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