integrated evaluation of closed loop air revitalization ...€¦ · integrated evaluation of closed...

NASA/CR—2010–216451

Integrated Evaluation of Closed Loop Air Revitalization System ComponentsK. MurdockWolf Engineering, LLC, Somers, Connecticut

November 2010

National Aeronautics andSpace AdministrationIS20George C. Marshall Space Flight CenterMarshall Space Flight Center, Alabama35812

Prepared for Marshall Space Flight Center under Contract NNM10AB15P

https://ntrs.nasa.gov/search.jsp?R=20100042325 2020-05-01T02:54:00+00:00Z

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NASA/CR—2010–216451


November 2010

National Aeronautics andSpace Administration

Marshall Space Flight Center • MSFC, Alabama 35812


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Available from:

NASA Center for AeroSpace Information7115 Standard Drive

Hanover, MD 21076 –1320443 –757– 5802

This report is also available in electronic form at<https://www2.sti.nasa.gov>

Acknowledgement

The work documented in this Contractor Report (CR) was performed over the period of 2004 through 2006 as a joint effort between NASA Marshall Space Flight Center (MSFC), Johnson Space Center (JSC), and Ames

Research Center (ARC); Hamilton Sundstrand; and Southwest Research Institute. JSC provided the initial funding for the preparation of a test report. MSFC provided funding for the completion and publication of this CR.

The author would like to thank all NASA civil servants and contractors for their support in completing this sizable project, especially Bernadette Luna, ARC; James Knox, Jay Perry, and Monserrate Roman, MSFC; Fred Smith, JSC;

Lee Miller, ECLS Technologies; and Melissa Campbell, Hamilton Sundstrand.

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TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................... 1

1.1 What Did We do ............................................................................................................. 2 1.2 Why Did We do It ........................................................................................................... 2 1.3 What Did We Learn ........................................................................................................ 2 1.4 What do We Want to do Next ......................................................................................... 3

2. INTEGRATED TEST CONFIGURATION ....................................................................... 4

2.1 Description of Equipment—Subsystems and Support Hardware ................................... 5 2.1.1 4-Bed Molecular Sieve (4BMS) Carbon Dioxide Removal Assembly (CDRA) ...... 6 2.1.2 Mechanical Compressor Engineering Development Unit and Accumulator .......... 9 2.1.3 Temperature Swing Adsorption Compressor (TSAC) ............................................ 11 2.1.4 Sabatier Carbon Dioxide Reduction Subassembly ................................................. 19 2.1.5 Support Hardware Configuration .......................................................................... 23 2.2 Integrated Test Using the Mechanical Compressor ......................................................... 32 2.2.1 Overall Test Plan Objectives .................................................................................. 32 2.2.2 Description of Test Plan Details ............................................................................ 35 2.2.3 Discussion of Test Results ..................................................................................... 43 2.2.4 Conclusions From This Test Section ...................................................................... 55 2.3 Integration Test Using the TSA Compressor .................................................................. 55 2.3.1 Description of Tests ............................................................................................... 55 2.3.2 Discussion of Test Results—Integration Test With TSAC ..................................... 63 2.3.3 Conclusions From This Test Section ...................................................................... 71

3 CONCLUSIONS .................................................................................................................. 73

3.1 Overall Conclusions From the Integration Test Experience ............................................ 73 3.2 Summary of Observation From the Integration Test ...................................................... 73 3.3 Lessons Learned ............................................................................................................. 76 3.3.1 Lessons Learned From the Integration Testing ...................................................... 76 3.3.2 Lessons Learned fFom the Sabatier Flight Program .............................................. 78 3.4 Recommendations for Subsystem Modification if Designing a New System ................... 79

4 RECOMMENDATIONS ..................................................................................................... 82

4.1 Recommended Future Testing ........................................................................................ 82 4.1.1 Recommended Test Objective ................................................................................ 82 4.1.2 Specific Recommended Tests .................................................................................

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TABLE OF CONTENTS (Continued)

4.2 Recommended Future Hardware Development .............................................................. 83 4.2.1 Subsystem Development ........................................................................................ 83 4.2.2 Component Development ............................................................................................... 84 4.2.3 Controls Development ........................................................................................... 84

5. APPENDICES ...................................................................................................................... 86 REFERENCES ......................................................................................................................... 190

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LIST OF FIGURES

1. Closed Loop Air Revitalization System .................................................................... 1

2. Overall block diagram of the Air Revitalization System (ARS) sub-systems. ........... 4

3. 4-Bed Molecular Sieve Schematic ............................................................................. 7

4. Work cycle of the TSAC ........................................................................................... 11

5. Flow diagram of the air-cooled TSAC ...................................................................... 12

6. TSAC and 4BMS beds temperature and pressure profiles ......................................... 13

7. Flow diagram of a three-bed TSAC device.. Internal pressure is controlled through a feedback loop to the heater. Inert gas vent tubes are not shown ............... 14

8. Adsorption isotherms and compression cycle ........................................................... 15

9. Heating and cooling assemblies of the TSAC ........................................................... 17

10. Schematic of 2-bed, liquid-cooled TSAC .................................................................. 17

11. Schematic of the air-cooled TSAC prototype ........................................................... 18

12. Air-cooled TSAC prototype ..................................................................................... 18

13. Sabatier Engineering Development Unit Schematic .................................................. 20

14. Original Sabatier EDU Hardware Configuration ...................................................... 22

15. Nodal representation of ISS for CO2 concentration prediction ................................ 25

16. Example metabolic load profile ................................................................................ 26

17. Example of Metabolic Load Profile CO2 Injection Rate .......................................... 26

18. CO2 Concentration for Simulated Lunar EVA Profile .............................................. 27

19. Integration of ARS Components ............................................................................. 29

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LIST OF FIGURES (Continued)

20. High CO2 rate requires excessive activation of vent valve ......................................... 30

21. Test setup of CDRA product CO2 moisture measurement using TILDAS ............... 32

22. CO2 inlet concentration fed to 4BMS for metabolic load profile case ....................... 34

23. Simplified Schematic of CDRA and CRA as intended to be integrated on ISS ........ 36

24. Integrated Test Schematic – 4BMS, Mechanical Compressor, Accumulator, Sabatier .............................................................................................. 37

25. Hardware configuration for 4BMS and compressor only tests. ................................. 40

26. Typical Performance Data for Mechanical Compressor Integration Tests ................ 51

27. Simplified Schematic of 4BMS and TSAC Integration Test ...................................... 56

28. Integrated Test Schematic – 4BMS, TSAC, Sabatier ................................................. 57

29. Lunar EVA Mission Scenario Cabin ppCO2 ............................................................ 63

30. Graphical presentation of integration effects on 4BMS efficiency ............................ 64

31. Typical TSAC Performance Data ............................................................................. 66

32. TSAC equilibrium loading pressure is dependent on CO2 feed to CDRA ................ 68

33. Results of simulated Lunar night .............................................................................. 70

34. Simulated Lunar EVA Excursion profile results in long periods of Sabatier starvation ............................................................................................... 71

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LIST OF TABLES

1. Compressor Operating Rules .................................................................................... 9

2. TSAC and 4BMS Synchronization Table .................................................................. 12

3. Production rates and resource requirements of TSAC sized for two kilograms CO2 production per day at 100 kPa .......................................................................... 16

4. Test conditions for mechanical compressor test ........................................................ 23

5. Test conditions for the TSAC test ............................................................................. 24

6. Standoff Valve Operating Rules ................................................................................ 30

7. Fluid Composition Analysis ..................................................................................... 31

8. Integrated Test Matrix Input Parameters, Mechanical Compressor Test ................... 42

9. Integration Test Metrics ............................................................................................ 43

10. Mechanical Compressor CO2 Capture Performance Data ........................................ 49

11. Sabatier Water Production Rate Efficiencies ............................................................. 54

12. Integrated Test Matrix—TSAC Test ......................................................................... 60

13. Operating parameters for 4BMS/TSAC comparison tests ......................................... 63

14. TSAC Performance Target and Actual Results ......................................................... 64

15. Test results for 4BMS/TSAC/Sabatier integrated testing ........................................... 67

16. Sabatier Efficiency Data when Integrated with TSAC ............................................... 69

1 Introduction

NASA’s vision and mission statement include an emphasis on human exploration of space, which requires environmental control and life support technologies. As the target destination becomes more distant and the target mission duration longer, closed loop life support systems become increasingly necessary for feasibility and success.

Figure 1 – Closed Loop Air Revitalization System

An air revitalization system (ARS) includes temperature and humidity control, oxygen and nitrogen supply and control, carbon dioxide and trace contaminant removal and carbon dioxide reduction for oxygen recovery. These processes also interact with the water recovery system. Crew oxygen is produced by the electrolysis of water. The hydrogen by-product of electrolysis is utilized by the carbon dioxide reduction assembly along with the waste carbon dioxide to re-form water. This last step, carbon dioxide reduction, is a necessary step for loop closure that minimizes the resupply needed for crew support.

This paper describes the development of components for a closed loop ARS, modeling and simulation of the components and integrated hardware testing, with the goal of better understanding the capabilities and limitations of this closed loop system. The integrated testing included a carbon dioxide removal assembly (CDRA), carbon dioxide reduction assembly (CRA), and two different compressor technologies that provided the necessary link between the CDRA and CRA.

Contractor Report

Integrated Evaluation of Closed Loop Air Revitalization System Components

1.1 What did we do

The overall test objective was to integrate the carbon dioxide removal assembly with the carbon dioxide reduction assembly. Two distinct compressor technologies were developed to provide the function of collecting and storing CO2 from the CDRA before it is consumed by the CRA. The systems were tested over a range of conditions that represented both ISS and Lunar surface activities. The test program was conducted from November 2004 through March 2006 in the Laboratory Module Simulator facility at the NASA Marshall Space Flight Center (building 4755).

1.2 Why did we do it

The purpose of the integrated testing was to operate the two configurations of ARS components to determine any limitations or requirements imposed on each component by the interfacing components. Each of the hardware assemblies (CDRA, mechanical compressor, Temperature Swing Adsorption Compressor (TSAC), and Sabatier Reactor Subassembly (SRS)) has been tested independently, and computer simulations have been run of the integrated system. Testing was required to evaluate the performance of the 4-bed molecular sieve (4BMS, another name for CDRA), compressor and Sabatier performance when integrated together and to verify the results from the engineering analysis. Specifically, the testing was intended to:

Provide understanding of transients and integration issues; Validate baseline operation/control logic for the compressors; Validate FORTRAN integrated model of the 4BMS, compressors and Sabatier;

and Validate the mechanical compressor and TSAC computer models.

1.3 What did we learn

The testing described herein was the first integrated test of a Four-Bed Molecular Sieve and Sabatier Carbon Dioxide Reduction Assembly with the interfacing CO2 compressor. Two compressor technologies were tested, a mechanical oil-free piston compressor and a temperature swing adsorption compressor (TSAC). The mechanical compressor was tested under simulated International Space Station parameters. The TSAC was tested under both ISS and Lunar Base parameters. Both sets of tests provided enhanced understanding of nominal steady operation and dynamic, transient scenarios that can be expected to occur in an integrated Environmental Control and Life Support System. In general, the 4BMS, Sabatier and both compressor technologies were proved compatible and able to perform their intended functions for a wide range of input conditions. It is feasible, using these technologies to recover oxygen in the form of water, to make the next step toward oxygen loop closure. These technologies are ready to be advanced to the next Technology Readiness Level (TRL) level and put in service in a flight mission.

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1.4 What do we want to do next

This test program showed not only that water recovery is feasible using CO2 reduction, but it also identified areas where each of the technologies could be improved. These improvements include upgrades to hardware components, changes to control logic and the implementation of artificial intelligence or smart controls. Additional testing should be performed with these systems to better define the proposed modifications to arrive at the best possible solution.

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2 Integrated Test Configuration

Integrated testing of carbon dioxide removal and reduction assemblies was performed at MSFC over the period from 2004 through 2006. This testing was performed to understand the interactions between the different subassemblies in order to plan for future phases of subsystem development. This section details the hardware used in the integration testing, test configurations and operating parameters, and test results. Figure 1 below depicts three main elements of an Air Revitalization System (ARS). These systems and their interactions were the focus of this test program. The three systems shown below are the carbon dioxide removal assembly (CDRA), the oxygen generation assembly (OGA) and the carbon dioxide reduction assembly (CRA). The CDRA collects and concentrates carbon dioxide and feeds it to the CRA. The OGA electrolyzes water for crew oxygen and feeds the by-product hydrogen to the CRA. The CRA reacts hydrogen and carbon dioxide to form methane and water. The water is returned to the OGA, thus partially closing the oxygen loop. The OGA/CRA interaction has been separately studied by Hamilton Sundstrand, the supplier of the ISS OGA, and is not reflected in this report. This report focuses on the interaction of the CDRA with the CRA.

Oxygen Generation System (OGS) Rack Air Revitalization (AR)Rack

Oxygen Generation Assembly (OGA) Carbon Dioxide Reduction

Assembly (CRA)

Carbon Dioxide Removal Assembly (CDRA)

Carbon Dioxide ManagementSubassembly (CMS)

Sabatier Reactor

Subassembly (SRS)

Waste Water Bus Overboard Vent

H2 CO2

H2O CH4

Oxygen Generation System (OGS) Rack Air Revitalization (AR)Rack

Oxygen Generation Assembly (OGA) Carbon Dioxide Reduction

Assembly (CRA)

Carbon Dioxide Removal Assembly (CDRA)

Carbon Dioxide ManagementSubassembly (CMS)

Sabatier Reactor

Subassembly (SRS)

Waste Water Bus Overboard Vent

H2 CO2

H2O CH4

Figure 2 – Overall block diagram of the Air Revitalization System (ARS) sub-systems.

The CRA is further separated into two sub-assemblies, the Sabatier Reactor Subassembly (SRS) and the Carbon dioxide Management Subassembly (CMS). The CMS includes the compressor and accumulator. The focus of this test program, therefore, is the insertion of different compressor technologies into the CMS role supporting the requirements of the CDRA and Sabatier in their respective roles in the overall Air Revitalization System.

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The 4BMS, Sabatier and compressors have each been independently tested over a range of operating conditions. These isolated tests are not covered in this test report, but are discussed in references [ ], with the focus of this study being to understand the subsystem interactions. The previous liquid and water-cooled versions of the TSAC were also tested in conjunction with the 4BMS. These tests are not reported here but are detailed in references [ ]. The sequence of test configurations presented here were planned to develop a working ARS originally for use on the International Space Station, and later as a potential solution for lunar missions. The test configurations are described below as they were conducted chronologically:

1. 4BMS with mechanical compressor and accumulator – (November, December 2004)

2. 4BMS, mechanical compressor, accumulator and Sabatier – (February, March 2005)

3. 4BMS with air-cooled TSAC – (November 2005) 4. 4BMS, air-cooled TSAC and Sabatier – (January 2006)

Referring back to Figure 1 of the Air Revitalization System, the Carbon Dioxide Reduction Assembly (CRA) consists of both the Carbon Dioxide Management Subassembly (CMS) and the Sabatier Reactor Subassembly (SRS). In these tests we evaluated two hardware configurations for the CMS. The mechanical compressor requires a separate accumulator; the TSAC serves as both compressor and accumulator. Regardless of which compressor technology was installed as CMS, the CMS would operate when required based on CO2 availability from the 4BMS, regardless of the operating state of the SRS. Since the compressor and 4BMS are so closely linked, each compressor was initially tested with the 4BMS prior to addition of the Sabatier.

2.1 Description of Equipment – Subsystems and Support

Hardware

This section describes each of the subsystems used in the integration testing. The summary includes the 4-bed molecular sieve (4BMS) carbon dioxide removal assembly (CDRA), the Sabatier reactor subassembly (SRS), the mechanical compressor and accumulator (the 1st evaluated compressor), and the temperature swing adsorption compressor (the 2nd evaluated compressor).

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2.1.1 4-Bed Molecular Sieve (4BMS) Carbon Dioxide Removal

Assembly (CDRA)

Throughout this paper different terminology will be used to reference the hardware that was tested. The term Carbon Dioxide Removal Assembly (CDRA) refers to any system that removes carbon dioxide from the breathing atmosphere of a spacecraft. This function can technically be performed by a variety of technologies, however the name CDRA was given to the CO2 removal system aboard the International Space Station, which is a 4-bed molecular sieve (4BMS) technology.

