New Development of a Two-Phase Mechanically Pumped Loop … · 2009. 8. 27. · tube17 1 2 1...

International Two-Phase Thermal Control Technology Workshop 2008 13-15 May 2008 ESTEC

Development of a Two-Phase Mechanically Pumped Loop(2ΦMPL) for the Thermal Control of Telecommunication Satellites

Julien HUGON - Thales Alenia SpaceAmaury LARUE de TOURNEMINE – CNES

Gennadiy GORBENKO – National Aerospace University (Kharkiv Aviation Institute)Pavlo GAKAL – National Aerospace University (Kharkiv Aviation Institute)

Vasyl RUZAYKIN – National Aerospace University (Kharkiv Aviation Institute)Tisna TJIPTAHARDJA – ESA

Rudolf BLEULER – Realtechnologie AG


Presentation plan

Background

Architecture/thermal hypothesis and requirements

2ΦMPL hydraulic scheme

2ΦMPL components

Mathematical modeling

2ΦMPL overall mass budget

2ΦMPL ground prototype

2008 perspectives


Background (1/2)

The future large and powerful telecommunication satellites could need theuse of large deployable radiators (DPR) and efficient thermal loop to transportlarge amount of heat on long distances

Main original need : @bus Extended RangeOther potential applications : very dissipative units like active antennas

South Panel

East Panel

South/East DR

North/West DR

North/East DR

South/West DR

H

LNorth PanelWest Panel

+Z

+X +Y

LDRlDR


About Mechanically Pumped Loops

Condenser

Three-Way Valves

Pump

ByPass

Control Valves

EvaporatorLiquid

Vapor or Liquid/Vapor

Accumulator (HCA)

2ΦMPL Scheme

Radiator Heat Exchanger (Cold Sink)

Three-WayValves

Pump

ByPass

Control Valves

Payload Heat Exchangers(Cold Plates) to Cool Units

Liquid

Liquid

Reservoir

Single Phase Loop (SPL)

Scheme

Main 2ΦMPL advantages wrt to

SPL :

•isothermallity

•mass

•pump power consumption

•temperature control

with HCA


Background (2/2)

A two-phase TCS was developed in the 90’s for ISS Russian Segment

In 2002, Russian/Ukrainian experience on both products has been investigated by ThAS through a Trade-Off study with mass as the main criterion : 30% mass saving with a two-phase system was demonstrated

In 2005, ThAS/CNES, through a R&T program, started a development phase with the first step consisting in the evaluation of an Ukrainian NH3 2ΦMPL prototype to be designed, manufactured and tested by the Kharkov Aviation Institute according to ThAS requirements


Architecture/Thermal Hypothesis & Requirements (1/5)

500

2500

2800

2000

500

Y

X

Z2nd FloorPanel

1st FloorPanel

ShearwallPanel

Platform with shelves

L

1100

Shearwall Panel

3200

Y

X

Z

DeployableRadiators

1st Floor Panel

2nd Floor Panel



Units layout on shelves

TWT and HPI units layout and dimensions on an horizontal panel(+ / -Z symmetric layout)

80

175

TWT collector

40

60 50

175175

X

Y

150

150

300

150

TWT

HPI

HPI

TWT

TWT body



Units thermal characteristics

Number of Active

Components

Dissipation per Unit (W)

Total Dissipation

(W)TWT 1st Floor TWTA 60 50 3000TWT 2nd Floor TWTB 60 30 1800OMUX Lower Shearwall Part OMUXA 30 22 660OMUX Upper Shearwall Part OMUXB 30 18 540

6000Total Heat Load (W)

Min Max Min MaxTWT +10 +70 -20 +70 -20OMUX +35 +75 -20 +75 -20

CalculationOperating Temperature (°C) Non Operating Temperature (°C) Cold Start Up (°C)

TWTA OMUXA TWTB OMUXBm (kg) 0,80 0,90 0,80 0,15

mCp (J/K) 720 810 720 135



Environmental conditions (1/2)

South Panel

East Panel

Sun Incidence at 06h00

Solstice CaseEast Panel Illuminated

South/West DR

South/East DR

Earth Panel

23.44° Sun Direction +X

+Y

+Z

West Panel

Hot environmental condition

South Panel

East Panel

Sun Incidence at 12h00

Equinoxe CaseNo illumination of East and West Panels

South/West DR

South/East DR

Earth Panel

Sun Direction //to Z axis

+Y+X

+Z

West Panel

Cold environmental condition



Environmental conditions (2/2)( ) ( ) XMPL4 Xenv4 XradradOSRspacerad QTTSF1 +++− =−σε+( ) ( ) XMPL4 Xenv4 XradradOSRspacerad QTTSF1 −−−− =−σε+

XMPLXMPLtot_MPL QQQ −+ +=

Tenv=f(Orbital position)Winter Solstice

0

50

100

150

200

250

0 100 200 300

Orbital position (°)

Tenv

(K)

Rad+X Trad=50°CRad-X Trad=50°CRad+X Trad=40°CRad-X Trad=40°CRad-X Trad=30°CRad-X Trad=30°C

S ra d (m ²) F ra d -s p a c e5 0 ,8 6

4 ,5 0 ,8 54 0 ,8 3

3 ,5 0 ,8 23 0 ,8 0

2 ,5 0 ,7 7

Environmental temperatures variation the deployable

radiators for different orbital positions in winter solstice

Srad=5m²


2ϕ MPL Hydraulic Scheme (1/2)

TWTB and HPI units.Number of ActiveComponents - 60.

