facility

with versatile capability for testing satellite and
launch vehicle subsystems has been designed and
installed. Vacuum level of this facility is 1x10-5 hPa,
maximum and minimum temperature range is +150
°C and -150 °C respectively. Additional features are
also incorporated for conducting thermovacuum tests
and helium fine leak tests of various subsystems
under simulated pneumatic pressure. Indigenous
design of the subsystems has helped to meet tailored
test demands and in increased facility throughput. In-
house system engineering helped in realizing the
facility with reduced testing costs. Indigenous know-
how for realization feedthroughs and control systems
will aid in the augmentation of facility to take up
future test requirements. This facility is fully
operational and serves as a valuable resource for
qualification and acceptance testing of launch vehicle
subsystems produced by Vikram Sarabhai Space
Centre.