2.1.1.1 4BMS Hardware Description

The carbon dioxide removal assembly tested in this development project is the same technology and configuration as the hardware currently installed and operating on the International Space Station (ISS). The ISS CDRA, developed by Honeywell (1), uses a four-bed molecular sieve process that consists of two desiccant beds and two CO2 sorbent beds. Ancillary components include a blower, air-save pump, heat exchanger, valves, and sensors. Figure 3 is a schematic representation of the major components of the four-bed molecular sieve process. Cabin air is drawn through one desiccant bed to remove the moisture then through one CO2 sorbent bed to remove the CO2. This processed air is then sent through the second, heated desiccant bed to re-humidify the stream before returning the air back to the cabin. At the same time, the second CO2 sorbent bed, which is loaded with CO2, is heated and evacuated to desorb the CO2. Prior to exposing the loaded bed to vacuum the air save pump removes ullage air out of the desorbing bed and vacuum circuit and pumps it to the cabin. This is done in the first 10 minutes of the desorption half-cycle. The vacuum circuit runs from the desorbing bed check valve to space vacuum, shown as the yellow line in Figure 3. A half-cycle refers to the timed period in which one bed is doing all of the CO2 removal function. At the start of the next half-cycle, all beds switch to the opposite mode and cabin air flow ‘swings’ to the other set of adsorbent beds; the alternate bed then performs the CO2 removal function. In this manner continuous CO2 removal is achieved. The Performance and Operational Issues System Testbed (POIST) 4BMS unit located in the ISS Laboratory Module Simulator (LMS) at MSFC was used for this testing. This system has been extensively modified to achieve functionally flight-like performance for ISS sustaining engineering ground support testing (2). The CDRA uses a pressure and temperature swing adsorption cycle to remove carbon dioxide from the crew breathing air. The CO2 removal beds are filled with 5A molecular sieve that is packed between heater plates. At the start of an adsorption cycle, the mass fraction of CO2 on the desiccant is very low and therefore the equilibrium concentration of CO2 in the air returned to the cabin is practically zero. With prolonged exposure to CO2, the bed adsorbs CO2 and ‘fills’, and the return air may contain small but increasing amounts of CO2. At the end of the half-cycle, it is desorbed with both heat and vacuum. The bed is heated electrically to 400°F during daytime operation when power on the ISS

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is plentiful, but during nighttime operation, the heaters are turned off. The length of the ISS orbit is approximately 90 minutes with the “day” portion running from 90 minutes maximum to 53 minutes minimum, depending on the inclination of the orbit. For all day/night cyclic testing, the worst case 53 minute day was used. The 5A molecular sieve material has a high affinity for water vapor, which preferentially adsorbs and displaces CO2. Because of this phenomenon, the two desiccant beds are included in the 4-bed design. One desiccant bed removes water prior to the air stream entering the 5A bed, while the other bed, previously loaded, replenishes the water to prevent over-drying of the cabin air.

AIR SAVEPUMP

OPEN LOOPVENT

VALVE

SELECTORVALVES

TOSPACE

VACUUM

CO2 SORBENT BED (2)(ADSORBING)

ELECTRICALHEATERS

CO2 SORBENT BED (4)(DESORBING) ELECTRICAL

HEATERS

AIR BLOWER

DESICCANT BED (3)(DESORBING)

DESICCANT BED (1)(ADSORBING)

AIRINLET

AIRRETURN

CHECKVALVE

ITCSINLET

SELECTORVALVES

SG 13X 5A

ABSOLUTEPRESSURE

SENSOR

SG 13X 5A

PRECOOLER

1

2

12

1

2 1

2 1

2 2

1

Air wit hout CO2, H2OAir wit h CO2, H2OAir wit h CO2 (no wat er) Air wit h H2O (no CO2)

CO2

13X

13X

Figure 3 - 4-Bed Molecular Sieve Schematic

2.1.1.2 4BMS Integration Characteristics

One of the peculiarities of the 4BMS CDRA is that it is designed to operate on a 144 minute half cycle (10 cycles per 24-hour day). This becomes an issue only when integrating CDRA with other systems designed to operate in synch with the 90 minute diurnal orbit of the International Space Station. The 4BMS operates on the physics of adsorption isotherms of 5A molecular sieve. As such, the temperature and pressure achieved during the desorption period affects the capacity for air scrubbing on the following cycle. This becomes an important factor when integrating with a downstream system that affects the desorption pressure and when nighttime power saving protocols limit the temperature the bed reaches. The two molecular sieve beds must have sufficient capacity such that the high efficiency periods can carry it through the times when the pressure and temperature are not so favorable for good desorption. The 5A molecular sieve material also has adsorptive capacity for chemicals other than CO2 and water. Some trace contaminants in the cabin atmosphere will be adsorbed on the zeolite and desorbed along with the carbon dioxide. Some of these chemicals have been

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shown to affect the operation of downstream systems, specifically the Sabatier reactor. A summary of contaminant testing that was performed on the Sabatier catalyst is detailed in J.D. Tatara and J.L. Perry; International Space Station Trace Contaminant Injection Test, Revision A, NASA Test Requirements Document, January 1997.

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2.1.2 Mechanical Compressor Engineering Development Unit and

Accumulator

2.1.2.1 Mechanical Compressor Hardware Description

A compressor is needed to provide a vacuum for 4BMS desorption as well as compression of CO2 for efficient storage and controlled delivery to the Sabatier. The first compressor design tested was a mechanical two-stage, reciprocating piston compressor design with three in-line cylinders, which was developed by Southwest Research Institute. There are two first stage pistons and one second stage piston. The compressor is an oil-free design so that no oil contamination is introduced to the downstream Sabatier reactor. A 2-micron filter on the inlet suction line traps any dust particles generated by the 4BMS beds. The compressor is cooled with 65°F chilled water representative of the medium temperature loop (MTL) on ISS. At median pressures of 4 psia suction and 70 psia discharge, the compressor delivers approximately 17.7 scfh (1.9 lb/hr) of CO2. To reduce compressor run time, the operating rules in Table 1 were established and programmed into the integrated control system. PACCUM is the compressor discharge or accumulator pressure while PSUCTION is the compressor suction or 4BMS desorbing bed pressure. These rules set the pressure limits for compressor activation and deactivation. For example, when the accumulator is almost full, at 110 psia, the compressor will not activate until the bed pressure exceeds 7.5 psia. These operating rules were developed with the goal of minimizing the compressor operating time, minimizing compressor power consumption and preventing starvation of the Sabatier. Starvation is defined as any time when hydrogen is produced by the OGA, but no CO2 is available for reaction. The performance goals are achieved by limiting the compressor operation to periods when CO2 is plentiful or the pressure rise is low. These operating rules were established during the model development period (described later) and were verified during this test activity. The compressor rules successfully minimize Sabatier starvation.

Table 1 – Compressor Operating Rules

Transition Conditions Compressor Transition PACCUM (psia) PSUCTION (psia)

>=100 AND <120 AND > 7.5 Standby to >25 AND <100 AND > PACCUM/58 + 3.6 Operate <=25 AND > 1.0

> 40 AND < PACCUM/58 + 1.5 Operate to <= 40 AND < 0.5 Standby >130 NA

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2.1.2.2 Accumulator

Due to the chromatographic nature of CO2 desorption from molecular sieves resulting in short duration ‘waves’ of CO2 flow, and the Sabatier requirement for constant inlet CO2 flow, a buffering capacity is needed to integrate a 4BMS and a Sabatier when using a mechanical compressor. This is accomplished with a 0.73 ft3 accumulator. Due to space limitations within the OGA rack where the CRA hardware would be located on orbit, the total accumulator volume is achieved by ganging several small vessels together. The accumulators used for this test matched those being installed in the OGS rack.

2.1.2.3 Mechanical Compressor / Accumulator Integration

Characteristics

Since the mechanical compressor has no storage capacity, an accumulator is required to buffer the short duration, high rate production of CO2 from the CDRA into the long duration, low flow rate consumption of the Sabatier. The initial sizing of the accumulator was to be one cubic foot. This resulted in an ultimate pressure of 90 psia needed to store adequate CO2 to prevent starvation. This pressure level is under the 100 psia threshold that requires additional analysis on pressure vessels. Due to the space limitations in the OGS rack, the maximum volume accumulator that could be packaged was 0.73 ft3. This results in a need for 120 psia storage pressure to prevent starvation. The CDRA desorbs carbon dioxide from the molecular sieve first, followed by a wave of water. Water vapor in the mechanical compressor could pose problems if condensation occurs in either the compressor or the accumulator tank. A series of tests were conducted to analyze the desorption flow from the CDRA for the concentration of water in the carbon dioxide. The details of this test series are given in section 2.2.2.5. The results indicated that there is not enough water vapor desorbed by the CDRA during the normal desorption cycle to cause condensation in the compressor at pressures up to 120 psia.

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2.1.3 Temperature Swing Adsorption Compressor (TSAC)

2.1.3.1 TSAC Hardware Description

The TSAC is a solid-state device that compresses CO2 using a temperature swing adsorption process on a CO2 selective molecular sieve. The TSAC combines the functions of a compressor and accumulator in one device.

2.1.3.1.1 Operating principle

Fundamental operating principles and designs of adsorption compressors have been applied in adsorption refrigeration cycles and heat pumps. Similar to the heat pumps, the TSAC operates based on thermal-swing adsorption compression.

Figure 4. Work cycle of the TSAC The typical work cycle of the TSAC is shown in Figure 4. The cycle includes four steps. [Ref. 1] STEP1: Adsorption of the gas (or gas component from a gas mixture) of interest at a low pressure and temperature. Adsorption is an exothermic process. Heat of adsorption is removed during this step by cooling the sorbent bed. STEP 2: Compression of the adsorbed gas by heating the sorbent. The bed volume is isolated during this step. The set point pressure of the process determines the temperature limit. The loading of the gas on the sorbent is reduced during heating, raising the pressure in the bed. STEP 3: Release of the compressed gas at the desired flow rate and pressure as required by the processor downstream. Heat must be applied to maintain production as the sorbent is depleted of the adsorbed gas. STEP 4: Decompression of the gas is achieved by cooling the sorbent. The bed volume is again isolated during this step. Temperature is reduced and gas pressure declines to the initial point in the work cycle.

2.1.3.1.2 Process Description

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The process flow diagram for the air-cooled TSAC is shown in Figure 5. To obtain continuous operation, two identical adsorption chambers (beds) are used.

Figure 5 - Flow diagram of the air-cooled TSAC

The basic function of the TSAC is to remove the carbon dioxide from the CDRA at a pressure varying roughly from vacuum to 12 psia and deliver the gas to the Sabatier reactor at 21 psia. The carbon dioxide removal assembly (CDRA) includes two CO2 adsorption beds for removing the carbon dioxide vapor from the cabin air. Like the TSAC, these beds function cyclically to switch between their adsorption and desorption processes to ensure a continuous operation. The TSAC must be synchronized with the CDRA‘s operation cycle to maintain complete regeneration of the CDRA beds and to supply compressed CO2 to the Sabatier reactor. The synchronization schedule for the 4BMS and the TSAC is shown in Table 2.

Table 2 – TSAC and 4BMS Synchronization Table

Half Cycle 1 Half Cycle 2

Time (min) 0 10 134 144 154 278 288 Desorb to TSAC A

Desorb to space

4BMS Bed A Adsorb CO2 from Cabin Air Air-Save

TSAC Bed A

Produce CO2 Cool Adsorb Compress

Desorb to TSAC

B Air

Save Desorb to

space 4BMS Bed B

Adsorb CO2 from Cabin Air TSAC Bed B

Cool Adsorb Compress Produce CO2

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Step 1 Step 2 Step 3Step 4


Step 1 Step 2 Step 3Step 4


Figure 6 – TSAC and 4BMS beds temperature and pressure profiles.

The correspondence for TSAC Bed 2 between Figure 6 and Figure 4 is as follows: Step 4, cooling/decompression in preparation for the CO2 intake, occurs from 0 to 10 minutes. Step 1 where the TSAC adsorbs CO2 from the 4BMS occurs from 20 to 134 minutes. Step 2, compression in preparation for the production step runs from 134 minutes to 144 minutes. Finally, Step 3, the production step, runs from 144 minutes to 288 minutes. Referring to the 4BMS desorbing bed in Figure 6, the segments are as follows: From 0 to 10 minutes is segment 1, when the desorbing bed is being evacuated to cabin via the air save pump and the primary heater is energized. Segment 2 is from 10 to 134 minutes; here primary and secondary heaters are energized. The bed is isolated for the first ten minutes of segment 2 to allow cooling of the TSAC bed. For the remainder of the segment, it is desorbing to the TSAC. Finally, during segment 3, the bed communicates with space vacuum for more complete desorption at low pressure.

2.1.3.1.3 TSAC Development History

13

Development of the TSA CO2 compressor at NASA ARC was originally started under the Mars In-Situ Resource Utilization (ISRU) program. An Engineering prototype of a CO2 compressor was developed and tested at NASA ARC under the payload proposal PROMISE, which was intended to fly in the 2005 Mars Surveyor Lander. The CO2 compressor prototype was designed to extract and separate atmospheric gases from the Mars environment to produce buffer gases and pure, compressed CO2 for rocket propellant production. The CO2 compressor operates based on the TSA technology to separate, compress and produce CO2 at a specified rate. The concept of a CO2 compressor for closing the air loop of an ECLS system was spun-off from the Mars CO2 compressor design. Three different TSAC compressors were sequentially developed during this program with process and equipment improvements implemented in each successive build.

2.1.3.1.4 Water Cooled TSAC

The first compressor developed utilized water as the cooling medium. This compressor was designed with a concept of using three sorbent beds to cyclically adsorb and desorb, thus providing a constant sink for the 4BMS to exhaust to, and also a constant source of CO2 for the Sabatier. These beds were synchronized to the 90 minute Sabatier cycle. A single prototype bed of this configuration was fabricated and tested at NASA Ames Research Center in August 2000. The operation of each bed is scheduled such that when one bed is available for adsorption of CO2 from CDRA, another is ready to produce CO2 for the CRA, and the third bed is in a standby or a cooling mode. A flow diagram for the proposed three bed processor is shown in Figure 7. The complete cycle of this TSAC is 270 minutes, with each desorption cycle taking 90 minutes. Each TSAC bed is designed to accommodate the full load of CO2 required by the CRA, which in this example is one-half the CO2 available from the CDRA.

CDRA CRA

space vacuum

PT

Figure 7 - Flow diagram of a three-bed TSAC device. Internal pressure is controlled through a feedback

loop to the heater. Inert gas vent tubes are not shown.

14

The baseline design for the TSAC uses a zeolite adsorbent and a working cycle that is shown in Figure 8. The intake cycle begins at a pressure of about 2.7 kPa (0.4 psi) and ends at 27 kPa (3.9 psi). The spacecraft coolant loop is used to maintain the temperature near 30°C during this step. During pressurization, the coolant flow is shut off and the sorbent is heated to approximately 60°C; production occurs at a pressure of 100 kPa (14.5 psi) and temperatures rising to about 90°C. For depressurization, the coolant is again allowed to flow through the device to bring the temperature back to about 30°C.

18

16

14

12

10

8

6

4

2

0

CO

2 lo

adin

g [w

t%]

10008006004002000

pressure [torr]

25°C

50°C

75°C

100°C

175°C

Figure 8 - Adsorption isotherms and compression cycle.

This cycle provides a working capacity of about 4.6 wt%. From it, a three-bed TSAC was sized to meet CDRA and CRA interface requirements for vacuum, CO2 pressure, and buffering capacity. A summary of the TSAC requirements is shown in Table 3.

15

Table 3 - Production rates and resource requirements of TSAC sized for two kilograms CO2 production per

day at 100 kPa.

Resource Requirement

Production level 2 kg CO2 / day

Production pressure 100 kPa Total mass 22.5 kg Average power 150 W Peak power 300 W Average heat rejection

150 W

Total volume 25 L

2.1.3.1.5 Liquid Cooled TSAC

The next development in the TSAC design was a change of the cooling medium from water to a heat transfer fluid known as Paratherm. This heat transfer fluid allowed the bed operating temperature to increase thus increasing the working capacity. This comes at the expense of added equipment to handle the heat transfer fluid, namely a pump, heat exchanger and reservoir. The operating schedule was also modified to reduce the number of beds to two. Rather than synchronizing with the Sabatier, the beds were synchronized with the 4BMS beds. One TSAC bed was sized to absorb the entire capacity of one 4BMS bed. The two-bed, liquid-cooled, TSAC consists of two identical sorption beds equipped with a heater in the middle and cooling coils brazed on the outer surface of the canister. The compressor canisters also contain multiple temperature sensors and pressure sensors. Pictures of the compressor canister with heating and cooling assemblies are shown in Figure 9.

16

Figure 9 - Heating and cooling assemblies of the TSAC

A flow diagram for the 2-bed, liquid-cooled TSAC is shown in Figure 10.

Figure 10 - Schematic of 2-bed, liquid-cooled TSAC

The compressor beds are conservatively designed for handling about 2 kg of CO2 per day, which is half of the requirement of ISS. Similar to the CDRA, the TSAC beds operate in a cyclical fashion. While one bed produces or desorbs CO2 for the Sabatier reactor, the other bed continues to adsorb or extract CO2 from the desorbing CDRA bed.

2.1.3.1.6 Air Cooled TSAC

The most recent TSAC design iteration was the development of an air cooled bed. Air is a safe and practical cooling medium in a spacecraft environment and eliminates all of the extra hardware mentioned previously that was needed for the liquid cooled bed. The disadvantage of the air cooled bed is that the bed itself is larger to accommodate the air cooling passages. However, the bed temperature can be operated up to 250 degrees C yielding higher working capacity.

17

The air-cooled TSAC design consists of multiple air slots and heaters spaced within the sorbent bed. A schematic of the TSAC design structure is shown in Figure 3.

