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Prognostic Fault Injection Rig Tested at Kennedy Space Center Cyrogenics Test Laboratory
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Prognostic Fault Injection Rig Tested at Kennedy Space Center Cyrogenics Test Laboratory

During the first week of December, 2013, the cryogenic valve Fault-Injection Rig (FIR), which was developed at the NASA Ames Prognostics Center of Excellence, was deployed at the Cryogenics Test Laboratory at Kennedy Space Center (KSC) for integration testing. Specifically, the FIR was integrated into the cryogenics processing testbed by tapping into the supply pressure lines for valves at four locations. The FIR laptop was connected to the Cryogenics Test Laboratory network and commanded the actuation of two cryovalves targeted for this study, while receiving data from sensors based on the testbed. Next, several different fault modes with increasing magnitude were emulated in the cryo testbed. The FIR experiments completed at KSC during integration testing consisted of operation of a nominal Reverse Osmosis (RO) valve and a Control Valve (CV):

  • RO valve with supply control fault (leak across controlling solenoid)
  • RO valve with supply line fault (decreased supply pressure)
  • CV valve with supply line fault (decreased supply pressure)
  • CV valve with control line fault (decreased control pressure)
  • Solenoid of RO valve operated using battery with parasitic load

At the conclusion of the deployment, a total of 22 experiments were completed with an average of 40 minutes per experiment. The FIR was deployed with full functionality and performed as intended throughout the experiment schedule. During the removal of the FIR from the cryogenics processing testbed, measures were taken to enable a quick reintegration of the FIR during the next deployment. Experimental data, as well as documented experimental setup procedures and recommendations for further refinement of the FIR, have been compiled and will be used to further develop the FIR following its return to NASA Ames Research Center.

BACKGROUND: The Simulated Propellant Loading System and the Cryogenics Test Laboratory work as a system used to demonstrate cryogenic fluid transfer between tanks in a manner similar to rocket fueling. The FIR was designed to emulate the aging of cryogenic fuel valves by modulating the gaseous nitrogen pressure used for valve actuation. This is accomplished by using remotely controllable valves that mimic leaking into the atmosphere, or leaking across the valves’ internal component boundaries. These remotely controllable valves provide capability for a continuous magnitude increase of the leakage amount, using relevant physics-inspired damage progression such as corrosion growth. The FIR can control fault progression in the control systems of two types of cryovalves: a bi-modal valve (RO) and a variable position valve (CV). The purpose is to test prognostic algorithms that are under development to determine the remaining time until the valves no longer meet functional specifications.

The test was performed as part of the KSC-led Advanced Ground Systems Management (AGSM) project, which is part of the 21st Century Launch Pad program that is looking towards reducing operations costs and increasing launch availability through a number of activities, including the use of Integrated Systems Health Management for launchpad ground systems. NASA PROGRAM FUNDING: Advanced Ground Systems Management (AGSM) project; also, Integrated Ground Operations Demonstration Units (IGODU) and Advanced Cyrogenic Loading Operations (ACLO) project funding in FY’12

TEAM: Matt Daigle (ARC), Kai Goebel (ARC), George Gorospe (SGT), Chetan Kulkarni (SGT), and Chris Teubert (SGT)

COLLABORATORS: Barbara Brown (KSC), Kevin Jumper (Sierra Lobo), Jared Sass (KSC), and Justin Youney (KSC)

Contact: Kai Goebel

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