STS demonstrated that you can move cryogens over a pipe then disconnect the pipe and leave it permanently disconnected until remoted by hand on the ground. But Atlas also demonstrated that decades earlier with the LOX feeds to the booster engines. The hard part will be a cryogenic fluid coupler that can mate in orbit, demate, and remate again, multiple times, in orbit, whilst still allowing the receiving end of that connector to seal against flight pressures. That's been done for storable propellants, but not for cryogens, and cryogenic sealing and connectors are a notorious pain.
The Shuttle did not have any in-tank boost pumps. Liquid propellants were pushed out of the tanks and over the tank-to-vehicle connections and into the engine pumpheads by pressure from the ullage gas, not suction from the pump heads. Being autogenously pressurised that gas was supplied by the SSMEs, but could just as well have come from gas bottles inside the tanks (terrible idea though, no mass margins). Disconnect the tank-to-vehicle lines, and that ullage pressure would have equally well pushed propellants out the end of the lines into free space.
Quote from: edzieba on 01/06/2023 06:13 pmThe Shuttle did not have any in-tank boost pumps. Liquid propellants were pushed out of the tanks and over the tank-to-vehicle connections and into the engine pumpheads by pressure from the ullage gas, not suction from the pump heads. Being autogenously pressurised that gas was supplied by the SSMEs, but could just as well have come from gas bottles inside the tanks (terrible idea though, no mass margins). Disconnect the tank-to-vehicle lines, and that ullage pressure would have equally well pushed propellants out the end of the lines into free space. Yes, of course and head pressure. The point was where the propellants were going and pumps were aiding in the pressure differential. The supply tank doesn't have to keep increasing pressure to over come back pressure.But you can go back even further with the connection: the GSE and umbilicals disconnects that filled the tanks have been used on almost all cryogenic vehicles.
Yes, of course and head pressure. The point was where the propellants were going and pumps were aiding in the pressure differential. The supply tank doesn't have to keep increasing pressure to over come back pressure.But you can go back even further with the connection: the GSE and umbilicals disconnects that filled the tanks have been used on almost all cryogenic vehicles.
Quote from: Jim on 01/06/2023 06:29 pmYes, of course and head pressure. The point was where the propellants were going and pumps were aiding in the pressure differential. The supply tank doesn't have to keep increasing pressure to over come back pressure.But you can go back even further with the connection: the GSE and umbilicals disconnects that filled the tanks have been used on almost all cryogenic vehicles.I'm not sure I'm getting your point here, but tanks can be filled by their internal pressure differential or filled at the same pressure by small pumps. In either case, it will be the responsibility of the receiver to vent to keep pressure more-or-less static as prop flows in, and the sender to pressurize as prop flows out.My favorite version of this is simply to connect the two ullage spaces together and use very small pumps to move the prop from one tank to the other. There are no vented ullage gas losses this way. In contrast, if you have an open system, where the receiver vents to the outside and the sender does something autogenous to keep the ullage space from becoming progressively lower pressure, you're wasting the receiver's ullage and doing something complicated and/or heavy on the sender.Another reason to use pumps and no pressure differential: If you're pressure-feeding the coupled tank system and you have an ullage oopsie where you uncover the high-pressure sump, the system will equalize more-or-less instantaneously, which will be a bummer. It's a recoverable bummer, but one that can cost you a couple of tonnes of vented ullage gas.
How much is minimum acceleration needed? I assume minimum as surface tension no?
Quote from: edzieba on 01/06/2023 06:13 pmSTS demonstrated that you can move cryogens over a pipe then disconnect the pipe and leave it permanently disconnected until remoted by hand on the ground. But Atlas also demonstrated that decades earlier with the LOX feeds to the booster engines. The hard part will be a cryogenic fluid coupler that can mate in orbit, demate, and remate again, multiple times, in orbit, whilst still allowing the receiving end of that connector to seal against flight pressures. That's been done for storable propellants, but not for cryogens, and cryogenic sealing and connectors are a notorious pain.What are the differences between doing this on the ground (as in the SS QD arm) and doing it in orbit, and do these differences make the job harder or easier? Clearly, the presence of a 1g gravity field on the ground is a big difference. What about others?