Figure 11. Schematic of the air-cooled TSAC prototype

The air-cooled TSAC prototype was designed to produce compressed CO2 at a rate of 8.8 lb/day at a CO2 loading pressure of about 4psia. The loading pressure of 4psia for TSAC is the minimum downstream pressure required for CDRA to regenerate completely within the scheduled cycle time (144 minutes). This is only a conservative estimate, derived from the characterization data of the CDRA sorbent material. The key objective that guided the design and material selection for the TSAC was to minimize the heat loss from the compressor to the surroundings and maximize the heat transfer from the heated sorbent core to the cooling surface.

Figure 12. Air-cooled TSAC prototype

18

The mechanical design of the TSAC was facilitated with a thermal model to finalize the size, material selection and coolant flow rate.

2.1.3.2 TSAC Integration Characteristics

In contrast to the mechanical compressor, the TSAC compresses and stores the carbon dioxide at the same time, eliminating the need for an accumulator. The CO2 is delivered to the Sabatier at a fixed pressure, which is controlled by regulating the temperature of the desorbing bed. This fixed delivery pressure eases the requirements on the Sabatier for CO2 flow control; i.e. the CO2 modulating valve would have only a 4:1 turndown requirement rather than 4:1 on flow and 6:1 on pressure. The 4BMS produces a high purity CO2 stream, but it will be contaminated by a small amount of nitrogen and oxygen. Because the TSAC is not a flow-through system, there is a potential for a buildup of non-adsorbing gases in the compressor. These could form a barrier to CO2 adsorption during the intake step. This situation is prevented by periodically venting this small amount of non-adsorbing gas to space vacuum via tubing between the TSAC beds and the CO2 vent line.

2.1.4 Sabatier Carbon Dioxide Reduction Subassembly

2.1.4.1 Sabatier Hardware Description

The Sabatier Engineering Development Unit (EDU), developed by Hamilton Sundstrand, was designed to simulate the proposed flight configuration of the Carbon Dioxide Reduction Assembly (CRA) for ISS. As described previously, the CRA is an integral part of a closed loop air revitalization system and makes use of waste products, CO2 from a 4BMS/CDRA and H2 from the OGA, which would otherwise be vented. The CO2 and H2 combine to produce methane (CH4) and water (H2O) as shown in the reaction below. The water and methane may then be used for other processes. In the case of ISS, the water would be sent to the wastewater bus and processed to potable quality for use by the crew. The methane would be vented overboard as a waste product. In future exploration missions, the waste methane could be used as a fuel source, or further reduced to carbon and hydrogen. Equation 1

CO2 + 4 H2 ⇔ CH4 + 2 H2O

The Sabatier EDU consists of a Sabatier methanation reactor, a condensing heat exchanger, a phase separator and accompanying valves and sensors necessary for safe operation. The Sabatier EDU was modified substantially after being tested with the mechanical compressor and before being tested with the TSAC. The overall function of the system was not changed, but the individual component fidelity was improved. The

19

most current Sabatier EDU schematic is shown here in Figure 13. A description of the differences between the two test series is given in the appendix.

SABATIERREACTOR

CONDENSINGHEAT

EXCHANGER

T

P

CG CG CONTROLLERAND EIB

N2 IN

CO2 IN

H2 IN

CH4 VENT

H2O OUT

MFC

P P

P

MFM

T

ΔP

MV202

SVO203 CV204F201

F001

P002FCV003

CV004

MFM005 P006-1

F101 SVC102

MFC103

CV104

R401

H402

T403-1,-8

DP405

T404-1,-2

SVO501

FAN502

T407-1,-2

DP409-1,-2

CV305

P304

P601

SVO604

BPR606

SVO608

CG411 CG412

P206

FR205HX406

TSVC007

P

ΔP

MV105

ΔP

DRUMSEPARATOR AND

PUMP L

SVC303

TT

COLD PLATE

COOLANTIN/OUT

T

PP106

P006-2

Manual Fill Port

RV207

RV009

RV107

P

L602

CP301

T413-1,-2

SEP411

FR607

TTT T T T T T

NN414

TT

T410-1,-2

GasSample

Port

BED412

GasSample

Port

SABATIERREACTOR

CONDENSINGHEAT

EXCHANGER

T

P

CG CG CONTROLLERAND EIB

N2 IN

CO2 IN

H2 IN

CH4 VENT

H2O OUT

MFC

P P

P

MFM

T

ΔP

MV202

SVO203 CV204F201

F001

P002FCV003

CV004

MFM005 P006-1

F101 SVC102

MFC103

CV104

R401

H402

T403-1,-8

DP405

T404-1,-2

SVO501

FAN502

T407-1,-2

DP409-1,-2

CV305

P304

P601

SVO604

BPR606

SVO608

CG411 CG412

P206

FR205HX406

TSVC007

P

ΔP

MV105

ΔP

DRUMSEPARATOR AND

PUMP L

SVC303

TT

COLD PLATE

COOLANTIN/OUT

T

PP106

P006-2

Manual Fill Port

RV207

RV009

RV107

P

L602

CP301

T413-1,-2

SEP411

FR607

TTT T T T T T

NN414

TT

T410-1,-2

GasSample

Port

BED412

GasSample

Port

Figure 13 – Sabatier Engineering Development Unit Schematic

The Sabatier EDU has two primary modes of operation: process and standby. In process mode, inlet gasses flow through the system and methane and water are produced. In standby mode, supply gasses are isolated, coolant air is stopped, the unit is evacuated to below 1 psia, and the system is isolated. Reactor heaters cycle as required maintaining a reactor temperature of approximately 300ºF. The Sabatier EDU is operated with excess CO2 (approximately 14%) to ensure that all hydrogen is reacted. The nominal molar ratio (MR) is 3.5 to 1, H2 to CO2. A hydrogen cylinder and a flow controller were used to simulate the delivery of hydrogen from an OGA. An operator sets the hydrogen flow rate, and the Sabatier system controller calculates the required carbon dioxide and controls the flow to achieve the desired molar ratio. The inlet CO2 and H2 gasses react in the catalytic reactor to produce methane and water vapor. This is an exothermic reaction that is self limiting at about 1000 F. The aft end of the reactor is air cooled to reduce the product exit temperature in order to achieve higher reactant conversion. Water vapor in the product stream is condensed in an air-cooled heat exchanger. The methane gas and liquid water are separated in a rotary drum phase separator. The rotation of the drum imposes an artificial gravity field that efficiently separates the two phases. When the delta pressure in the phase separator indicates a high level of liquid in the drum, the system controller increases the separator speed and the separator pumps the accumulated water to a pressurized water storage tank. The methane and excess, un-reacted gasses are vented to a facility combustible gas vent through a

20

combustible gas compatible vacuum system. The Sabatier system is operated at sub-ambient pressures, as planned for the flight design, to ensure that combustible gasses do not leak out to the surrounding atmosphere.

2.1.4.2 Sabatier Hardware Changes between Tests

The first series of fully integrated tests included the four bed molecular sieve, the mechanical compressor and accumulator, and the Sabatier engineering development unit. The Sabatier EDU, in its original configuration, matched the schematic shown here in Figure 14. Some of the more prominent features that were upgraded between the first and second test series are listed below:

• Addition of the rotary drum separator and pump with two differential pressure sensors for level monitoring. The original Sabatier used a tank as a 1-g separator and a small gear pump to transfer the water to the water storage device when the separator tank was full. The rotary separator included in the upgrade is of flight-like quality and is the design basis that would be used for a flight installation of Sabatier technology.

• Addition of a liquid sensor in the methane vent line. The original Sabatier had no liquid sensor. This sensor was included as a means to gather operational test data on the liquid sensor design.

• Incorporation of a multi-point thermocouple in the reactor bed for data collection. The original Sabatier had only two temperature sensors that were used for heater control and over-temperature protection. A flight system would rely on only the two or three sensors in the hot end of the bed. The Sabatier EDU was upgraded to include a multi-point thermocouple in order to gather additional reactor performance data during operation, which will lead to improved reactor designs in the future.

• Addition of a flight like modulating valve for CO2 control. The original Sabatier EDU used a commercial modulating valve with a stepper motor to control the CO2 flow. While this technology performed adequately, it could not be considered flight-like. The EDU was upgraded with a flight-like modulating valve that uses a variable solenoid to position the valve stem to control the flow. This valve was designed and manufactured with flight requirements in mind, including redundant seals and manifold mounting.

• Upgrade of the back pressure regulator to a flight-like design. Again, the original back pressure regulator was a commercial-off-the-shelf design. The new regulator was designed and manufactured to meet flight requirements including a welded diaphragm, manifold mounting and double seals.

21

SABATIERREACTOR

CONDENSINGHEAT

EXCHANGER

T

P

CG CG

N2 IN

CO2 IN

H2 IN

CH4 VENT

H2O OUT

LFCV

MFC

P P

P

T

T

ΔP

MV202

SVO203 CV204F201

F001

P002 FCV003

CV004MFM

MFM005 P006

F101SVC102

MFC103

CV104

R401

H402

T403

DP405

T404

SVO501

FAN502

T407

ST408

DP409

PUMP301

SVC303

P304

P601

RV602 SVO604

RV603 SVO605

BPR606

FR607

SVO608

CG411 CG412

P206

FR205

HX406

TT T

RV410

SVC007

P

T

ΔP

MV609

MV105

CV305

F406

SABATIERREACTOR

CONDENSINGHEAT

EXCHANGER

T

P

CG CG

N2 IN

CO2 IN

H2 IN

CH4 VENT

H2O OUT

LFCV

MFC

P P

P

T

T

ΔP

MV202

SVO203 CV204F201

F001

P002 FCV003

CV004MFM

MFM005

MFM

MFM005

MFM

MFM005 P006

F101SVC102

MFC103

CV104

R401

H402

T403

DP405

T404

SVO501

FAN502

T407

ST408

DP409

PUMP301

SVC303

P304

P601

RV602 SVO604

RV603 SVO605

BPR606

FR607

SVO608

CG411 CG412

P206

FR205

HX406

TT T

RV410

SVC007SVC007

P

T

ΔP

MV609

MV105

CV305

F406

Figure 14 – Original Sabatier EDU Hardware Configuration

2.1.4.3 Sabatier Integration Characteristics

The Oxygen Generation Assembly delivers its hydrogen byproduct to the Sabatier. The OGA has two hydrogen valves, one that goes directly to the vacuum vent of the ISS and the other that interfaces directly with the Sabatier. The control software includes a handshake between the OGA and CRA, which requires that both systems have to be ready to interact before the valve to the Sabatier is opened. This control software was not part of this test series, but has been independently verified. The Sabatier requires carbon dioxide pressurized at 18 psia or higher in order to operate. If the CO2 pressure available at the interface is too low, or the OGA is not ready, the Sabatier system will transition to Standby mode. The Sabatier CRA is designed to operate below ambient pressure. This prevents leakage of flammable gas to the cabin atmosphere after two failures. In order to test the system, a vacuum must be drawn on the methane vent line. This vacuum source must be compatible with methane and hydrogen and pose no explosion hazard. A water ejector setup was used in this integrated testing to simulate the vacuum source. The water ejector could only achieve about 4 psia under maximum flowing conditions; however, this did not seem to affect the system operating parameters elsewhere in the Sabatier system.

22

2.1.5 Support Hardware Configuration

2.1.5.1 4-BMS Inlet ppCO2 Control – Metabolic Load Simulation

The metabolic load contribution to the integrated tests was created by injecting CO2 according to a mass flow schedule into the air stream at the inlet to the 4-bed molecular sieve. Some of the testing was done with constant CO2 concentration, while other tests were designed to mimic the time profile predicted for a volume with crew performing various activities. During testing, CO2 was injected into the 4BMS inlet per the test matrices in the two following tables: Table 4 lists the conditions used for the mechanical compressor test and Table 5 lists the conditions used for the TSAC test. Test conditions ranged from a 2.3-person crew to an 8.3 person crew (CO2 partial pressure of 1.5 to 5.3 mmHg respectively). Table 4 - Test conditions for mechanical compressor test.

Voz

dukh

O

pera

tion

(on=

25%

CO

2 lo

ad)

H2/

CO

2 M

olar

R

atio

Day

/nig

ht

Dur

atio

n (m

in)

4BM

S C

O2

Inle

t C

once

ntra

tion

(mm

Hg)

Com

p S

peed

(rp

m)

Min

. Num

ber

HC

Req

uire

d

US

H2

Feed

R

ate

(slp

m)*

CO

2 Fe

ed

Rat

e (s

lpm

)

Day

/nig

ht

Cyc

lic o

r C

ontin

uous

Rus

sian

E

leck

tron

Load

(EP

)

Mod

elin

g C

DR

A

Loca

tion

EP

tota

l

TP

1** 1.5 3 off 0 2.461 3.5 0.703 cont 3 1000 - 53/37

2** 1.5 3 off 0 4.179 3.5 1.194 day/night 4 1000 - 53/37

3** 1.5 3 off 0 4.179 3.5 1.194 day/night 4 800 - 53/37

4 3.5 7.25 on 2 4.289 3.5 1.225 continuous 3 1000 - 53/37

5 3.5 7.25 on 2 7.282 3.5 2.081 day/night 4 1000 - 53/37

6 3.5 7.25 on 2 7.282 3.5 2.081 day/night 4 800 - 53/37

met profile 8 6 off 0 8.724 3.5 2.493 day/night 50

hrs 1000 Node3 53/37

met profile 10 7.25 on 2 7.282 3.5 2.081 day/night 50

hrs Node

3 1000 53/37

met 11 profile 7.25 on 2 7.282 3.5 2.081 day/night 48 hrs 1000 Lab 53/37

*includes air leakage compensation of 0.24 lb/day air ** tests repeated after air leakage detected

23

Table 5 – Test conditions for the TSAC test.

US

H2

Feed

Rat

e sl

pm (l

b/hr

)

TSA

C P

rodu

ctio

n P

ress

ure

kPa

(psi

a)

4BM

S In

let C

O2

Con

c.

Sab

atie

r CO

2 Fe

ed R

ate

slpm

(lb

/hr)

TSA

C L

oadi

ng

Pre

ssur

e kP

a (p

sia)

H2/

CO

2 M

olar

R

atio

Equ

iv. P

ers.

Test

Poi

nt #

4BM

S C

O2

Load

ing

kg/d

ay

(lb/d

ay)

Mm

Hg

(%)

EP

Test Point Description

Integrated 4BMS/TSAC baseline test

133 (19.3) 1 8 (17.6) -- 8 27.6 (4) -- -- --

Integrated 4BMS/TSAC at reduced CO2 loading

133 (19.3) 2 5 (11) -- 5 27.6 (4) -- -- --


133 (19.3) 3 4 (8.8) -- 4 TBD -- -- --


133 (19.3) 4 4 (8.8) -- 4 TBD -- -- --


133 (19.3) 5 3 (6.6) -- 3 TBD -- -- --

Integrated 4BMS/TSAC at reduced CO2 loading pressure

133 (19.3) 6 5 (11) -- 5 41.4 (6) -- -- --

Integrated 4BMS/ TSAC/ Sabatier at TSAC baseline conditions for TSAC health check

The test points in Table 4 reflect the test conditions used for the mechanical compressor testing. During cyclic operation (all test points except 1 and 3), the system mimics ISS protocols for power savings during orbital night. During the “night” cycle the 4BMS desorbing bed heaters are turned off and the OGA goes to standby, stopping H2 production and signaling the Sabatier to transition into standby as well. For test points 1 through 6, the CO2 load was constant and was set at the average metabolic load generation rate for the number of crew listed in the table. For test points 8, 10, and 11 in Table 4, 4BMS inlet CO2 levels were varied to simulate variations in ISS atmosphere, which result from changes in crew locations and activities. These transient

7 -- 5.3

(0.7%) 124 (18)

6.766 (0.0798)

1.933 (0.502) 8.3 -- 3.5

Integrated 4BMS/ TSAC/ Sabatier for comparison to mechanical compressor test point #2

3.5 (0.46%)

124 (18)

4.459 (0.053) 8 -- 5.46 -- 3.5

1.274 (0.331)


1.5 (0.2%)

124 (18)

1.925 (0.023) 9 -- 2.34 -- 3.5

0.550 (0.143)

Integrated 4BMS/ TSAC/ Sabatier Lunar night scenario, non-optimal TSAC shutdown/ startup 10 --

2.52 (0.33%)

124 (18)

3.273 (0.037) 4 -- 3.5

0.935 (0.243)

Integrated 4BMS/ TSAC/ Sabatier EVA full crew departure scenario, CO2 regenerated to cabin

Per profile

124 (18)

3.273 (0.039) 11 -- 4 -- 3.5

0.935 (0.243)

24

cabin CO2 levels, or metabolic profiles, were generated using an integrated model developed at NASA JSC. The model allows for atmosphere mixing and air revitalization hardware analysis of multiple integrated modules as configured on ISS [3] or as a potential Lunar base. Crewmember location and metabolic activity levels were based on the location of sleep stations, work stations, galley, and exercise equipment. The CO2 metabolic generation rate was defined by NASA document SSP41000 [4]. The model provided transient cabin CO2 levels, or metabolic profiles, for the United States Operating Segment (USOS) modules that will contain carbon dioxide removal units (Lab and Node 3) when ISS assembly is complete. Testing was conducted to evaluate integrated performance for the two different ISS CDRA locations. A generalized representation of the model is shown below.

