ROLE OF CRYOGENICS IN INDIAN SPACE PROGRAM L. MUTHU

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1 ROLE OF CRYOGENICS IN INDIAN SPACE PROGRAM L. MUTHU Chief General Manager, LPSC, ISRO, Mahendragiri. April 10 11, 2006 New Delhi

2 INDIAN SPACE PROGRAM Vibrant and Multi-dimensional Satellites: Remote-sensing, telecommunication & other applications. Polar and Geo-stationary orbits. Launchers: Satellite launch vehicles. Sounding rockets. Space sciences and applications. Operational services. Commercialization.

3 SATELLITE LAUNCH VEHICLES Satellites are becoming heavier. INSAT 1A [1982] 1150 kg INSAT 2A [1992] 1900 Kg INSAT 3C [2002] 2750 Kg INSAT 4A [2005] 3080 kg requiring more powerful launchers Launcher PSLV GSLV Mk II GSLV Mk III Liftoff mass 300 ton 400 ton 600 ton Typical payload 1200 kg SSPO 2500 kg GTO 4000 kg GTO

4 GSLV-Mk-III GSLV-Mk-II ASLV PSLV SLV-3

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6 WHY CRYOGENICS? Propulsion system: The power Centre of a launcher. Specific Impulse (Isp): Index of efficiency of a propulsion system. Isp = Thrust / Weight flow rate of propellants. Traditionally expressed in seconds. Isp of different propulsion systems (sea-level): Solid propulsion 265 s Earth-storable liquid propulsion 285 s Cryogenic propulsion 450 s

7 CRYOGENIC PROPELLANTS Propellant Density (kg/m3) Liquid Hydrogen (Fuel) 70.8 Liquid Oxygen (Oxidizer) 1141 Boiling point at atmospheric pressure (K)

8 CRYOGENIC PROPULSION MERITS: High Specific Impulse Non-toxic and non-corrosive propellants Non-hypergolic, improved ground safety DEMERITS: Low density of liquid Hydrogen more structural mass Low temperature of propellants - Complex storage & transfer systems and operations Hazards related to cryogens Overall cost of propellants relatively high Need for ignition system

9 CRYOGENIC PROPULSION LAUNCH VEHICLE STAGES STAGE CUS C25 Application GSLV Mk II GSLV Mk III Propellant loading (kg) Thrust (kn) Operating cycle Specific Impulse 12, Staged combustion , Turbopump Gas generator 445

10 CRYOGENIC PROPULSION FACILITIES PRODUCTION AND SUPPLY OF CRYO FLUIDS: Integrated Liquid Hydrogen Plant Gas bottling plants TEST FACILITIES: For rocket engines, subassemblies and components For integrated stages of launch vehicles ASSEMBLY OF VEHICLE SYSYEMS: For testing For launch

11 CRYO FLUIDS PRODUCTION FACILITY INTEGRATED LIQUID HYDROGEN PLANT HYDROGEN PLANT Gaseous hydrogen by steam-reforming of naphtha Liquefaction by Linde-Hampson cycle with liquid nitrogen pre-cooling AIR SEPARATION PLANT Liquid Nitrogen and Liquid Oxygen

12 CRYO FLUIDS PRODUCTION FACILITY INTEGRATED LIQUID HYDROGEN PLANT Fluid Production capacity (l/hr) Storage capacity (m3) Purity (%) Liquid x Hydrogen Liquid Oxygen Liquid Nitrogen

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14 LIQUID HYDROGEN FILLING IN TANKER

15 GAS BOTTLING PLANTS Hydrogen: Liquid -> Vaporizer -> Gas -> Compressor -> Cylinder Presently up to 250 bar; being augmented to 400 bar. Nitrogen: Liquid -> Pump -> Evaporator -> HP gas -> Cylinder Presently up to 300 bar; being augmented to 400 bar. AUGMENTATION OF CRYOGENIC STORAGES For Liquid Hydrogen, Helium, Oxygen & Nitrogen.

16 CRYOGENIC TEST FACILITIES STEERING ENGINE TEST FACILITY (SET) Capability: Hot test of Gas Generator, injector elements, turbo-pumps for LH2 and LOX Systems: LH2 run tank 4.5 m3, 80 bar LOX run tank 1.5 m3, 80 bar Gas storages at high pressure HAT facility.

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19 MAIN ENGINE AND STAGE TEST FACILITY (MET) Capability: Hot tests of 200 kn cryo engine and stage Propellant expulsion tests Systems: Test stand structures Liquid hydrogen tanks: 107 m3 & 15 m3 Liquid Oxygen tanks: 40 m3 & 7 m3 Super-insulated Cryogenic piping Gas Storages: Hydrogen (250 bar) Helium (350 bar) Nitrogen (300 bar)

20 MAIN ENGINE AND STAGE TEST FACILITY (MET) Systems: Safety systems: Gas monitors, Fire/smoke detectors Deluge and sprinklers CC TV, Access control Inerting systems Instrumentation systems: Command and control Monitoring and Data logging Propellant Disposal systems: Burners, stacks, pits.

21 MAIN ENGINE AND STAGE TEST FACILITY (MET)

22 CUS ENGINE TEST AT MET

23 MEASUREMENT AND CONTROL CENTRE FOR MET

24 THRUST CHAMBER TEST FACILITY (TCT) (under construction) Capability: Hot tests of 250 kn Thrust Chamber and engine Hot tests in high-altitude simulated condition Systems: Liquid hydrogen tank: 9.6 m3, 220 bar Liquid Oxygen tank: 4.1 m3, 220 bar Hydrogen and Nitrogen Gas storages at 400 bar High-pressure cryogenic piping HAT systems

25 CRYO SUBSYSTEM TEST FACILITY (under realization) Calibration of LH2 and LOX flow meters Static and dynamic testing of umbilical connectors Testing of valves with actual fluids Pressure and deflection tests of polyimide pipes Pressure cycling test of GHe gas bottles in LH2 Development and calibration of level sensors Systems: LH2 run tank: 40 m3, 10 bar LOX run tank, 12 m3, 21 bar LH2, LOX disposal systems Gas storages

26 CRYO ENGINE & STAGE ASSEMBLY ENGINE: Rotor balancing Injector calibration Functional assembly Leak checks, P checks Cold gimbal tests STAGE: Proof pressure tests Cleaning, composite insulation Leak checks, functional checks Instrumentation and check out

27 CRYOGENIC ENGINE - CUS

28 CRYOGENIC STAGE - CUS

29 CRYOGENICS SAFETY Process safety: Inertization, Insulation, Alarms, Interlocks, trips H2, O2 & flame detectors Fire fighting: Deluge & sprinklers Fire hydrants Nitrogen inerting of hydrogen handling areas Safety showers & Personal protective equipments Electrical safety Explosion protection

30 Present programs relate to Cryogenic Upper Stages for launch vehicles Future plans envisage development of powerful cryogenic booster stages Increasing role for cryogenics envisaged in Indian Space Program.

31 THANK YOU