Quote from: BT52 on 01/07/2023 07:59 pmHow much is minimum acceleration needed? I assume minimum as surface tension no?SpaceX knows the answer. But not sure if we ever became privy to that value for SS. Without knowing that value with significant margins the SS on orbit would have some difficulties. Such as performing a circularizing burn at apogee after a drift in a preliminary elliptical transfer orbit.
All of that vented ullage is actually needed to provide acceleration to maintain the prop settling. So it is not wasted.
If you have three sets of tanks each for LCH4 and LOX, one can be active, one can be in redundant standby, and one can be refilling, heating, and pressurizing.
Let's make the following assumptions:Settling acceleration: 5mm/s² (I'm being conservative).Prop transfer time: 2000s (a bit more than half an hour).Cold (or maybe warm) gas Isp: 70s.Methox or methalox combusting gas Isp: 300sDepot dry mass: 90t. Prop capacity: 1600t.Tanker dry mass: 120t: Prop payload: 150t.Then the lightest coupled system is an empty depot with a tanker transferring the first load of prop: 90t + 120t + 150t = 360t. Using cold-to-warm ullage gas for the target acceleration requires 1800N, and the target transfer time would therefore require 5.2t of ullage gas. Not great, but OK.But the heaviest system is a depot receiving its last load of prop: 90t + 1450t + 120t + 150t = 1810t. Now cold gas requires 9050N of thrust, and 26.4t of gas for the full transfer. That's not only unacceptable from a prop efficiency standpoint, but there isn't enough cold ullage gas available in the first place.In contrast, the heavy case with combusting methox or methalox would only require 6.2t of prop.
Quote from: oldAtlas_Eguy on 01/07/2023 08:46 pmQuote from: BT52 on 01/07/2023 07:59 pmHow much is minimum acceleration needed? I assume minimum as surface tension no?SpaceX knows the answer. But not sure if we ever became privy to that value for SS. Without knowing that value with significant margins the SS on orbit would have some difficulties. Such as performing a circularizing burn at apogee after a drift in a preliminary elliptical transfer orbit.I think ULA had done successful experiments with about 1mm/s² for long-term settling.Note that settling for pre-ignition of engines is different from settling for prop transfer. The former can be relatively high-thrust, because it's only active for a couple of seconds. The latter has to be as low-thrust as possible, because it'll be active for minutes or even hours. But your engines don't blow up if you accidentally uncover the sump.Quote from: oldAtlas_Eguy on 01/06/2023 10:19 pmAll of that vented ullage is actually needed to provide acceleration to maintain the prop settling. So it is not wasted.I just don't see how they're gonna use cold or warm gas thrusters for settling for prop transfer. Isp is too low, which requires way too much mass flow to hit the proper thrust. Let's make the following assumptions:Settling acceleration: 5mm/s² (I'm being conservative).Prop transfer time: 2000s (a bit more than half an hour).Cold (or maybe warm) gas Isp: 70s.Methox or methalox combusting gas Isp: 300sDepot dry mass: 90t. Prop capacity: 1600t.Tanker dry mass: 120t: Prop payload: 150t.Then the lightest coupled system is an empty depot with a tanker transferring the first load of prop: 90t + 120t + 150t = 360t. Using cold-to-warm ullage gas for the target acceleration requires 1800N, and the target transfer time would therefore require 5.2t of ullage gas. Not great, but OK.But the heaviest system is a depot receiving its last load of prop: 90t + 1450t + 120t + 150t = 1810t. Now cold gas requires 9050N of thrust, and 26.4t of gas for the full transfer. That's not only unacceptable from a prop efficiency standpoint, but there isn't enough cold ullage gas available in the first place.In contrast, the heavy case with combusting methox or methalox would only require 6.2t of prop.We've rehashed this elsewhere about a zillion times, but a set of redundant COPVs solve an awful lot of problems if they have the following duty cycle:1) Vent the empty COPV to some very low pressure, into which it's easy to pump liquid prop.2) Pump LCH4 or LOX into it until full.3) Seal the vent and the pump inlet.4) Heat it with electric heaters until it's supercritical at flight pressure (300-500bar).5) Use it for whatever you need:a) Bringing cold main or header tanks up to flight pressure.b) Pushing liquids into pressure-fed methalox engines.c) Driving monopropellant hot-gas thrusters.d) Driving methox combustion thrusters.6) When the COPV drops below minimum flight pressure, switch over to another redundant COPV and start the cycle over.If you have three sets of tanks each for LCH4 and LOX, one can be active, one can be in redundant standby, and one can be refilling, heating, and pressurizing.