Figure 15 - Nodal representation of ISS for CO2 concentration prediction.

Figure 13 is an example of a predicted crew metabolic profile including sleep, waking and exercising periods. This graph represents the gross overall CO2 load generated within the ISS for the 6 crew members. Figure 14 illustrates the predicted atmosphere concentration resulting from the crew activities and the calculated injection flow rate needed to simulate the mission profile.

25

Metabolic Profiles - Max Crew Size

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0 4 8 12 16 20 24

Time (hrs)

CO

2 lo

adin

g, lb

/hr

Crew 1Crew 2Crew 3Crew 4Crew 5Crew 6

NOTE - crew 4 and 5 have the same profile.

Figure 16 - Example metabolic load profile

CO2 Injection Rate to Simulate Metabolic Profile

0

0.5

1

1.5

2

2.5

3

3.5

4

59.5 60 60.5 61 61.5 62

Time (days)

CO

2 In

ject

ion

Flow

Rat

e (s

lpm

)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

4BM

S In

let C

O2

Con

cent

ratio

n (%

)

Concentration

Injection Rate

Figure 17 - Example of Metabolic Load Profile CO2 Injection Rate

26

The data in Table 5 reflects the test conditions used for the TSAC testing. For the TSAC testing, the system was configured to be always in “daylight”, in other words, there was no nighttime disabling of heaters and idling of the hydrogen generation. These conditions were set to simulate a Lunar habitat. For test points 10 and 11, 4BMS inlet CO2 levels were varied to simulate variations in a lunar habitat atmosphere based on crew locations and activities. The model used for ISS CO2 concentrations was modified to represent a Lunar habitat. Figure 16 shows the resulting CO2 concentration profile for the simulation of the Lunar EVA activity.

TSAC CO2 Injection Rate

0

0.5

1

1.5

2

2.5

3

3.5

4

27 27.5 28 28.5 29 29.5 30 30.5Time (days)

CO

2 In

ject

ion

Rat

e (s

lpm

)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

4BM

S In

let C

O2

Con

cent

ratio

n (%

)

Injection Rate

Concentration

Figure 18 - CO2 Concentration for Siumulated Lunar EVA Profile

27

2.1.5.2 4BMS venting

When a 4BMS bed is desorbing, the compressor operation is governed by a set of operating rules based on the suction and discharge pressure. These rules have been established to optimize the compressor operation, including minimizing compressor power and compressor operating time without causing starvation of the Sabatier. These compressor rules allow the compressor to turn off while the 4BMS bed is still desorbing. Within the 4BMS, there are check valves that are closed when the bed is under vacuum and open when the bed is flowing cabin air. These check valves will crack open and leak CO2 back to the cabin atmosphere if the bed pressure gets too high. To prevent the check valves from opening, the standoff vacuum valve is used to vent the bed pressure when the compressor is not operating. The rules governing the operation of this valve are shown in Table 6. The desorbing sorbent bed pressure must remain low enough to maintain closing force on the flapper-style check valve. (Refer back to Figure 2 in Section 2.1.1) This pressure was set at 8 psia during the mechanical compressor testing and 12 psia during the TSAC testing. During 4BMS venting, the valve V2, shown in Figure 17 below, functions as the vent CO2 valve listed in the table. During high metabolic load cases, the accumulator often becomes full and the vent valve has to open to relieve the pressure in the 4BMS desorbing bed. Figure 18 shows how the vent valve is activated multiple times during each 4BMS half cycle. This would cause unnecessary wear on the valve. The actual Space Station implementation of this venting control will open the valve and leave it open until the end of the half cycle. This keeps the number of valve cycles at one actuation per half cycle. More CO2 is vented to vacuum, however, as seen in the chart, when the CO2 loading is high, there is more than enough CO2 available and it is not necessary to capture all of the CO2 from the 4BMS.

28

Simplified Schematic of Ground Test HardwareSimplified Schematic of Ground Test Hardware

V209

V2

Vent Line

CDRA

To Vacuum

V209 Air SaveV200LMS

Space VacuumSimulator

V2

FacilityVent

SabEDU

N2

Vacuum vent

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

CDRA

To Vacuum



V2

FacilityVent

SabEDU

N2

Vacuum vent

PGPG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

V209

V2

Vent Line

CDRA

To Vacuum



V2

FacilityVent

SabEDU

N2

Vacuum vent

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

CDRA

To Vacuum



V2

FacilityVent

SabEDU

H2Bottle/regulator

N2

Vacuum vent

H2Bottle/regulator

CO2 inletPGPG

VenturiVacVent

TSAC

Figure 19 - Integration of ARS Components

29

Table 6 – Standoff Valve Operating Rules

Vent Valve Command Time in Cycle

(minutes) Decision Criteria ISS

Implementation Integrated Test

0-10 ALWAYS CLOSED CLOSED

Psuction <8 AND Compressor OFF CLOSED CLOSED

Psuction < 10 AND Compressor ON CLOSED CLOSED

OPEN until end of half cycle

10-134 Psuction > 8 AND Compressor OFF OPEN for 20 sec

OPEN until end of half cycle

Psuction > 10 AND Compressor ON OPEN for 20 sec

134-144 ALWAYS OPEN OPEN

Vent Valve Operation at High CO2 Rates

0

1

2

3

4

5

6

7

8

9

10

45.4 45.6 45.8 46 46.2 46.4 46.6 46.8

Time (days)

Pre

ssur

e

0

20

40

60

80

100

120

140

Vacuum Pressure Accumulator Pressure Figure 20 - High CO2 rate requires excessive activation of vent valve.

30

2.1.5.3 Sampling

Influent CO2 and product Sabatier gasses were sampled at least once per test point and measured for purity. Sabatier product water was also collected once per test point for analysis. Gas samples were taken of the CDRA inlet, Sabatier reactor inlet and reactor outlet. Table 7 lists the test parameters for each sample type. This data is detailed in the results section for each test configuration. Table 7 - Fluid Composition Analysis

Sample Type Analysis Sabatier Inlet Concentrated CO2

CO2. O2. N2 (%)

Sabatier Product Outlet CO2, CH4, H2, O2, N2 (%) Sabatier Product Water Total Carbon, Total Inorganic

Carbon, Total Organic Carbon, pH, Conductivity

2.1.5.4 CO2 Moisture Content

Moisture content of the concentrated CO2 from the 4BMS is a concern for the mechanical compressor since the moisture can condense in the chambers of the compressor. Two independent tests were conducted to quantify the amount of moisture in the CO2 from this test equipment. One test used a low moisture analyzer to measure the quantity of water vapor in the CO2 as it was evolved from the 4BMS desiccant. The instrument is a tunable infrared diode laser differential absorption spectrometer (TILDAS) provided by the NASA Glenn Research Center. A schematic of the moisture measurement test setup is shown in Figure 21. The box labeled “Moisture Measurement” indicates the location where the TILDAS instrument was connected to the system. The TILDAS was used to measure moisture concentration in the CDRA product carbon dioxide during both continuous day and day/night simulated operation.

31

CDRA

To Vacuum

P

TPT

V209 Air SaveV200

Mechanical Compressor Simulator

LMS

Space VacuumPump Simulator

PT

TP

Dew Point

TPT

Flow

V2 V3Moisture Measurement

V4BottledN2

CDRA

To Vacuum

PP

TPTTPT

V209 Air SaveV200

Mechanical Compressor Simulator

LMS

Space VacuumPump Simulator

PT

TP

PTPT

TPTP

Dew Point

TPTTPT

Flow

V2 V3Moisture MeasurementMoisture Measurement

V4BottledN2BottledN2

Figure 21 – Test setup of CDRA product CO2 moisture measurement using TILDAS.

The other test involved running the compressor from the desorbing CDRA to various fixed discharge pressures and measuring the resulting dew point. The discharge pressure was set to 20, 47.5, 75, 102.5 and 130 psia during different test points. The compressor on/off operation was still controlled based on the Compressor Operating Rules defined in Table 1 of Section 2.1.3.

2.2 Integrated Test Using the Mechanical Compressor

2.2.1 Overall Test Plan Objectives

The integration tests using the mechanical compressor were designed specifically to determine how the hardware would operate in the Space Station configuration. The Space Station currently has a 4BMS CDRA installed in the Lab Module. An Oxygen Generator was launched July 2006 and activated in July 2007. The OGA is also installed in the Lab Module. The operating conditions of the Space Station were used to develop the test matrix in Table 1.

32

In addition to the missions operations described below, test parameters were also established as a result of

modeling of the systems that was being conducted in parallel to the test program. A FORTRAN program

was developed by the NASA Johnson Space Center to simulate the 4BMS, mechanical compressor and

accumulator. During the course of testing, the test data was correlated to the model predictions.

2.2.1.1 Test Requirements Based on ISS Implementation

The Sabatier design points detailed in Table 8 define operating conditions that serve as a simple baseline around which the Sabatier was designed to optimize water recovery performance. The Sabatier must be capable of responding to the variability of the full flow regime of both feed gases and continue operating robustly without compromising the life of any components. The interface conditions described next set the boundary conditions for the operation of the different subsystems and were used to define the test conditions. The following assumptions were used as the basis for the flow rates and settings used in the test points: Oxygen / Hydrogen Generation Rates The OGA is required to produce oxygen for the station at a commanded rate between 0.212 and 0.85 lb/hr. The command to the OGA will be from the station level controller that will request 25% to 100% of the maximum power setting. Crew consumption of oxygen is nominally 1.84 lb O2/crew-day. This translates to 0.23 lb/crew-day of hydrogen that is delivered by the OGA to the Sabatier. Air leakage from the station is also made up by oxygen from the OGA and nitrogen from storage tanks. A nominal leakage rate of 0.24 lb/day of air (0.05 lb/day O2) was assumed, which translates to an additional 0.0063 lb/day of hydrogen delivered. The nominal crew size expected when the Sabatier is initially installed on station is 3 crew, the max expected is 6 crew plus 1.25 EP worth of animals. Since the OGA is a high power user, it will likely only operate during the daylight time of the Space Station orbit. At the worst case azimuth, the available operating time is 53 minutes out of a 90 minute period. The daily average hydrogen flow rate is therefore multiplied by 90/53 to arrive at the instantaneous flow rates given in Table 8. CO2 Generation / Removal CO2 generation by the crew is 2.2 lb CO2/crew-day. CO2 is desorbed from the 4BMS and is compressed by the compressor into an accumulator. The beds of the TSA compressor act as an accumulator and no external device is necessary. The mechanical compressor stores CO2 in a tank so that the wave of CO2 desorbed from the 4BMS over a short time span can be delivered to the Sabatier at a fixed rate over a longer duration. The CO2 feed rates given in Table 8 are based on the crew size and the operating schedule (continuous or day/night). The day/night flow rates are 90/53 times the continuous rates per crew member. The contribution of CO2 lost due to station leakage is considered insignificant and not included in the calculations. The concentration of CO2 at the inlet of the 4BMS to achieve the desired rate of CO2 removal was obtained from a Fortran model of the 4BMS. The model and CO2 inlet control are described in more detail in Section 2.1.5.1. The model predicted the

33

atmospheric steady state concentration given a specific crew size and the actual operating conditions of the 4BMS. The model did not include adsorption/desorption of CO2 onto the desiccant beds. The initial prediction of 1.5 mmHg for a crew size of 3 turned out to be low, and the CO2 removal rate did not match the flow rate of hydrogen available to the Sabatier for the first three test points. These test points were later repeated with a different CO2 feed concentration. The graph below shows the CO2 concentration at the inlet of the 4BMS for one of the metabolic load cases. The concentration is calculated from the predicted crew activity and location coupled with the effectiveness of the 4BMS. The tall spikes in concentration are the result of the daily sensor calibration. The small spikes are due to the valves changing position between adsorbing bed cycles.

Metabolic Profile CO2 Concentration to 4BMS

0

0.2

0.4

0.6

0.8

1

1.2

59.5 60 60.5 61 61.5 62Time (days)

CO

2 C

once

ntra

tion

(%)

Figure 22 – CO2 inlet concentration fed to 4BMS for metabolic load profile case.

Load Sharing between US and Russian Hardware Some assumptions had to be made to establish the load sharing of Russian and US life support equipment on the Space Station. Since the Russian and US CO2 removal devices will be operating from the same mixed atmosphere aboard the Space Station, the split of CO2 concentrated by each system is a function of each one’s removal efficiency and the total amount of CO2 available. The Russian CO2 removal system (Vozdukh) specification requires that the CO2 partial pressure be maintained at 5.3 mmHg with a CO2 load of 3 EP. This can be considered the worst case performance point as actual Station data indicates that the CO2 partial pressure with the Vozdukh only operating is between 3.5 and 4.0 mmHg. The Station CDRA performance gives 3.0 mmHg pCO2

34

with a 5.29 EP CO2 load. The following equation is used to calculate the removal split when both systems are operating at a given metabolic load: metabolic

loadflow rate

removal rate

molar fraction of CO2

Vozdukh

X X= + flow rate

removal rate


CDRA

X Xmetabolic load

flow rate

removal rate


Vozdukh

X X= + flow rate

removal rate


CDRA

X X

Solving for the removal fraction yields approximately 25% Vozdukh and 75% CDRA, given the previous minimum Vozdukh performance. At actual performance levels of the Vozdukh, the split is really about 32.5% and 67.5%. Crew Size The crew sizes selected for ISS simulation testing include the current 3 person crew, a future planned 6 person crew when the station assembly is completed and a load of 7.25 EP which reflects 6 crew plus animals.

2.2.2 Description of Test Plan Details

2.2.2.1 Integrated Test Schematic

35

Simplified Schematic of ISS Life Support Hardware

Node 3Bulkhead

ARRack

P

Adsorbing5A Bed

Desorbing5A Bed

DesorbingDesiccant

Bed

Precooler

AdsorbingDesiccant

Bed

Carbon Dioxide RemovalAssembly (CDRA)

CH4/CO2

P

CO2

Airfrom

CCAA

Air toCCAAInlet

H2O

H2

OGSRack

CO2ACCUMULATOR

Carbon Dioxide ReactorAssembly (CRA)

COMPRESSOR

SabatierReactor

CondensingHeat

Exchanger

PP

Oxygen GeneratorAssembly (OGA)H2

P

P H2O

M

P

M

P

STANDOFF

V209

V2

V3P002P000

Figure 23 – Simplified Schematic of CDRA and CRA as intended to be integrated on ISS.

Figure 23 above shows simplified schematics of the CDRA and the CRA as they would be installed on the International Space Station. The highlighted components are shown with the component numbers as used in the ground integration testing. Figure 24 below is a schematic of the ground-integrated system with the same control components highlighted.

36

Simplified Schematic of Ground Test Hardware

CDRA

To Vacuum

V209 Air SaveV200

LMS


PT

TP1

V2

V3

Accum

FacilityVent

Dew Point

HV1

HV2

BPRV1

FM1

TP2

HV3

CO2Bottle

SabEDU

HV4

BPRV2

SVC007

PT P002

N2

H2O productto weight scale

Vacuum vent

RV@150 psia

HV5

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2

MechanicalPiston Compressor

FM2

Coolant in/out

FM2

HV6

P000

CDRA

To Vacuum

V209 Air SaveV200

LMS


PTPT

TP1TP1

V2

V3

AccumAccum

FacilityVent

Dew Point

HV1

HV2

BPRV1

FM1

TP2TP2

HV3

CO2Bottle

SabEDU

HV4

BPRV2

SVC007

PTPT P002

N2


Vacuum vent

RV@150 psia

HV5

PGPG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2


FM2

Coolant in/out

FM2

HV6

P000

V209

Figure 24 – Integrated Test Schematic – 4BMS, Mechanical Compressor, Accumulator, Sabatier

These components control the interaction between the different systems as follows: • V209 – this 3-way valve switches the desorbing 4BMS bed from air-save to vent.

Air save is the first 10 minutes of the desorbing half cycle before CO2 is evolved from the bed. After air save, the valve switches to deliver CO2 to the vent line.

• V2 – this shut-off valve is in the standoff of the space station. When this valve is open, the desorbing CO2 is vented to space vacuum. This valve must be commanded closed by the supervisory controller in order for the compressor to be able to draw the CO2 from the bed. If there is excess CO2 in the 4BMS that is not removed by the compressor, this valve opens to direct the excess to vent.

• P000 – this pressure sensor is located within the CO2 Management Subsystem (CMS) within the CO2 Reduction Assembly (CRA). This sensor measures the pressure of the desorbing bed, which is also the compressor suction pressure.

• V3 – this valve is also in the CMS portion of the CRA on the suction side of the compressor. Whenever the compressor is commanded to operate, V3 is opened.

• P002 – this pressure sensor is in the CRA and is used by both the CO2 Management Subsystem (CMS) and Sabatier Reactor Subsystem (SRS). This sensor measures the quantity of CO2 in the accumulator. It is used to tell the compressor when to turn on and off, and also tells the Sabatier when there is enough CO2 in the accumulator to process.

• SVC007 - Valve SVC007, inside the Sabatier, opened to allow CO2 to flow when the Sabatier was in its processing state.

