ROLE OF CRYOGENICS IN INDIAN SPACE PROGRAM
L. MUTHUChief General Manager, LPSC,
ISRO, Mahendragiri.
April 10 – 11, 2006New Delhi
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.
SATELLITE LAUNCH VEHICLES
Satellites are becoming heavier …. INSAT 1A [1982] – 1150 kgINSAT 2A [1992] – 1900 KgINSAT 3C [2002] – 2750 KgINSAT 4A [2005] – 3080 kg
……… requiring more powerful launchers
4000 kg GTO600 tonGSLV Mk III
2500 kg GTO400 tonGSLV Mk II
1200 kg SSPO300 tonPSLV
Typical payloadLiftoff massLauncher
SLV-3
ASLVPSLV
GSLV-Mk-II
GSLV-Mk-III
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 sEarth-storable liquid propulsion – 285 sCryogenic propulsion – 450 s
CRYOGENIC PROPELLANTS
90.220.2Boiling point at atmospheric pressure (K)
114170.8Density (kg/m3)
Liquid Oxygen (Oxidizer)
Liquid Hydrogen
(Fuel)
Propellant
CRYOGENIC PROPULSION
MERITS:High Specific ImpulseNon-toxic and non-corrosive propellantsNon-hypergolic, improved ground safety
DEMERITS:Low density of liquid Hydrogen – more structural massLow temperature of propellants - Complex storage &
transfer systems and operationsHazards related to cryogensOverall cost of propellants relatively highNeed for ignition system
CRYOGENIC PROPULSION LAUNCH VEHICLE STAGES
445460Specific Impulse
Turbopump –Gas generator
Staged combustion
Operating cycle
20075Thrust (kN)
25,00012,000Propellant loading (kg)
GSLV Mk IIIGSLV Mk IIApplication
C25CUSSTAGE
CRYOGENIC PROPULSION FACILITIES
PRODUCTION AND SUPPLY OF CRYO FLUIDS:Integrated Liquid Hydrogen PlantGas bottling plants
TEST FACILITIES:For rocket engines, subassemblies and componentsFor integrated stages of launch vehicles
ASSEMBLY OF VEHICLE SYSYEMS:For testingFor launch
CRYO FLUIDS PRODUCTION FACILITY
INTEGRATED LIQUID HYDROGEN PLANT
HYDROGEN PLANT
Gaseous hydrogen by steam-reforming of naphthaLiquefaction by Linde-Hampson cycle with
liquid nitrogen pre-cooling
AIR SEPARATION PLANT
Liquid Nitrogen and Liquid Oxygen
CRYO FLUIDS PRODUCTION FACILITY
INTEGRATED LIQUID HYDROGEN PLANT
99.841477Liquid Nitrogen
99.752675Liquid Oxygen
99.9955 x 40300LiquidHydrogen
Purity (%)Storage capacity
(m3)
Production capacity
(l/hr)
Fluid
LIQUID HYDROGEN FILLING IN TANKER
GAS BOTTLING PLANTS
Hydrogen:
Liquid -> Vaporizer -> Gas -> Compressor -> CylinderPresently up to 250 bar; being augmented to 400 bar.
Nitrogen:
Liquid -> Pump -> Evaporator -> HP gas -> CylinderPresently up to 300 bar; being augmented to 400 bar.
AUGMENTATION OF CRYOGENIC STORAGES
For Liquid Hydrogen, Helium, Oxygen & Nitrogen.
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 barLOX run tank – 1.5 m3, 80 barGas storages at high pressureHAT facility.
MAIN ENGINE AND STAGE TEST FACILITY (MET)
Capability:
Hot tests of 200 kN cryo engine and stagePropellant expulsion tests
Systems:
Test stand structuresLiquid hydrogen tanks: 107 m3 & 15 m3Liquid Oxygen tanks: 40 m3 & 7 m3Super-insulated Cryogenic pipingGas Storages: Hydrogen (250 bar)
Helium (350 bar)Nitrogen (300 bar)
MAIN ENGINE AND STAGE TEST FACILITY (MET)
Systems:
Safety systems:Gas monitors, Fire/smoke detectorsDeluge and sprinklersCC TV, Access controlInerting systems
Instrumentation systems:Command and controlMonitoring and Data logging
Propellant Disposal systems: Burners, stacks, pits.
MAIN ENGINE AND STAGE TEST FACILITY (MET)
CUS ENGINE TEST AT MET
MEASUREMENT AND CONTROL CENTRE FOR MET
THRUST CHAMBER TEST FACILITY (TCT)(under construction)
Capability:Hot tests of 250 kN Thrust Chamber and engineHot tests in high-altitude simulated condition
Systems:
Liquid hydrogen tank: 9.6 m3, 220 barLiquid Oxygen tank: 4.1 m3, 220 barHydrogen and Nitrogen Gas storages at 400 barHigh-pressure cryogenic pipingHAT systems
CRYO SUBSYSTEM TEST FACILITY(under realization)
Calibration of LH2 and LOX flow metersStatic and dynamic testing of umbilical connectorsTesting of valves with actual fluidsPressure and deflection tests of polyimide pipesPressure cycling test of GHe gas bottles in LH2Development and calibration of level sensors
Systems:
LH2 run tank: 40 m3, 10 barLOX run tank, 12 m3, 21 barLH2, LOX disposal systemsGas storages
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
CRYOGENIC ENGINE - CUS
CRYOGENIC STAGE - CUS
CRYOGENICS – SAFETY
Process safety: Inertization, Insulation, Alarms, Interlocks, trips
H2, O2 & flame detectors
Fire fighting: Deluge & sprinklersFire hydrants
Nitrogen inerting of hydrogen handling areas
Safety showers & Personal protective equipments
Electrical safety – Explosion protection
Present programs relate to Cryogenic Upper Stages forlaunch vehicles
Future plans envisage development of powerful cryogenic booster stages
Increasing role for cryogenics envisaged in Indian Space Program.
THANK YOU