ROLE OF CRYOGENICS IN INDIAN SPACE PROGRAM

L. MUTHU
Chief General Manager, LPSC, ISRO, Mahendragiri. April 10 11, 2006 New 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] INSAT 2A [1992] INSAT 3C [2002] INSAT 4A [2005]

1150 1900 2750 3080

kg Kg Kg 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

GSLV-Mk-III GSLV-Mk-II

PSLV ASLV

SLV-3

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

CRYOGENIC PROPELLANTS

Propellant

Liquid Hydrogen (Fuel) 70.8

Liquid Oxygen (Oxidizer) 1141

Density (kg/m3) Boiling point at atmospheric pressure (K)

20.2

90.2

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

CRYOGENIC PROPULSION
LAUNCH VEHICLE STAGES

STAGE Application Propellant loading (kg) Thrust (kN) Operating cycle Specific Impulse

CUS GSLV Mk II 12,000 75 Staged combustion 460

C25 GSLV Mk III 25,000 200 Turbopump Gas generator 445

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

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

CRYO FLUIDS PRODUCTION FACILITY INTEGRATED LIQUID HYDROGEN PLANT

Fluid

Production capacity (l/hr) 300

Storage capacity (m3) 5 x 40

Purity (%)

Liquid Hydrogen Liquid Oxygen Liquid Nitrogen

99.995

75

26

99.75

477

41

99.8

LIQUID HYDROGEN FILLING IN TANKER

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.

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.

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)

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.

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 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

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

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 & sprinklers Fire hydrants Nitrogen inerting of hydrogen handling areas Safety showers & Personal protective equipments Electrical safety Explosion protection

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.

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