Quote from: TheRadicalModerate on 01/07/2023 09:46 pmIf you have three sets of tanks each for LCH4 and LOX, one can be active, one can be in redundant standby, and one can be refilling, heating, and pressurizing.How much do the COPVs weigh dry?
Possibly off topic for this thread, but I'm working on animating a spin-G setup aimed at eliminating the prop losses and orbit change due to settling acceleration.If there are ~12 transfer cycles to fill the depot, the final heavy case you've mentioned there is 6.2t, and the first light case (I think) requires ~1.2t. Is that implying that even with combusting methalox, that we're expending around 44t of prop just to fill a depot if we're relying on linear acceleration to settle the prop? Also, does that imply that as long as less propellant than this (1.2t-6.2t/cycle) is used to perform a spin up/down cycle for each transfer, then any (reasonable) amount of extra mass dedicated to spin-G infrastructure on a depot will eventually pay itself off in prop mass savings over time?
There was a report of a small engine test at MacGregor but no details. IIRC, all that was visible on the video was the heat plume. Maybe an ullage thruster. Maybe a lunar landing engine. Maybe something else.Small, mid range ISP engines do seem to be handy things to have in your tool box.
Quote from: InterestedEngineer on 01/08/2023 06:26 amQuote from: TheRadicalModerate on 01/07/2023 09:46 pmIf you have three sets of tanks each for LCH4 and LOX, one can be active, one can be in redundant standby, and one can be refilling, heating, and pressurizing.How much do the COPVs weigh dry?You'd need to do a budget for the max amount of supercritical gas you'd need in a short period (i.e., in a period shorter than it took to pump more liquid into the COPV and heat it to flight enthalpy), then pick a max pressure.The Akin mass estimation for COPVs (which I assume is implicitly at 300bar) is (115.3*V + 3)kg, where V is in m³. John had linked an old paper a while back that had mass proportional to pV, specifically:M = C(⍴/Σ)pVWhere ⍴ is the average density of the COPV walls, Σ is the strength of the COPV material, and C is a coefficient that's 3 for the most straightforward designs. This'll work as an estimate for whatever pressure and volume you choose.Note that I left off an important application for high-pressure gas: e) spin-up gas for air- or space-restarts of the Starship Raptors.Also, note that b) up-thread, the pressure-fed methalox thrusters, may also be the LSS landing thrusters, which could consume more prop, and therefore need bigger COPVs, than ullage or attitude control applications that used methalox thrusters.
So, to answer your question: In high cadence, there's probably a number where rotational settling makes more sense than ullage thrust. But it doesn't make any sense early on, when low cadence will almost certainly boil the depot dry between missions. And even at high cadence, you'll have to show your work on why the extra complexity is worth it.
Quote from: OTV Booster on 01/08/2023 08:12 pmThere was a report of a small engine test at MacGregor but no details. IIRC, all that was visible on the video was the heat plume. Maybe an ullage thruster. Maybe a lunar landing engine. Maybe something else.Small, mid range ISP engines do seem to be handy things to have in your tool box.If there was a heat plume, then it's definitely not a cold gas thruster. Even a warm gas thruster wouldn't show much of a plume, because adiabatic expansion will drop the temperature a lot.The problem with small methox or methalox combustion thrusters is that they need igniters, which are a lot more complex, and likely have bigger impulse bits, than you'd like for something doing attitude control, prox ops, or docking. But my guess is that they'll be essential for lunar landing, or even small orbital maneuvers.And (to stay nominally on-topic) they make a big difference if ullage accelerations have to be anything over about 1.5-2.0mm/s².