TIM8May2002

TRD Gas System TIM Report: 

TRD Gas System TIM Report Peter Fisher MIT May 8, 2002

TRD Gas System : 

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

TRD Gas System: 

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 80:20 mix Structural Materials - Tanks: Composite over-wrapped stainless steel - Lines and fittings: stainless steel (welded connections)

Outline: 

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

TDR Gas System-Mechanical : 

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

Slide6: 

TRD Gas Supply Mounted to USS-02

Box S Component Layout: 

Box S Component Layout Box C Vacuum case

Slide8: 

    Xe Bottle: 1550psia CO2 Bottle 940psia V10a V1a V20a V3a V4b V4a V5 V3b V2a V20b F3a P1a V2b V1b P2b RV3-300psi V10b D Vessel (Mix) F1a O1a 60cc 30cc P1b P2a 7 liters per day to Box C O1b F2a F3b F2b 15cc 30cc VG1a VG1b F1b Figure 2: Box S Diagram   RVG1b-1200psi RVG1a-2800psi CO2 Xe Ground Equipment Ground Equipment V17a V17b O2a O2b        

TRD Gas System (Cont): 

TRD Gas System (Cont) Ground Equipment Purifier CO2 Analyzer P5 RV4 – 29psig P3 CP2 CP1 V8B V8A RV5-200psig P4 To Manifold From Manifold From Box S (From V4a) From Box S (From V4b) V18a V18b V6b V6a V9a V9b

Magnetic Field at Gas System: 

Magnetic Field at Gas System Vacuum case Marotta Valves Xe CO2 C

Slide11: 

TRD Gas System (Cont) TRD segment There are a total of 41 segments fed in parallel from the manifold. TRD Segment n From Gas System To Gas System PMnB PMnA VMnA VMnB VMnC VMnD 430 cu. in (7 liters)

TRD Gas System - Mechanical: 

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

TDR Gas System - Electrical : 

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

Slide14: 

Box S Signals and Power

Box S Electronic Simulator: 

Box S Electronic Simulator

Slide16: 

Box C Electrical Signals Three GlenAir connectors: 21-pin power 9-pin high current 25-pin signal 24 V supply still unresolved!!

Box S Pinout: 

Box S Pinout

TRD Gas System Components: 

TRD Gas System Components Box S Composite overwrapped pressure vessels (COVP) High pressure valves GP-50 (“gyppie fifty”) pressure sensors Box C Pumps

Box S Component List: 

Box S Component List

Arde Vessels: 

Arde Vessels

TRD Gas System - Components: 

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

TRD Gas System Components: 

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

TRD Gas System Components: 

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

Xe Vessel During Assembly: 

Xe Vessel During Assembly

TRD Gas System Components: 

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

TRD Gas System Components: 

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)

CO2 Vessel Prior to Overwrap: 

CO2 Vessel Prior to Overwrap

Marotta MV197: 

Marotta MV197 At storage tanks - 3200 psi Inline valves - does not leak out Based on MV100 design - same drivers Space qualified??

Slide29: 

Box C Components List

Pumps: 

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

Pumps: 

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

Slide32: 

Gas system test setup

Test system Results: 

Test system Results Pressure (psia) Time (h) 1% 0.8 psi 11 automated filling cycles Mix in Box S, transfer to C, monitor for 45 minutes 1% pressure stability

CO2 Concentration test: 

CO2 Concentration test

Component testing: 

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

Slide36: 

MV100 Test 1 Doc

Slide37: 

Temperature compensated pressure readings Three kinds: 0-25psi, 0-300psi and 0-3000psi 0.15% accuracy for pressure GP50 testing

Slide38: 

GP50 testing Susceptible to magnetic fields (under study) B sensitivity can be compensated by orientation or mu-metal shielding Working on acceptance testing

Slide39: 

MV100 Testing Status

System Test: 

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

TRD Gas System Operations: 

TRD Gas System Operations Ground operations Flight operations Normal data taking Normal filling Emergency response Startup, shutdown Scheme

TRD Ground Operations: 

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

TRD testing at KSC: 

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

Slide44: 

Recovery System RGA VH2 VH3 PH3 VH4 VH5 VH8 VH6 10 liter Bottle PH4 VH1 VH0 30cc Bottle RVH0 1 liter Bottle 25 liter Bottle PH1 PH0 PH2 Regulator Rotary Vacuum Pump VH7 To box S Sorption pump 2800 psid

Slide46: 

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)

Recovery system operations - filling Box S vessel: 

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

Recovery system - recovering procedure: 

Recovery system - recovering procedure Seal TRD straws Open Box S vessel to cold 25 l standard gas bottles Xe condenses Seal storage vessels

Slide49: 

Box C Operations: Normal on-orbit

Slide50: 

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!

Slide51: 

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. Box C daily filling procedure Black: UGBC control Blue: UGM, UGBS

Slide52: 

Box S Emergency Response Under review!

Slide53: 

Box C Off-Nominal Responses

Slide54: 

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.

Slide55: 

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.

Assembly schedule: 

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

Assembly Schedule: 

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

Slide58: 

TRD Gas System Weight Estimate (unchanged)

TRD Gas System Issues: 

TRD Gas System Issues Where is >24 V? Need thermal environment designed around 20 C Dallas temperature sensors where? How many?