Dissipation per Unit - 30 W.Total Dissipation - 1800 W.

Dissipation per Unit - 50 W.

TWTA and HPI units.Number of ActiveComponents - 60.

Total Dissipation - 3000 W.

OMUXB units (Lower Shearwall Part).

Number of Active Components - 30.

OMUXA units (Upper Shearwall Part).

Number of Active Components - 30.


HCA



Dissipation per Unit – 50 W.

Temperature sensors

Regulation laws to control the minimal

acceptable temperature of units (centralized

heating)

+ Heatingzones

Liquid state

Two-phase state

Throttle

Heaters for the saturattion temperature

control


2ϕ MPL Hydraulic Scheme (2/2)

30014002800

2450

130

1400

3040

500

4200

1080

1250

124010001000

300

300

HCA

Pump

Throttles

Throttles

TWTB panel

TWTA panel

OMUXpanel

Configuration within the Platform


2ϕ MPL Components (1/5)

• Evaporator tubing• Pump• Heat-controlled accumulator (HCA)• Radiators with embedded heat pipes• Condenser/subcooler components• Throttles • Heaters

Optimization of the components design to minimize the overall system mass :

( ) min→++++= radpowerpumpfluidtubeMPL MMMMMM



Evaporators tubing



Lrad

1100

Subcooling cavity

Condensation cavity

Two-phase flow

One-phase flow

Condenser/subcooler components in the radiators



NACPA II Pump Opportunity (1/2)

In 2005-2006, ThAS has been invited by ESA to follow NACPA project that has consisted in Realtechnologie AG review of the NACPA centrifugal pump package (documentation + hardware, performance tests included) developed by ESA/ETEL in the 90’s

Between 2006 and 2008, ThAS collaborates for the ESA/Realtechnologie AG development of a new NH3 pump/motor engineering model and of a prototype of the associated driver motor electronic unit (NACPA II project)



NACPA II Pump Opportunity (2/2)

•ThAS is responsible for the thermal analysis of the NACPA II pump

•Cavitation issue in the pump can be critical at low temperature

Pressure reserve : maximum allowable local pressure drop inside

the pump (only 0.44bar at –10°C)

Temperature reserve : maximum allowable local temperature increase in the pump


Mathematical Modeling (1/2)

K K+1j

1

2

j

Nin

1

2

NexQw-f,k

Tw,kQcond,k

Tw,n

Qrad,k

- control volume; - branch (junction)

- radiative heat conductor.

- convective heat conductor;

- conductive heat conductor;

tb3_ tb14

subc2_tb2

TGA_P

subc2

tb5_cond1

tb7_subc1

21 2

2

tb2_

tb3

tb8_subc2

tube

1, 1

.4 m

,8.

5 m

mtu

be2,

1.4

m,

8.5

mm

tube4,3 .5 m, 7 mm

1

tb19_tb5

tb4_T W TA

tb14

_tb8

tb14

_tb7

tube7, 3 m,

4 mm

TGA

tube14, 1 .95 m,4 mm

tb14_tb4 1

subc1

cond

11

4

111214 13

rad1

1

3

2

1

3

2

1

3

2

1

3

2

3 2 1

5 6 7 8

111

121141 131

4 3 2 1

h_cond11

h_cond12

h_cond13

h_cond14 cond

12

cond

13

rad_cond14

rad_cond13

rad_cond12

rad_cond11

cond

14

tube16

cond

21

4

212224 23

rad2

1

3

2

1

3

2

1

3

2

1

3

2

3 2 1

5 6 7 8

211

22 124 1 23 14 3 2 1

h_cond21

h_cond22

h_cond23

h_cond24 con

d22

cond

23

rad_cond24

rad_cond23

rad_cond22

rad_cond21

cond

24

tube17

1

2

1

tb1_

tb3

subc1_tb1

1

2

tube8, 0.8 m,

4 mm

2

1

tube5, 1.4 m,

9 mm

1

2

tube6, 1.4 m,

9 mm

2

1

tb19_tb6tb6_cond2

4 4 4 4

4 4 4 4

4

24

1

3

2

5

241

4

h_cond24

6

2

1

35

4

rad_cond24

7

cond

24

4

1 2

tube3 , 3.85m,10 .4 mm

2

8

EH1

3

H _TW T B_profile

EH 3

1

EH 2 1 2 3tb4_TW T B

T W TB

T W TA

H _TW TA_profile

1 2 3

O M UX

H _O M U X_profile

2

tube18 , 1 .39 m,10 .9 mmTW TA_tb18

TW TA _tb18

tb18_OM

UX

OM

UX_tb 19

tube

19, 5

.71

m,

11.2

mm

2

1

H _H C A_body

3

3

H_TW TB_un it

H _TW T A_unit

H _O M U X_unit

H _H C A_hr

Nodalisation of flight 2ΦMPL


Mathematical Modeling (2/2)

TWTB and HPI units. Number of Active Components - 60.