• CO2 Bottle – for tests that did not utilize the 4BMS (compressor mapping, for example), bottled CO2 was used as the source by closing HV6 and opening HV4.

V2

P000V3

P002

37

• Accumulator - The compressor delivered CO2 to the Sabatier/Accumulator inlet. The accumulator is simply a buffer volume that fills and empties when the compressor flow is greater or less than the Sabatier usage rate.

The 4BMS was operated in the nominal ISS CDRA mode. Half-cycle time was 144 minutes and process air flowrate was 95 lbs/hour average. For the last 10 minutes of the desorb cycle, the desorbing bed was exposed directly to the space vacuum simulator pump. This would be the recommended operating procedure for ISS in order to fully desorb the 4BMS bed prior to its next adsorption cycle. The CO2 loading profile to the 4BMS is described in Section 2.1.5.1.

2.2.2.2 Single Component Tests

2.2.2.2.1 4BMS

The 4 bed molecular sieve system was tested alone to verify that it met the removal capability that had been demonstrated in prior baseline cases. The test conditions are listed in the table below. The baseline testing was repeated throughout the project to ensure that there was no performance degradation as a result of the integration. Test Case # ppCO2 Inlet CO2 Removal

Rate Test Duration

torr Lb/hr

4BMS Baseline, 3 EP

1.48 0.23 8 hour min

4BMS Baseline, 6 EP

3.39 0.52 8 hour min

2.2.2.2.2 Mechanical Compressor

This configuration tested the compressor as a stand-alone item. The test results would be compared to the vendor test results prior to delivery of the compressor to NASA. This testing is referred to in the test plan as “Compressor Health Check.” The Table below list the test conditions. Test Point

Suction Pressure

Discharge Pressure

Pump Speed

(psia) (psia) (RPM) 4 20 1000 1

2 4 130 1000 Each test point will last a minimum of 5 minutes.

38

2.2.2.2.3 Sabatier

Sabatier stand alone tests were performed to generate a baseline of the Sabatier efficiency for comparison to previous Sabatier testing and to compare to the performance achieved during the integrated tests. The test conditions used are listed in the table below. Test Point

JSC Test Point

Reference

CO2 Supply

Pressure

Day Cycle Time

Night Cycle Time

US H2

Feed Rate

(lb/hr)

US H2

Feed Rate

H2/CO2 Molar Ratio

Sabatier CO2 Feed Rate

Sabatier CO2 Feed Rate

Cyclic or Continuous

(psia) (min) (min)(slpm) (lb/hr) (slpm)

1 3 85 - - 0.031 2.660 3.5 0.197 0.760 Continuous2 7 25 53 10 0.106 9.000 3.5 0.567 2.570 Cyclic

2.2.2.3 4BMS + Mechanical Compressor + Accumulator

Two test objectives were completed in this configuration. The purpose of the first test was to measure the dew point of the product CO2 to determine if there would be condensation in either the compressor or the accumulator during operation. The 4BMS was operated with constant 0.2% CO2 inlet concentration. The compressor operated with the varying inlet pressure as produced by the 4BMS and with fixed outlet pressures and set by a backpressure regulator. The outlet pressures were set to 20, 47.5, 75, 102.5, and 130 psia.

39

Simplified Schematic of Ground Test Hardware

CDRA

To Vacuum

V209 Air SaveV200

LMS


PT

TP1

V2

V3

Accum

FacilityVent

Dew Point

HV1

HV2

BPRV1

FM1

TP2

HV3

CO2Bottle

SabEDU

HV4

BPRV2

SVC007

PT P002

N2


Vacuum vent

RV@150 psia

HV5

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2


FM2

Coolant in/out

FM2

HV6

P000

CDRA

To Vacuum

V209 Air SaveV200

LMS


PTPT

TP1TP1

V2

V3

AccumAccum

FacilityVent

Dew Point

HV1

HV2

BPRV1

FM1

TP2TP2

HV3

CO2Bottle

SabEDU

HV4

BPRV2

SVC007

PTPT P002

N2


Vacuum vent

RV@150 psia

HV5

PGPG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2


FM2

Coolant in/out

FM2

HV6

P000

V209

V2

P000V3

Open

P002

Controlled by 4BMS for venting

Controlled by Sabatier for compressor control

Closed

Closed

Open

Figure 25 – Hardware configuration for 4BMS and compressor only tests.

In this test configuration, the 4BMS and compressor were integrated together with no other systems operating. The hand valves that connect the CO2 tank (HV4) and the accumulator (HV5) were closed. The Sabatier was powered on, but not processing so that it could monitor the compressor inlet (P000) and outlet (P002) pressures, and operate the compressor and inlet valve (V3). The back pressure regulator (BPRV1) was set to varying pressures according to the test plan. A closed hand valve isolated the accumulator. The other test was to start up the compressor under vacuum. Normally, the compressor discharge pressure ins never less than 18 psia, however a system self check is being considered that would evacuate the accumulator and compressor exit. The purpose of the test was to determine if there were any operational issues with the compressor.

2.2.2.3.1 4BMS + Mechanical Compressor + Accumulator +

Sabatier

Table 8 below details the test conditions used for the integration of the mechanical compressor with the 4BMS and the Sabatier. The column data in the table is as follows:

40

• Column 1 is the test point number used for recording test conditions and resulting data.

• Column 2 is the constant CO2 concentration fed to the 4BMS at the cabin air flow inlet. These tests were run open loop, therefore the feed concentration to the 4BMS was set by a CO2 mass flow controller with measured CO2 concentration feedback to the mass flow control setpoint.

• Column 3, EP, is Equivalent Persons. Early mathematical modeling of the 4BMS predicted that 1.5 mmHg partial pressure of CO2 fed to the inlet of the 4BMS would result in the equivalent CO2 removal rate of 3 EP generation rate. After testing this condition and analyzing the data, it was found that 1.5 mmHg inlet resulted in only 2.3 EP worth of CO2 collected and delivered to the Sabatier for processing. The correction to the inlet feed rate was made in later tests.

• Column 4 indicates the status of a virtual Vozdukh, the Russian CO2 removal system. When the Vozdukh is off, all of the CO2 from the entire crew is collected and concentrated by the US CRDA equipment and available for processing by the Sabatier. When the Vozdukh is on, 25% of the crew load of CO2 is collected by the Russian equipment and therefore not available to the Sabatier.

• Column 5 indicates the status of a virtual Elektron, the Russian oxygen generator. The contributing level of the Elektron is given in EP of oxygen delivered by the Elektron. When the Elektron is producing oxygen, the US OGA production level is lowered by the same amount and therefore the hydrogen available to the Sabatier for processing is decreased. These contributions from other hardware become important when determining the amount of water recovery available from the Sabatier system.

• Column 6 is the US hydrogen feed rate to the Sabatier. This value is the amount of hydrogen generated along with the rate of oxygen generated to make up for losses. The oxygen consumption rate is calculated from the crew size, the contribution supplied by the Elektron (subtracted out) and a component for make up oxygen for station air leakage amounting to 0.24 lb/day. The value of hydrogen in column 6 is used as the set point of the hydrogen mass flow controller in the Sabatier EDU.

• Column 7 is the set point for hydrogen/CO2 molar ratio. While this number is a variable in the Sabatier control program, it was set to a constant 3.5 for these tests. The Sabatier calculates the control set point for its CO2 control valve based on the hydrogen feed rate and the molar ratio.

• Column 8 is the CO2 feed rate. This is the average feed rate of CO2 that the Sabatier should be calculating for the set point of its control valve.

• Column 9 indicates day/night cyclic or continuous operation. When the integrated system is operating in day/night mode, the OGA transitions to a standby mode when the space station is in the dark side of the orbit and power is scarce. When the station is back in the daylight side of the orbit, the OGA transitions back to Process mode. Hydrogen is only available to the Sabatier when the OGA is in Process mode. The times used for the duration of the day and night portions of the orbit are given in Column 13.

41

• Column 10 indicates the minimum number of half cycles (HC) required to reach nominal steady state conditions for the test point. These values were used to schedule the test point in order to complete the series.

• Column 11 is the compressor speed. Determining the correct size for the mechanical compressor was one of the objectives of this test program. Adjusting the speed of the compressor was a simple method of adjusting the compressor capacity to see its effect on integration. A compressor designed for the flight application of this system would be made with smaller pistons if necessary rather than slower speed. Motor speeds under 1000 rpm have major impacts on sizing of EMI filters in the controller.

• Column 12 indicates the location of the CDRA (the station 4BMS) in the model used to develop the metabolic profile. The location of the CO2 removal equipment with respect to the location of crew members during different activities affects the instantaneous concentration of CO2 seen at the 4BMS inlet.

• Column 13, as described previously, is the duration in minutes of the daylight and night portions of the space station orbit.

Table 8 – Integrated Test Matrix Input Parameters, Mechanical Compressor Test

Voz

dukh

O

pera

tion

(on=

25%

CO

2 lo

ad)

H2/

CO

2 M

olar

R

atio

Day

/nig

ht

Dur

atio

n (m

in)

4BM

S C

O2

Inle

t C

once

ntra

tion

(mm

Hg)

Com

p S

peed

(rp

m)

Min

. Num

ber

HC

Req

uire

d

US

H2

Feed

R

ate

(slp

m)*

CO

2 Fe

ed

Rat

e (s

lpm

)

Day

/nig

ht

Cyc

lic o

r C

ontin

uous

Rus

sian

E

leck

tron

Load

(EP

)

Mod

elin

g C

DR

A

Loca

tion

EP

tota

l

TP

1** 1.5 3 off 0 2.461 3.5 0.703 cont 3 1000 - 53/37

2** 1.5 3 off 0 4.179 3.5 1.194 day/night 4 1000 - 53/37

3** 1.5 3 off 0 4.179 3.5 1.194 day/night 4 800 - 53/37

4 3.5 7.25 on 2 4.289 3.5 1.225 continuous 3 1000 - 53/37

5 3.5 7.25 on 2 7.282 3.5 2.081 day/night 4 1000 - 53/37

6 3.5 7.25 on 2 7.282 3.5 2.081 day/night 4 800 - 53/37

met profile 8 6 off 0 8.724 3.5 2.493 day/night 50

hrs 1000 Node3 53/37

met profile 10 7.25 on 2 7.282 3.5 2.081 day/night 50

hrs Node

3 1000 53/37

met 11 profile 7.25 on 2 7.282 3.5 2.081 day/night 48 hrs 1000 Lab 53/37

*includes air leakage compensation of 0.24 lb/day air ** tests repeated after air leakage detected

42

2.2.3 Discussion of Test Results

2.2.3.1 Description of Result Metrics for Fully Integrated Tests

Table 2.2-2 lists the parameters used to evaluate the performance of the subsystems during the integration

tests. The parameters are listed as Set points or Performance. Set points are input parameters that are

established for each test case. They are the input variables to which the systems respond. Parameters are the

responses of the subsystems. The input parameters include the items discussed in Section 2.2.3.2 as well as

some additional items not included on the previous tables. Some of the additional parameters were not

changed between test points, but would have to be considered in the development of an Air Revitalization

System for other exploration mission scenarios.

Summary plots of each Test Point are assembled in Appendix A.

Table 2.2-9 – Integration Test Metrics

Integration Test Parameters Set point Performance

Overall System Test Test Duration Frequency of Vacuum Vent Day/Night or Continuous Sabatier Starvation Crew Size

4BMS CO2 Inlet Concentration or Feed Rate CO2 Removal Efficiency Half Cycle Duration Power

Mechanical Compressor Compressor Speed Power Accumulator Working Pressure Range Number of Start/Stop Cycles Accumulator Volume Duty Cycle

Sabatier Hydrogen Feed Rate (based on crew size) Water Recovery Efficiency Molar Ratio Actual Water Production Day/Night Cycle Times Power Theoretical Water Production (based on H2 available)

Reactor Temperatures

Reactor Pressure Drop

43

The significance of the Set points and Performance parameters are discussed in detail below:

Overall System Test

• Test Duration – the duration of each test was pre-established to attempt to reach steady state

operation within the 4BMS. The tests with constant CO2 concentration fed to the 4BMS were run

for three or four half cycles. The tests that incorporated a metabolic profile to simulate the

movement of crew within the habitat were run for 50 hours or more to include repetition of the

profile.

• Day/Night or Continuous – Day/night vs. continuous operation affects the availability of power. It

is assumed that when the ISS is in the night portion of the orbit that power consuming devices

must be tuned down or off. This affects the Sabatier operation and the heater power allowed in the

4BMS.

• Crew Size – crew size is used as an indicator of overall load on the systems. Crew consumption of

oxygen (reflected in hydrogen flow rate) and crew production of carbon dioxide drive the sizing

requirements for the subsystems.

• Frequency of Vacuum Vent – the vacuum vent is controlled at the system level based on what is

going on with the 4BMS. Excessive venting is an indication of poor CO2 management and likely

is associated with Sabatier starvation.

• Sabatier Starvation – the overall goal of the system integration is to recover as much water as

possible. Sabatier starvation means that there is hydrogen produced ready to be converted, but

there is not enough carbon dioxide available to run the reaction. The overall mass balance of

hydrogen and carbon dioxide is such that there is always excess CO2 available, so starvation is

another indicator of poor CO2 management.

4BMS

• Inlet CO2 concentration or feed rate – The feed rate of CO2 to the 4BMS falls out of the crew size

parameter and sets the operating envelope for the integrated systems.

• Half Cycle Duration – A half cycle refers to the length of time that all beds of the 4BMS system

are in either adsorb or desorb. The length of the half cycle affects how well the molecular sieve

beds adsorb and desorb CO2. The integration tests were all performed with a 144 minute half

44

cycle, however some of the stand alone tests were done with 155 minute half cycles to compare to

the manufacturer’s baseline tests. Shorter half cycle times increase the CO2 removal performance.

• CO2 Removal Efficiency – CO2 removal efficiency is a measure of the amount of CO2 actually

captured by the 4BMS compared to the amount fed to it. Most of the tests were done open loop,

which means that the scrubbed air from the 4BMS was not returned to the inlet. Because the

testing was open loop, there was no buildup of CO2 concentration that would otherwise be seen

with a poor performing 4BMS. CO2 removal efficiency is affected by the desorption pressure, a

significant artifact of integration with a compressor instead of space vacuum venting.

• Power – The 4BMS heaters consume power to desorb CO2 and water from the zeolite. The power

requirement is a function of the CO2 loading isotherms. The lower the vacuum pressure available

for desorption, the lower the power requirement to drive off the CO2.

Mechanical Compressor

• Compressor Speed – In this series of testing, the compressor speed was varied to effectively

change the flow rate capacity of the compressor. In reality, the piston size and stroke would be

optimized to achieve the desired volumetric flow rate. The speed change allowed an easy way to

change flow conditions and observe the results.

• Accumulator Working Pressure Range – The accumulator used in the mechanical compressor tests

was restricted to operation between 18 and 120 psia. There are several factors that influence this

range that could change for other than and ISS application. The low set point pressure is based on

the pressure drop allocation for the control components in the Sabatier at maximum flow rate. This

pressure drop is added to the reactor inlet pressure and the minimum pressure of 18 psia is

achieved. The actual pressure drop of the EDU hardware was lower than the allocation because

there were no filters installed in the lines. The upper pressure limit is based on pressure ratio

achievable by the compressor, inlet dew point and the resulting dew point of the gas once

compressed, and the pressure rating of the downstream components. The accumulator vessel can

withstand over 2000 psia, however, not all of the shutoff valves can be exposed to that pressure.

The maximum operating pressure selected for these tests was 120 psia, which was sufficiently low

enough to prevent condensation.

45

• Accumulator Volume – The accumulator volume for the ISS application is 0.73 ft3. This is the

largest volume of accumulator bottles ganged together that could fit in the Space Station rack

designated for Sabatier installation. All of the integration tests using an accumulator used similar

size bottles to simulate the ISS available volume.

• Power – Power is one of the key performance variables of the mechanical compressor. The power

consumption is based on the work done to compress the carbon dioxide and also the mechanical

and electrical efficiency of the compressor and motor.

• Number of Start/Stop Cycles – The number of start/stop cycles resulting from the integration

dynamics is an important factor in the life of the compressor. The number of start/stops affects

wear of moving parts and life of electronic components.

• Duty Cycle – Duty cycle is the most important factor affecting life of the compressor. The life

limiting component of the compressor is the piston rings, and their life is directly attributed to run

time.

Sabatier

• Hydrogen Feed Rate – The hydrogen feed in these tests was delivered from gas cylinders. In a real

ARS application, the hydrogen would come from an oxygen generator and would be a function of

the oxygen produced for crew consumption. The hydrogen feed rate can be any value for other

mission scenarios.

• Molar Ratio – Molar ratio is the ratio of hydrogen to carbon dioxide fed to the Sabatier reactor.

The stoichimetric ratio is 4 moles hydrogen to 1 mole CO2. In these tests, the molar ratio was set

to 3.5. In the space station application, CO2 is in excess of hydrogen. The reactor works more

efficiently when the molar ratio is not at the stoichiometric value. In other applications, Mars for

example, the reactor might be run at molar ratios greater than 4.