Dissipation per Unit - 30 W. Total Dissipation - 1800 W. Dissipation per Unit - 50 W.

TWTA and HPI units.Number of ActiveComponents - 60.


OMUXB units(Lower Shearwall Part).

Number of ActiveComponents - 30.

OMUXA units(Upper Shearwall Part).

Number of ActiveComponents - 30.


HCA



1

2

3

4

5 6 7

8 9 10

11’ 12

13 14

15 16

17

11


18

P, MPa T, oC x m, g/s

1 2.3918 56.392 0.90412 6.3116

2 2.3912 56.384 0.90411 6.3116

3 2.3911 56.382 0.90411 3.4308

4 2.3946 56.441 0.71332 2.3988

5 2.3946 56.441 0.72941 3.9128

6 2.3946 56.441 0.72330 6.3116

7 2.3945 56.439 0.72330 6.3116

8 2.3912 56.382 0.90411 2.8808

9 2.3804 51.887 0.0 11.337

10 2.3803 51.559 0.0 23.045

11 2.4557 51.479 0.0 23.045

11’ 2.4476 51.478 0.0 16.734

12 2.4555 51.479 0.0 6.3116

13 2.3970 51.900 0.0 3.9128

14 2.3995 51.900 0.0 2.3988

15 2.3821 51.546 0.0 8.2778

16 2.3804 51.220 0.0 11.708

17 2.3802 51.546 0.0 8.4586

18 2.3800 51.560 0.0 23.045

3280W

2720W


2ϕ MPL Mass Budget

Overall Mass BudgetMPL components Mass, kg Comments

Mass of radiators +

tubes + HCA

104

Surface area of one side of radiator is equal to 4.3 m2 calculated based on conservative hot heat removal conditions corresponding to 2700 with the same environmental conditions of both radiators. Thermal gradient of MPL between TWT unit and radiator skin is equal to 22.2 K : 9.5K between TWT and evaporator fluid (two-phase thermal exchange calculation) and 12.7K between condenser fluid and radiator => Global conductance>120W/K and Heat Rejection Capacity>650W/m²

Ammonia 8

Pump unit (redunded, with electronics)

8 Operating point of pump corresponds to 1.17 bar and 44×10-6 m3/s at 50°C temperature of ammonia. Required power of pump is less than 50 W.

Total 120 20 kg/kW but without the shielding against micrometeorits =>25kg/kW is nevertheless reachable (P=0.998 for 15 years)


2ϕ MPL Prototype (1/4)

Honeycomb panel

Heat pipe

Condenser wall imitator

Electrical heater

675

1100

950

General view of the prototype

Cooling systemRemote air condensers ofcooling system

RS installation

Control panels (MPL and CS) Filling systemHCA

OMUX panelTWT panel

RadiatorsPump

Cooling systemRemote air condensers ofcooling system

RS installation

Control panels (MPL and CS) Filling systemHCA

OMUX panelTWT panel

RadiatorsPump



Condenser and cooling fluid circulation

Antifreeze

Antifreeze

Liquid ammonia

Two-phaseammonia

Cooling system inlet collector

Coolingsystem outletcollector

Rubber hose

Condenser

Thermally-isolated box

Antifreeze

Antifreeze

Liquid ammonia

Two-phaseammonia

Cooling system inlet collector

Coolingsystem outletcollector

Rubber hose

Condenser

Thermally-isolated box



Side

Positions of heat transfer surface between unit and tube

BottomTop

TWT collector baseplate

TWT body baseplate

Electrical heater

Ammonia

Ammonia Payload simulation means



The prototype partly assembled


2008 perspectives

MPL Prototype Functional Testing

The proof, leak and filling phases are foreseen for the end of May

During the second semester of 2008

Both steady-state (hot and cold cases) and transient (hot to cold and cold to hot) will be testedThe regulation concept using HCA heating and centralized heating will be investigatedStart-up issue of the system will be investigated too

NACPA Pump

The pump BBM shall be successfully tested for performances (including cavitation test) for the end of MayThe pump+motor DM and the DME BBM shall be assembled/tested for the end of 2008

New Development of a Two-Phase Mechanically Pumped Loop … · 2009. 8. 27. · tube17 1 2 1...

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