• Day/Night Cycle Times – The day night cycle time for most of the tests was set to 52 minutes day,

37 minutes night. This corresponds to the longest night duration of the ISS orbit. The length of the

night cycle affects how much the reactor cools off before being restarted.

46

• Theoretical Water Production – This value is the amount of water that could be generated by the

Sabatier if every mole of hydrogen was consumed, and all of the water was collected. The molar

ratio of water generated to hydrogen consumed is 1:2.

• Actual Water Production – This is actual mass of water collected over each test duration. The

water production is affected by the reactor efficiency, the separator waste heat and the number of

shutdown cycles for night time operation.

• Water Recovery Efficiency –This is the ratio of actual water to theoretical water. It is the most

telling of the Sabatier performance metrics for overall system performance.

• Power – Power is consumed by the Sabatier to preheat the reactor and to operate the separator, in

addition to valves and sensors.

• Reactor Temperatures – The reactor temperatures indicate the general health of the Sabatier

reaction and vary with different inlet feed rates and molar ratios.

• Reactor Pressure Drop – Reactor pressure drop varies with feed flow rate, unless there is

excessive water condensation in the reactor bed. A high value would indicate a

performance issue that would require adjustment.

2.2.3.2 4BMS Baseline Test

The table below lists the results of 4-BMS stand alone testing that was performed after the integrated tests

were completed.

Test Case # ppCO2 Inlet CO2 Removal Rate

In – Out CO2 Removal Efficiency

torr Lb/hr

4BMS Baseline 3.79 0.52 74% 4BMS Baseline TP2 Conditions

1.48 0.23 84%

4BMS Baseline TP4 Conditions

3.39 0.52 81.5%

4BMS Baseline TP5 Condition

3.40 0.52 81.8%

47

2.2.3.3 Mechanical Compressor Baseline Test

The mechanical compressor was tested in a stand-alone configuration to compare its performance against the baseline data recorded by the manufacturer. The compressor was tested at 4 psia inlet pressure, 130 psia outlet pressure and produced about 2 lb/hr. The compressor was also tested at 4 psia inlet pressure and 20 psia outlet pressure. The flow rate varied between the three runs, with approximate averages of 1.2, 1.4, and 2 lbs/hr. Large variations in inlet pressure were observed. Test Point

Suction Pressure

Discharge Pressure

Pump Speed

Flow Achieved

(psia) (psia) (RPM) 4 20 1000 1.2-2 lb/hr 1

2 4 130 1000 2 lb/hr Each test point will last a minimum of 5 minutes.

2.2.3.4 4BMS + Mechanical Compressor

The purpose of these integrated tests was to measure the dew point of the product CO2 to determine if there would be condensation in either the compressor or the accumulator during operation. The 4BMS was operated with constant 0.2% CO2 inlet concentration. The compressor operated with the varying inlet pressure as produced by the 4BMS and with fixed outlet pressures set by a back pressure regulator. The outlet pressures were set to 20, 47.5, 75, 102.5, and 130 psia. Dew point of the compressed CO2 remained below 31 F for all conditions tested. During extended compressor operation, the dew point remained around 0 F. CO2 removal from the 4BMS using the mechanical compressor was the same as using the space vacuum simulator within the measurement accuracy of the tests. Test Case # ppCO2 Inlet CO2 Removal

Rate In – Out CO2 Removal Efficiency

torr Lb/hr

4BMS CEDU 1.48 0.24 87% 4BMS CEDU 3.37 0.54 85% 4BMS CEDU 3.38 0.58 92% 4BMS Stand Alone 1.48 0.23 84% 4BMS Stand Alone 3.39 0.52 81.5% 4BMS Stand Alone 3.40 0.52 81.8% Dew Point Data Test Day Compressor outlet

pressure Max Dew Point

Day 7 20 31 F

48

Day 8 50, 75, 100 30, 29, 27 Day 9 130 31

2.2.3.5 Mechanical Compressor Startup Under Vacuum

One of the safety checks envisioned for the Sabatier CRA system required vacuum venting of the entire Sabatier system including the mechanical compressor and accumulator. The mechanical compressor was tested by starting it with vacuum at both the inlet and outlet to determine if there were any performance issues. Three successive tests were conducted with no problems encountered. No unusual noises or other unusual behavior were observed.

2.2.3.6 4BMS + Mechanical Compressor + Accumulator + Sabatier

This section describes the test results for the 4BMS, Mechanical Compressor/Accumulator and Sabatier integration test series. Eleven different test points were run, each with a different set of operating conditions. The summary of test results is given below in Table 2.2-3. Test points 1,2 and 3 were conducted at the minimum crew loading of 3 Equivalent Persons, with all of the CO2 removal performed by the 4BMS (no Vozdukh simulation). Test Point 1 was continuous operation, or no day/night cycling. This means the Sabatier and the 4BMS heaters were allowed to operate all of the time. Test Points 2 and 3 used a 53 minute day/37 minute night cycle. Test Point 3 was run with the slower compressor speed (800 rpm) compared to 1 and 2 with the 1000 rpm speed. Test Points 4,5 and 6 mimicked 1,2, and 3 except they were run at the maximum crew loading of 7.25 Equivalent Persons with simulation of 2 EP of CO2 removal and H2 production by Russian hardware. Test Points 8, 10 and 11 were run with metabolic profile inputs for the CO2 feed to the 4BMS. Test Point 8 was 6EP with no Russian hardware, 10 and 11 were 7.25 EP with 2 EP of Russian hardware. Test Points 8 and 10 were simulated with the ARS components installed in the Node 3 location of the ISS. Test Point 11 was simulated with the components in the Laboratory Module of ISS.

Table 2.2-10 – Mechanical Compressor CO2 Capture Performance Data

Num

ber o

f 4B

MS

Hal

f Cyc

les

Num

ber o

f Sa

batie

r D

ay/N

ight

Cyc

les

Tota

l Com

pres

sor

Run

Tim

e (m

in)

Com

pres

sor D

uty

cycl

e (%

)

Ave

rage

C

ompr

esso

r Run

Ti

m p

er H

alf

Cyc

le (m

in)

Tota

l Sab

atie

r St

arva

tion

Tim

e (m

in)

Com

pres

sor

Cyc

les p

er H

alf

Cyc

le

Tim

e Pe

riod

Eval

uate

d (h

rs)

Num

ber o

f C

ompr

esso

r O

N/O

ff C

ycle

s

Test

Poi

nt

CO

2 EP

1 3 16.10 6.75 - 21 3.11 168 25 17 15 2 3 3.78 1.5 2.75 5 3.33 42 28 19 9

49

3 3 22.50 9 15 25 2.78 324 36 25 9 4 5.4 7.80 3.25 - 11 3.38 67 21 15 0 5 5.4 14.43 6 9.75 23 3.83 136 23 16 0 6 5.4 27.35 11.5 18 42 3.65 251 22 15 0 8 6 (met) 40.78 17 27.5 68 4.00 399 23 16 0 10 5.4 (met) 28.78 12 19 50 4.17 235 20 14 0 11 5.4 (met) 43.20 18 28.5 80 4.44 355 20 14 0

Acc

umul

ator

A

vera

ge M

inim

um

Pres

sure

(psi

a)

Tota

l Num

ber o

f 4B

MS

Ven

t C

ycle

s

Acc

umul

ator

A

vera

ge

Max

imum

(i

)

Ave

rage

4B

MS

Ven

t Cyc

les p

er

Hal

f Cyc

le

Test

Poi

nt

CO

2 EP

1 3 0 0 20 60 2 3 0 0 20 40 3 3 0 0 20 55 4 5.4 6 1.85 50 130 5 5.4 7 1.17 50 130 6 5.4 13 1.13 60 130 8 6 (met) 11 0.65 50 130 10 5.4 (met) 9 0.75 60 130 11 5.4 (met) 23 1.28 55 130

The number of compressor cycles and compressor duty did not vary greatly from between test conditions. The greatest difference noted is at the lower CO2 loading, there is a marked difference between the low and high speed compressor tests. As expected, the lower speed had a higher duty cycle. This difference is not seen in the higher CO2 loading cases. The compressor rules are less demanding on the compressor when the accumulator is near its full mark, and therefore the compressor operation is nearly the same for both cases. Some of the test periods evaluated were quite short and therefore there is significant round off error associated with the results. The minimum EP cases (1, 2 and 3) experienced periods of Sabatier starvation when H2 was being

produced by the OGA but there was not enough CO2 in the accumulator for processing. The accumulator

pressure dropped to the minimum operating pressure of 20 psia and only reached to a maximum pressure of

60 psia. There were no vent cycles, which indicates that no CO2 was wasted. At these low rates, the impact

of leakage is more significant, and it may not be possible to avoid starvation.

The higher EP cases (test points 4, 5 and 6) did not experience any starvation. There were numerous vent

cycles and overall high accumulator pressures. The overall water production efficiency was generally

higher, since all of the hydrogen was processed.

The compressor duty cycle for all cases was on the order of 13-21% with the higher CO2 loading cases

having the lower duty cycle. There was not a large difference in duty cycle between the cases with the

different compressor speeds (Test points 2 vs. 3 and 5 vs. 6).

50

Figure 2.2-26 below is a typical example of performance data collected during the mechanical compressor

integration tests. The performance data described above is shown in this plot of one CDRA half cycle. The

top purple line is the accumulator pressure. In this test case, the accumulator is regularly near the upper

limit of 130 psia. When the accumulator pressure is at this maximum value, the compressor rules do not

allow the compressor to turn on to pump CO2 from the CDRA. In time, the CDRA bed pressure, indicated

by the pink line, reaches the maximum allowable pressure of 8 psia and the vacuum vent valve is opened.

The vent valve opening is noted by the sharp increase in pressure of the vacuum tank indicated by the dark

blue line. The aqua line indicates when the Sabatier is in Process mode, and the green line indicates when

the compressor is activated. For this test case, the compressor activates between 3 and 4 times per CDRA

half cycle.

0

2

4

6

8

10

12

14

4:13 4:27 4:42 4:56 5:11 5:25 5:39 5:54 6:08 6:23

Time

Data

0

20

40

60

80

100

120

140

Accumulator Pressure

Vacuum Tank Pressure

Compressor Activation

Sabatier Process Mode

CDRA Discharge Pressure

Pressure relief by vacuum vent valve, accumulator is full

Compressor Operation

Compressor runs until max accumulator pressure is met

Sabatier operation uses CO2 from

accumulator, then compressor refills

Test Point 6, 5.4 EP, Day/Night, 800 RPM

Sabatier Process Mode

Figure 2.2-26 – Typical Performance Data for Mechanical Compressor Integration Tests

The following four plots show the characteristic water recovery data for some of the test points. In Test

Point 4, the overall water recovery was 95%. This test point was at continuous operation at the higher CO2

51

loading. There was no starvation of the Sabatier during this test point. This is the highest water recovery

expected from the Sabatier system at these operating conditions. In contrast, Test Point 1, which was

continuous at the lower CO2 loading, showed signs of Sabatier starvation and yielded only 89% water

recovery. The offset of the blue line with the two small steps from the straight gray line is the loss of water

due to insufficient CO2 available to the Sabatier. The water recovery of the Sabatier based on its operating

time is 91%, the two percent difference is due to starvation.

Test Point 6 is a cyclic day/night case. The water recovery suffers more in this mode due to the cyclic

operation. Each time the Sabatier transitions to and from Standby, the system is evacuated and steam is lost

to the vacuum vent. The reactor also is not at the optimal temperature due to the constant change of flow

rate. The efficiency drops from the high of 94% in Test Point 4 down to 89% in Test Point 6 due to cyclic

operation. Further, the recovery worsens in Test Point 3, which is cyclic at the lower CO2 loading.

Starvation occurs in this scenario dropping the water recovery to 82% overall.

The three metabolic load cases (Test Points 8, 10 and 11) did not experience any Sabatier starvation. Their

water recovery numbers are slightly lower than the equivalent fixed CO2 feed cyclic case (Test Point 6).

0

100

200

300

400

500

600

700

800

900

1000

45.9 45.95 46 46.05 46.1 46.15 46.2 46.25 46.3

Time

Wat

er (g

)

Theoretical Water Production

Actual Water Collected

Theoretical water production based on H2 delivered to

Sabatier

Actual water periodically

discharged from phase separator

Water recovery efficiency is 89%


0

100

200

300

400

500

600

700

800

900

1000

45.9 45.95 46 46.05 46.1 46.15 46.2 46.25 46.3

Time

Wat

er (g

)



Theoretical water production based on H2 delivered to

Sabatier

Actual water periodically

discharged from phase separator



52

0

200

400

600

800

1000

1200

41.75 41.8 41.85 41.9 41.95 42 42.05 42.1 42.15 42.2

Time

Wat

er (g

)



Test Point 4, 5.4 EP, Continuous, 1000 RPM


53

Table 2.2-11 - Sabatier Water Production Rate Efficiencies

Actual Water Collected (gm)

Theoretical Water Production Rate

Actual Water Production Rate Time Period

Evaluated (hrs) Water Production

Efficiency Test Point CO2 EP (gm/min) (gm/min) 1 3 16.10 876.3 0.99 0.85 89% 2 3 3.78 197.1 0.99 0.85 84% 3 3 10.85 574.6 0.99 0.81 82% 4 5.4 5.97 576.0 1.72 1.6 94% 5 5.4 6.65 637.7 1.72 1.6 93% 6 5.4 15.05 1341.8 1.72 1.5 89% 8 6 (met) 14.90 1590.3 2.06 1.8 88% 10 5.4 (met) 19.97 1836.6 1.72 1.4 87% 11 5.4 (met) 19.98 1713.9 1.72 1.5 86%

The water production performance is presented in Table 2.2-4. As expected, the steady state cases (Test Points 1 and 4) had the highest water recovery rates as there was no water vapor lost due to venting during Standby operation. The higher EP cases had slightly higher water recovery as there were no periods of Sabatier starvation.

54

2.2.4 Conclusions from This Test Section

The integration test of the 4-Bed Molecular Sieve, Mechanical Compressor and Accumulator and Sabatier was a successful test program. The testing showed that these systems could be properly integrated together. There is no significant, detrimental impact on the 4-Bed CO2 removal system when desorbed with a compressor instead of space vacuum. 4-BMS CO2 removal efficiency was well above requirements for the wide range of CO2 inlet concentrations tested. The compressor control logic in place during this test program supported the wide range of conditions tested. Modifications were made in the flight CO2 compressor control logic to accommodate pressure sensor accuracy requirements. Also, the 4-BMS vent valve flight control strategy is different than what was tested and results in fewer valve cycles. As a result of this testing, the compressor simulation model was modified to better predict flow at low suction pressures. The 4-BMS model was also updated to incorporate a leakage factor to estimate air leakage into the system components that operate at vacuum.

2.3 Integration Test Using the TSA Compressor

2.3.1 Description of Tests

2.3.1.1 4BMS + TSAC

The TSAC integration tests were conducted in three phases at MSFC. The first phase included the integration test of the 4BMS and TSAC only with constant 4BMS CO2 loading. Phases 2 and 3 included the Sabatier with constant and variable CO2 loading of the 4BMS. The primary objective of the first phase was to demonstrate the TSAC performance in a realistic environment where the CO2 flow and pressure from the 4BMS varied with time. The objectives of these tests were to gather data for the validation and optimization of the air-cooled TSAC design, and for development of a low power CO2 removal system that incorporates the functions of the 4BMS and the TSAC. Figure 1 below shows a simplified schematic of the 4BMS and the TSAC configured for the initial phase of the stand alone tests. The Sabatier simulator was a mass flow controller set to draw a fixed flow rate of CO2 from the TSAC.

55

Figure 27 - Simplified Schematic of 4BMS and TSAC Integration Test

56

2.3.1.2 4BMS + TSAC + Sabatier

Simplified Schematic of Ground Test HardwareSimplified Schematic of Ground Test Hardware

V209

V2

Vent Line

CDRA

To Vacuum



V2

FacilityVent

SabEDU

N2

Vacuum vent

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

CDRA

To Vacuum



V2

FacilityVent

SabEDU

N2

Vacuum vent

PGPG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

V209

V2

Vent Line

CDRA

To Vacuum



V2

FacilityVent

SabEDU

N2

Vacuum vent

PG

VenturiVacVent

H2Bottle/regulator

H2Bottle/regulator

CO2 inlet

TSAC

CDRA

To Vacuum



V2

FacilityVent

SabEDU

H2Bottle/regulator

N2

Vacuum vent

H2Bottle/regulator

CO2 inletPGPG

VenturiVacVent

TSAC

Figure 28 – Integrated Test Schematic – 4BMS, TSAC, Sabatier

Figure 2 above is a simplified schematic of the 4BMS integrated with the TSAC and the Sabatier. The same V209 and V2 valves were used as with the mechanical compressor test. The two beds of the TSAC and the associated valves that allow switching are not shown in this diagram. These are all contained in the box labeled TSAC. The V209 valve again is used to allow the desorbing 4BMS bed to first perform the air-save function (removing ullage air volume back to the cabin). This valve then switched to the vent direction (to compressor or vacuum) once air-save was completed. The V2 valve, again was used to pressure relieve the 4BMS beds if the desorbing CO2 pressure was too high. The logic for this valve operation is described in Section 2.1 (Hardware Description). The integrated hardware shown above in Figure 2 operated as follows:

• During bed desorption, the 4BMS (labeled CDRA in the figure) delivers CO2 through valve V209.

• Excess CO2 is vented through valve V2 to the space vacuum simulator. The venting logic is described in more detail in Section 2.1.5.2, 4BMS Venting.

• CO2 for processing is delivered through valve V3 to the suction of the TSAC. The TSAC controlled all of the valves necessary to switch between the two sorbent beds and isolate the TSAC from the 4BMS and Sabatier. The Sabatier controller did not perform this function.

• A separate vent line from the TSAC to the space vacuum simulator was used to allow the TSAC beds to bleed diluent gases (nitrogen and oxygen) from the beds.

57

Without the bleed stream, these diluents would build up and the compression capacity would diminish.

• The compressor delivered CO2 to the Sabatier inlet. The TSAC sorbent beds act as both accumulator and compressor. A separate accumulator is not needed with this compressor configuration.

• Valve SVC007, inside the Sabatier (not shown), opened to allow CO2 to flow when the Sabatier was in its processing state.

As with the mechanical compressor integration, during the TSAC integration the 4BMS was operated in the nominal ISS CDRA mode. Half-cycle time was 144 minutes and process air flow rate was 95 lbs/hour average. For the last 10 minutes of the desorb cycle, the desorbing bed was exposed directly to the space vacuum simulator pump. The CO2 loading profiles for the different test points are described in detail in Section 2.0.

2.3.1.3 Test Conditions

Table 5 below details the test conditions used for the integration of the TSA compressor with the 4BMS with and without the Sabatier. The column data in the table is as follows:

• Column 1 is a description of the conditions being simulated. • Column 2 is the test point number for recording test parameters and resulting data. • Column 3 is the target CO2 loading on the 4BMS for the TSAC/4BMS parametric

tests without the Sabatier. • Column 4 is the target CO2 inlet concentration to the 4BMS for fully integrated

tests with the Sabatier. These tests were run open loop, therefore the feed concentration to the 4BMS was set by a CO2 mass flow controller with measured CO2 concentration feedback to the mass flow control set point.

• Column 5 is the number of equivalent persons in the crew. The test points used for comparison of the two compressors were set with the same number of crew. For the test points that simulated a Lunar Base, the crew was set to 4. The compressor parametric tests used various crew sizes to achieve the desired loading values.

• Column 6 is the TSAC loading or suction pressure. This value is controlled in each test.

• Column 7 is the TSAC production or discharge pressure. The pressure was set at 19.3 psia for the 4BMS/TSAC only tests. The pressure was set at 18 psia for the 4BMS/TSAC?Sabatier tests.

• Column 8 is the US H2 feed rate. This designation was carried over from the ISS simulation tests even though there currently is no concept of multiple life support hardware components for Lunar operations. The H2 feed rate is calculated from the crew O2 consumption with an allotment of 0.24 lb/day of air leakage.

• Column 9 is the H2/CO2 molar ratio. While this value is a variable in the Sabatier control logic, it was set to a constant value of 3.5 for all tests.

58

• Column 10 is the feed rate of CO2 from the compressor to the Sabatier. This value is calculated by the Sabatier controller from the indicated hydrogen flow rate and the desired molar ratio.

The following describes the different test points and objectives: • Test Points 1 through 5 were performed with the 4BMS and TSAC only, without

the Sabatier • Test Point 1 was a maximum loading test with 8 kg/day loading on the 4-BMS

and TSAC loading at 4 psia. The TSAC production rate was 4.2 kg/day. • Test Point 2 was to determine the maximum TSAC production capacity at 5

kg/day 4-BMS loading. • Test Point 3 was to determine the maximum TSAC production capacity at 4

kg/day 4-BMS loading . • Test Point 4 was to determine the maximum TSAC production capacity with the

4-BMS loaded to 4 kg/day, but the 4-BMS was not desorbed to vacuum at the end of the half cycle. This test would provide data pertinent to LPCOR development.

• Test Point 5 was to determine the maximum TSAC production capacity at 3 kg/day 4-BMS loading.

• Test Point 6 was a parametric test with the TSAC loading pressure intended to be 6 psia.

• Test Points 7 through 11 were integrated tests including the Sabatier. • Test point 7 was a baseline configuration that mimicked conditions of a

previously run 4BMS/TSAC only test. The purpose of this test was to verify that the integration of the Sabatier did not impact the performance of the TSAC and 4BMS.

• Test points 8 and 9 were designed to mimic previous integration tests with the 4BMS/Mechanical Compressor and Sabatier. The purpose of these tests was to obtain direct comparisons of the compressor technologies as they relate to the integration requirements.

• With the current focus on the Vision for Space Exploration, the team decided to develop test conditions that would reflect possible future exploration mission scenarios. These missions simulate a manned outpost at the Lunar south pole. Test Point 10 simulated the extended Lunar night and Test Point 11 simulated EVA activities. The basis for these test points is described in more detail in the next section.

In all of these tests, the objectives also included measurement of the effects of integration on the efficiencies of the stand-alone components.

59

Table 12 - Integrated Test Matrix – TSAC Test

US

H2

Feed

Rat

e sl

pm (l

b/hr

)

TSA

C P

rodu

ctio

n P

ress

ure

kPa

(psi

a)

4BM

S In

let C

O2

Con

c.

Sab

atie

r CO

2 Fe

ed R

ate

slpm

(lb

/hr)

TSA

C L

oadi

ng

Pre

ssur

e kP

a (p

sia)

H2/

CO

2 M

olar

R

atio

Equ

iv. P

ers.

Test

Poi

nt #

4BM

S C

O2

Load

ing

kg/d

ay

(lb/d

ay)

Mm

Hg

(%)

EP


Integrated 4BMS/TSAC baseline test

133 (19.3) 1 8 (17.6) -- 8 27.6 (4) -- -- --

Integrated 4BMS/TSAC at reduced CO2 loading, 5 kg/day

133 (19.3) 2 5 (11) -- 5 27.6 (4) -- -- --


2.3.1.4 Mission scenario development

This section describes the operating conditions set for each series of integration tests. Section 0 explains the reasons for choosing the test point in the matrices and how each series of tests relates to future missions. Section 2.3.1.3 details the input parameters in terms of crew size, processing duration, etc. Specific, quantitative test conditions, like any requirement, must be traceable back to some realistic higher level requirement, which in turn is traceable to a mission scenario. Rather than starting “at the bottom” with candidate test points the test point definitions

3 4 (8.8) -- 4 TBD 133

(19.3) -- -- -- Integrated 4BMS/TSAC at reduced CO2 loading and no vacuum desorb ot 4BMS

133 (19.3) 4 4 (8.8) -- 4 TBD -- -- --

Integrated 4BMS/TSAC at reduced CO2 loading, 3 kg/day 5 3 (6.6) -- 3 TBD

133 (19.3) -- -- --

Integrated 4BMS/TSAC at reduced CO2 loading pressure

133 (19.3) 6 5 (11) -- 5 41.4 (6) -- -- --

Integrated 4BMS/ TSAC/ Sabatier at TSAC baseline conditions for TSAC health check 7 --

5.3 (0.7%)

124 (18)

6.766 (0.0798)

1.933 (0.502) 8.3 -- 3.5


3.5 (0.46%)

124 (18)

4.459 (0.053) 8 -- 5.46 -- 3.5

1.274 (0.331)


1.5 (0.2%)

124 (18)

1.925 (0.023) 9 -- 2.34 -- 3.5

0.550 (0.143)

Integrated 4BMS/ TSAC/ Sabatier Lunar night scenario, non-optimal TSAC shutdown/ startup 10 --

2.52 (0.33%)

124 (18)

3.273 (0.037) 4 -- 3.5

0.935 (0.243)

Integrated 4BMS/ TSAC/ Sabatier EVA full crew departure scenario, CO2 regenerated to cabin

Per profile

124 (18)

3.273 (0.039) 11 -- 4 -- 3.5

0.935 (0.243)

60

can be derived “top down” from the mission scenarios. This process ultimately links the tests and the data produced to the mission need. Because of the configuration of the Sabatier scar in the OGS rack, the TSAC compressor is a less likely candidate for the ISS application, however its technical merits make it a viable candidate for other space exploration missions where interface conditions have not already been set. The TSAC test conditions were based on possible Lunar mission operating parameters. Various scenarios were explored that taxed the systems’ capabilities over a range of conditions. These Lunar mission scenarios were used to develop the input parameters of Table 5. Lunar Base CRA Installation With the current focus on the VSE, it was decided that test points should be included to reflect possible future mission scenarios. Three basic mission scenarios were developed: 1) Impact of lunar day/night cycles at the south pole, 2) Lunar mission EVA, and 3) Reduced pressure cabin atmosphere. For this test series, the third mission scenario was ruled out since time constraints would not allow the reconfiguration of test hardware for sub-ambient operation. Impact of Lunar Day/Night Cycles at the South Pole Lunar missions will operate with very different power cycle availability than the more familiar ISS power-cycle profile. Due to a reduction in resupply water capability, the use of a CDRA/TSAC/Sabatier system is most advantageous as part of an Outpost life support system, which will most likely be positioned at the Lunar South Pole. At the South Pole, solar power is available nearly continuously for most of the month, with periods of 24 to 48 hrs where no solar power is available and stored battery power is required. Reduced power operations will probably be necessary during this night period. Since OGA provides hydrogen to Sabatier, one test point included shutting down the Sabatier production during what would be the Lunar night. With the Sabatier shut down during Lunar night, TSAC need not operate to produce CO2. Depending on the TSAC state when the system shuts down, the start-up could be simple or more complex. The CDRA would continue operating to maintain CO2 levels in the habitat. Due to time constraints, the most challenging scenario was selected where the lunar night cycle begins relatively early in a CDRA half cycle and ends towards the end of a CDRA half cycle. This results in the TSAC shutting down when only a fraction of the adsorbing bed has been loaded and only a fraction of the desorbing/producing bed has been unloaded. Hence, when the lunar night is over and the TSAC/Sabatier re-started, for the first TSAC cycle after the half cycle change, there is too much CO2 on the adsorbing TSAC bed for the CDRA to fully desorb. Preliminary testing found that by approximately 70-80 min into the 4BMS 144 min cycle, about 25% of the available CO2 was adsorbed onto TSAC. Hence for this test point, Lunar night or TSAC/Sabatier shutdown occurred at this time. Due to time constraints, the Lunar night cycle was reduced to a minimum of 6 hrs, about the time it takes to fully cool down the TSAC and Sabatier systems. After the lunar night cycle, the TSAC and

61

Sabatier were started back up at roughly 120 min into the current 4BMS cycle. Since there is almost no CO2 remaining on the 4BMS desorbing bed at this time, the TSAC was not able to adsorb any additional CO2. Since the TSAC requires roughly 20 min to heat up before it can provide CO2 to the Sabatier, the desorbing TSAC bed at first was not able to unload any additional CO2 to Sabatier. Hence, when the CDRA half cycle change occurred, the TSAC was essentially in a worst-case configuration with both beds partially loaded with CO2. The results of this test configuration will be discussed below. Lunar Mission EVA Lunar Exploration missions will be highly EVA intensive, with crews of two to four making trips on the lunar surface multiple times in a week. The number of crewmembers actually in the habitat can change significantly during the day or the week, changing the load on each of the air systems. It was assumed that if an OGA were used for oxygen generation, it would also be used to generate oxygen that is stored for consumption during EVAs resulting in continuous H2 availability. It was also assumed that the CDRA would remain operational even if all crew were on EVA since this is the most likely flight configuration due to its simplicity. Multiple possible EVA scenarios were evaluated. These included: 1) 4 crew EVA where CO2 exhausted on EVA is stored and later regenerated back to the cabin, 2) 4 crew on EVA but CO2 is vented during EVA, 3) 4 crew on EVA but depart habitat in groups of two offset by 4 hrs, and 4) 2 crew on EVA and 2 remain in habitat. METOX regeneration was used as a model for the regenerable EVA CO2 removal technology. Overall, approximately ten different possible EVA scenarios were developed. Several of the configurations were modeled in JSC’s integrated model discussed previously. In comparing the predicted cabin ppCO2 profiles, it was concluded that the most dynamic and therefore worst case test scenario was defined as a 4 crew, single departure EVA where CO2 is stored and later regenerated to the cabin. Based on modeling, the most realistic EVA CO2 regeneration scenario involved 2 crew worth of CO2 being regenerated starting 2 hours post EVA followed by the remaining 2 crew’s worth of CO2 regenerated the following day. Figure 3 depicts the cabin ppCO2 results of this scenario.

62

0

1

2

3

4

5

6

7

8

9

0 10 20 30 40 50

Time (hours)

ppCO

2 (m

mH

g)

60

sleep sleep sleep

EVA CO2 regen exercise exercise CO2 regen

Figure 29 - Lunar EVA Mission Scenario Cabin ppCO2

2.3.2 Discussion of Test Results – Integration Test with TSAC

2.3.2.1 Results - 4BMS + TSAC

The 4BMS and TSAC were tested together over a range of CO2 feed rates to better define the TSAC operating envelope and to provide data for further design improvements. In order to understand the impact of the TSAC on the 4BMS, a test plan was developed to compare operating effects. The 4BMS was operated in a stand-alone open loop mode, and then integrated with the TSAC under similar input conditions. Table 2 below lists the test conditions and the results for the two different operating modes. The CO2 removal efficiency of the 4BMS was an average of 2.75% less when integrated with the TSAC than in open-loop mode, desorbing to vacuum. The worst effect was in the middle of the range of input CO2 concentration, 2.6 mmHg ppCO2, where the efficiency dropped 5% when the TSAC was added. Figure 4 below shows the difference between the two sets of operating conditions. Table 13 - Operating parameters for 4BMS / TSAC comparison tests

Inlet CO2 Concentration

CO2 Removal

4BMS CO2 Removal

Efficiency Loss with Data File

63

(mmHg) Rate (lb/hr) Efficiency (%)

TSAC

4BMS Compare #1 5.30 0.73 69 2% TSAC Test #1 5.27 0.71 67 4BMS Compare #3 3.31 0.56 85 3% TSAC Test #2 3.28 0.54 82 4BMS Compare #4 2.63 0.44 84 5% TSAC Test #3 2.65 0.41 79 4BMS Compare #5 1.96 0.32 84 1% TSAC Test #4 1.94 0.32 83

Effect of Adding TSAC to 4BMS CO2 Removal Efficiency

0

10

20

30

40

50

60

70

80

90

1.9 2.6 3.3 5.3

Inlet CO2 Concentration (mmHg)

CO

2 R

emov

al E

ffici

ency

(%)

Open Loop 4BMS Efficiency4BMS with TSAC Efficiency

Figure 30 - Graphical presentation of integration effects on 4BMS efficiency

One objective of the 4BMS / TSAC testing was also to obtain parametric data for the TSAC for sizing and evaluation. Table 3 lists the test parameters for these tests along with the performance targets and actual results. These tests were described in the ICES paper 2006-01-2271 “Integrated Test and Evaluation of a 4-Bed Molecular Sieve, Temperature Swing Adsorption Compressor, and Sabatier Engineering Development Unit.” Table 14 - TSAC Performance Target and Actual Results


Test #

4 BMS Inlet

ppCO2

4 BMS CO2

Removal

TSAC Production

Rate

TSAC Delivery Pressure

TSAC Loading Pressure

Comments

psi

mmHg kg/day kg/day mmHg Target /

Result Target / Result

Target / Result

Target / Result

1 5.27 8 / 7.7 4 / ?? 4.2 / 4.24 1000 / This Integrated 4BMS/TSAC

64

1002 condition is not listed in the ICES paper

baseline test

2 3.28 5 / 5.39 4 / ?? Max / 4.24 1000 / 1002

ICES Test #1


4.2 kg/day 3 2.65 4 / 4.5 4 / ?? Max / 4.07 1000 /

1004 ICES Test #3 11/18/05 9:06 AM to 11/19/05 6:13 AM


4 2.58 4 / 4.16 4 / ?? Max / 2.89 1000 / 1004

ICES Test #4 11/21/05 9:06 AM to 11/22/05 7:12 AM

Integrated 4BMS/TSAC at 4 kg/day and no vacuum desorb of 4BMS

5 1.94 3 / 3.49 4 / ?? Max / 3.99 1000 / 1003

ICES Test #5 11/19/05 4:28 PM to 11/20/05 11:41 AM


6 3.26 5 / 5.96 6 / ?? Max / 4.75 /

1000 / 1004

ICES Test #2

Integrated 4BMS/TSAC at increased CO2 loading pressure

4.8 kg/day

2.3.2.2 Results - 4BMS + TSAC + Sabatier

This section describes the test results for the 4BMS, Temperature Swing Adsorption Compressor and Sabatier integration test series. Five different test points were run, each with a different set of operating conditions. The summary of test results is given below in Table 3 along with the summary data from 4BMS + TSAC parametric testing.

2.3.2.2.1 Integrated Test Results - Nominal Steady State Operation

Some of the TSAC integration tests were conducted at nominal steady state inlet conditions to baseline the performance of the systems together. These first three test points were conducted with steady CO2 feed flow to the CDRA and continuous operation of the Sabatier. These cases resulted in sufficient CO2 capture by the TSAC so that there were no periods of Sabatier starvation. The excess CO2 not needed by the Sabatier was

65

vented by the CDRA directly to the vacuum vent. Figure 5 below illustrates typical TSAC performance for Test Point #1. This test point was run with very high CO2 loading, 8.3 EP. The pink and blue lines are the alternating TSAC bed pressures. There is instrumentation error between the pressure sensor measuring the 4BMS bed and the pressure sensor measuring the TSAC bed. The CDRA discharge pressure must be higher in order to flow to the TSAC. The saw tooth lines at about 10 psia are the equilibrium pressures when each TSAC bed has completed adsorbing CO2 from the desorbing CDRA bed. The saw tooth pressure is the result of the 4BMS bed heater cycling to maintain temperature while the CO2 is desorbing. The smooth lines at about 20 psia are each of the desorbing TSAC beds providing continuous flow to the Sabatier. As long as the green line at the top of the graph (Sabatier inlet CO2 pressure) remains above 18 psia, then the Sabatier is allowed to operate (shown by the purple line at the bottom of the graph). The brown line is the vacuum tank pressure. The large spike at each TSAC bed change is from the CDRA going into the 10 minute space vacuum desorb portion of its operating cycle. The smaller peaks in the middle of each half cycle are from the vent valve opening to relieve the CDRA pressure.

0

5

10

15

20

25

10.75 10.8 10.85 10.9 10.95 11 11.05

Sabatier Inlet CO2 Pressure

TSAC Bed A Discharge Press

TSAC Bed B Discharge Press

Sabatier Operating Status

Test Point 1 4BMS/TSAC Comparison

Sabatier Inlet pressure is always

above 18 psia

End of adsorption equilibrium pressure

CDRA Discharge Pressure

Vacuum Tank Pressure

Sabatier is always on Large peak, 10

minute vacuum desorb

Small peak, vent valve relief

Figure 31 - Typical TSAC Performance Data

66

Tab

le 1

5 - T

est r

esul

ts fo

r 4B

MS

/ TSA

C /

Saba

tier

inte

grat

ed te

stin

g

TSAC

Load

ing

(Suc

tion)

Pr

essu

re

at E

nd o

f Cyc

le

(kPa

) (T

orr)

Sab

atie

r Rea

ctor

H

ot

Zon

e Te

mp

(°C)

TSAC

Prod

uctio

n (S

abat

ier

Dem

and)

Rat

e (k

g/da

y)

(slp

m)

Sab

atie

r Rea

ctor

O

utle

t Te

mp

(°C)

TSAC

Prod

uctio

n Pr

essu

re a

t En

d of

Cyc

le (

kPa)

(T

orr)

Sab

atie

r Rea

ctor

In

let

Pres

sure

(k

Pa)

(psi

a)

Num

ber

of 4

BM

S

Ven

t Cyc

les

in

Inte

grat

ed

Ope

ratio

n

4BM

S

Inle

t CO

2 Con

c.

(mm

Hg)

4BM

S

CO

2 Lo

adin

g (k

g/da

y)

4BM

S

Rem

oval

(k

g/da

y)

Sab

atie

r H

2 Fe

ed

Rat

e (s

lpm

)

Sab

atie

r Sta

rvat

ion

Period

(m

in)

Sab

atie

r W

ater

Pr

oduc

tion

Effic

ienc

y

Obj

ectiv

e of

Tes

t Po

int

Cab

in

CO

2 U

tiliz

atio

n

Test

Po

int

(lb/

hr)

(°F)

(°

F)

Ste

ady

Sta

te L

oad

Con

ditio

ns,

8.3

EP

1 10

.90

5.21

7.

57

72.7

9 14

1.09

5.

23

6.76

72

.48

534

74

0

93%

70

%

(0.7

2)

(10.

56)

(105

8.26

) 1.

85

10.5

1 99

3 16

6

SS 5

.46

EP

2 7.

51

3.42

6.

20

42.7

5 14

1.11

3.

43

4.45

69

.21

527

74

0

93%

55

%

(0.5

7)

(6.2

0)

(105

8.42

) 1.

21

10.0

4 98

1 16

5 SS 2

.34

EP

3 3.

27

1.48

2.

46

26.2

8 14

1.15

1.

49

1.91

65

.05

472

69

0

92%

61

%

(0.2

3)

(3.8

1)

(105

8.69

) 0.

53

9.43

88

2 15

7 Lu

nar

Nig

ht

4 5.

56

2.52

4.

50

32.3

6 14

1.15

2.

53

3.26

67

.50

518

73

41

0 95

%

45%

(0

.41)

(4

.69)

(1

058.

74)

0.90

9.

79

965

163

Luna

r EV

A

Exit

5

Part

1

2.91

1.

34

0.54

31

.61

141.

17

2.51

3.

2 67

.32

517

72

14

95

%

71%

0.

18

4.59

10

58.8

7 0.

89

9.76

96

2 16

2

Luna

r EV

A

Ret

urn

5 6.

07

2.74

4.

27

42.3

0 13

7.38

2.

37

3.16

64

.59

512

71

174

23

92%

62

%

Part

2

0.39

6.

14

1030

.45

0.84

9.

37

953

100

67

Test points 2 and 3 were designed to copy the operating conditions of the previously completed mechanical compressor integrated tests. The 3 and 5.4 EP CO2 loading cases with continuously operating Sabatier were chosen to replicate (refer to cases 1 and 4 of the Mechanical Compressor tests). As expected, the equilibrium pressure of the adsorbing TSAC bed for each case is related to the CDRA inlet CO2 concentration. This equilibrium data is summarized below in Table 5 and illustrated in Figure 6.

0

200

400

600

800

1000

1200

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

Time

Pres

sure

(tor

r)/T

empe

ratu

re (C

)

TP1 Bed A Press

TP1 Bed A Temp

TP2 Bed A Press

TP2 Bed A Temp

TP3 Bed A Press

TP3 Bed A Temp

8.3 EP 5.46 EP 2.34 EP

Equilibrium pressure of adsorbing TSAC bed

Bed heater temps

Production pressure of desorbing TSAC bed

TSAC Performance at Various CO2 Loading

0

200

400

600

800

1000

1200

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

Time

Pres

sure

(tor

r)/T

empe

ratu

re (C

)

TP1 Bed A Press

TP1 Bed A Temp

TP2 Bed A Press

TP2 Bed A Temp

TP3 Bed A Press

TP3 Bed A Temp

8.3 EP 5.46 EP 2.34 EP

Equilibrium pressure of adsorbing TSAC bed

Bed heater temps

Production pressure of desorbing TSAC bed

TSAC Performance at Various CO2 Loading

Figure 32 - TSAC equilibrium loading pressure is dependent on CO2 feed to CDRA.

Table 5 below lists water production efficiency data for the various scenarios tested with the 4BMS, TSAC and Sabatier. The Sabatier was upgraded from the previous configuration that was tested with the mechanical compressor, so the efficiency data cannot be directly compared. The upgraded Sabatier EDU has a rotary phase separator, which spins all the time to separate the gas and liquid phases in micro-gravity. Some of the excess heat from the separator motor goes into evaporating the product water, which lowers the recovery efficiency. The previous version of the Sabatier EDU had a tank separator with a pump that only operated when the tank was emptied. For a gravity based mission, such as a lunar habitat, a tank and pump would be the preferred separator.

68

Table 16 - Sabatier Efficiency Data when Integrated with TSAC

Sabatier Hot Zone

Temperature with

Mechanical Compressor

Sabatier Water

Production Efficiency in Equivalent Mechanical Compressor

Test

Sabatier Reactor Hot

Zone Temperature

(C)

Sabatier Water

Production Efficiency

Sabatier H2 Feed Rate

(slpm)

Sabatier Starvation

Period (min)


(C) (F) (F)

Compare to 4BMS/TSAC baseline

534 1 6.76 0 993 94%

Compare to Mech. Comp TP4

527 510 2 4.45 0 981 92% 950 94%

Compare to Mech. Comp TP1

472 454 3 1.91 0 882 87% 850 89%

518 Lunar night scenario 4 3.26 41 965 89% Full crew EVA

departure 5 Part 1 3.20 14 517 962 96%

Full crew EVA return and regenerate

512 86% 5 Part 2 3.16 174 953 (peak 91%)

Stand alone Sabatier EDU Test prior to Mech

Comp. Integration

535

NA 9.0 NA 995 92% Stand alone Sabatier

Upgrade EDU test prior to TSAC Integration

504

NA 2.65 NA 940 92%

2.3.2.2.2 Integrated Test Results - Simulated Mission Profiles

In addition to the steady state tests, lunar mission cases described previously in Section 2.2.3.1.2 were tested. The simulated cabin CO2 concentration profile, which was the result of the cabin atmosphere simulation model, was used as the input profile of CO2 fed to the CDRA. Test point number 4 was a lunar night scenario. At the South Pole, the lunar night lasts 24 to 48 hours straight, once per month. Since operations would depend on battery power when no solar power is available, it is likely that the oxygen generator would be turned off. Without hydrogen, the Sabatier would also shut down and the TSAC compressor, likewise. A scenario was simulated in which the TSAC and Sabatier were turned off part-way through a CDRA cycle, and allowed to completely cool down before restarting. Figure 7 below shows the results of the simulation when the systems were turned off, allowed to cool, then turned back on.

69

32 minutes into Bed B adsorb cycle CDRA turned off

After turning back on, Bed B doesn’t have enough CO2 for full cycle

Lunar Night Cycle Simulation with CDRA/TSAC/Sabatier

Sabatier should have turned on here

Figure 33 - Results of simulated Lunar night

During the simulation, the CDRA continued to operate as it would be required to properly maintain the atmosphere in the habitat. The CO2 desorbed from the CDRA was vented to the vacuum system as long as the TSAC was turned off. The systems were turned back on 120 minutes into the CDRA cycle, when there was essentially no more CO2 to transfer to the TSAC. The bed that had been adsorbing during the shutdown had only received a partial fill and during the following cycle there was not enough CO2 captured to operate the Sabatier continuously. The systems recovered to normal operation following one full CDRA cycle. The starvation effect could be minimized by starting up the TSAC one half cycle ahead of the oxygen generator and Sabatier as long as the atmosphere oxygen concentration would allow further delay.

70

0

5

10

15

20

25

27.5 28 28.5 29 29.5 30 30.5

Tme (days)

CO

2 Pr

essu

re (p

sia)

0

0.25

0.5

0.75

1

1.25

1.5

CO

2 C

once

ntra

tion

(%)

TSAC Bed A Press TSAC Bed B Press Sabatier Inlet CO2 Press Cabin CO2 Conc Sabatier Status

Sabatier feed pressure falls every TSAC bed change

One full cycle delay between CDRA intake

and TSAC delivery

Integrated Performance During Simulated Lunar EVA Mission

0

5

10

15

20

25

27.5 28 28.5 29 29.5 30 30.5

Tme (days)

CO

2 Pr

essu

re (p

sia)

0

0.25

0.5

0.75

1

1.25

1.5

CO

2 C

once

ntra

tion

(%)

TSAC Bed A Press TSAC Bed B Press Sabatier Inlet CO2 Press Cabin CO2 Conc Sabatier Status

Sabatier feed pressure falls every TSAC bed change

One full cycle delay between CDRA intake

and TSAC delivery

Integrated Performance During Simulated Lunar EVA Mission

Figure 34 - Simulated Lunar EVA Excursion profile results in long periods of Sabatier starvation.

Figure 8 above shows the results of a simulated lunar EVA mission. The CO2 concentration feeding the CDRA is the result of a simulation of a habitat with 4 crewmembers with periods of EVA followed by regeneration of the EMU CO2 collection canisters in the habitat. There is a time delay of one CDRA cycle (4.8 hours) between when the CO2 concentration in the cabin drops and when the CO2 delivered to the Sabatier is insufficient. This effect could possibly be corrected with intelligent software that lowers the O2 production rate (therefore lowering the Sabatier processing rate) during periods when the TSAC bed loading is low. The final loading pressure of the TSAC bed in its previous half cycle is an indicator of the total bed loading and what the delivery capability will be in the next half cycle.

2.3.3 Conclusions from This Test Section

The testing described herein was the first integrated test of a 4-Bed Molecular Sieve, Temperature Swing Adsorption Compressor, and Sabatier Reactor. Five successful tests were completed with these three systems. These tests provided enhanced understanding

71

of both nominal, steady-state operation and dynamic, transient scenarios that can be expected to occur on a Lunar base. Six additional 4BMS-TSAC tests explored widely varying 4BMS loading conditions and the corresponding response of the TSAC. In general, the three systems were proved compatible and able to perform their intended functions for a wide range of input conditions. These specific conclusions are drawn from these test results:

• The dynamic transients expected in a Lunar EVA scenario were played out in Test Point 5. The CO2 concentration changes due to crew movement into and out of the habitat. The response of the systems is delayed, one system to the next, as each system progresses through half cycles. The hydrogen generation rate (by-product from oxygen generation) is current with crew activity. The CO2 delivery rate is delayed by one half cycle. This mismatch results in Sabatier starvation. Adaptive software may be a solution to better match the hydrogen and CO2 rates to feed the Sabatier. There should be sufficient oxygen concentration buffer to allow delayed oxygen production while waiting for the CO2 to be concentrated.

• Large variations between half cycles were noted during the Lunar EVA scenario. The causes for these variations need to be understood and rectified.

• The TSAC had, on average, less than 5% negative impact on the 4BMS performance. However, much higher deviation was noted at 2.6 torr inlet ppCO2 and bears further review.

• A 4BMS heater ramp control algorithm can save about 50 watts (time averaged power). However, refinements to the TSAC operation will be required to prevent gaps in the CO2 production to the Sabatier.

• Additional work is required to prevent TSAC exposure to humidity from room air. The TSAC material’s sensitivity to humidity required it to be extensively purged after inadvertent exposure to room air. Isolation mechanisms should be implemented and tested to prevent air leakage during 4BMS shutdowns.

• Additional refinements to the overall control software are required for better communication between the 4BMS, TSAC and Sabatier.

• The Sabatier software performed a vacuum leak check during every transition to Standby. If the water level was sufficiently high, the separator would be instructed to pump out the water during the vacuum leak check. The separator cannot create enough pressure rise when at vacuum to satisfy the pump out requirement, which then causes a system shutdown. An adjustment to the Sabatier control is required to prevent separator triggered shutdowns during standby mode.

• The Sabatier required CO2 pressure deadband should be a minimum of 3 psi when integrated with a TSAC. The low pressure for Standby should be 16 psia and the high pressure should be 19 psia when operating at the conditions used in this test program. A smaller deadband results in valve chatter while the TSAC is heating up and generating pressure.

• The TSAC and 4BMS need sufficient communications to synchronize their half cycles and to signal each when shutdowns and initiated.

72

3 Conclusions

The testing described herein was the first integrated test of a Four-Bed Molecular Sieve, Sabatier Carbon Dioxide Reduction Assembly with the interfacing CO2 compressor. Two compressor technologies were tested, a mechanical oil-free piston compressor, and a temperature swing adsorption compressor. The mechanical compressor was tested under simulated International Space Station parameters. The TSAC was tested under simulated Lunar Base parameters. Both sets of tests provided enhanced understanding of both nominal steady operation and dynamic, transient scenarios that can be expected to occur in an integrated Environmental Control and Life Support System. Additionally, the compressors were tested independently and with only the 4BMS over varying CO2 loading conditions. The corresponding compressor response to changing conditions was observed. In general, the 4BMS, Sabatier and both compressor technologies were proved compatible and able to perform their intended functions for a wide range of input conditions.

3.1 Overall Conclusions from the Integration Test Experience

The integration test of the 4-Bed Molecular Sieve with two different compressors and a Sabatier reactor was a successful test program. The testing showed that these systems could be properly integrated together. There is no significant, detrimental impact on the 4-Bed CO2 removal system when desorbed with a compressor instead of space vacuum. 4-BMS CO2 removal efficiency was well above requirements for the wide range of CO2 inlet concentrations tested. The different systems’ control logic in place during this test program supported the wide range of conditions tested. These tests provided enhanced understanding of both nominal, steady-state operation and dynamic, transient scenarios. In general, the three systems were proved compatible and able to perform their intended functions for a wide range of input conditions.

3.2 Summary of Observation from the Integration Test

These specific conclusions are drawn from the test results: • Both compressors (TSAC and mechanical) had a small but measurable effect

on the CO2 removal performance of the 4BMS. Since the vacuum level is not as low as space vacuum, some residual CO2 remains on the CO2 removal beds, which in turn reduces their capacity on the next adsorb cycle. During the mechanical compressor testing, the performance reduction was 5.4%. During the TSAC testing, the performance reduction ranged from 1-9% with an average of 4.2%. The integrated

73

performance may be improved with longer space vacuum desorb time or higher temperature. This subject is a candidate for further testing.

• As a result of this testing, the mechanical compressor simulation model was modified

to better predict flow at low suction pressures. • The 4-BMS model was also updated to incorporate a leakage factor to estimate air

leakage into the system components that operate at vacuum. • The dynamic transients expected in a Lunar EVA scenario were evaluated in the

TSAC testing. The test results showed a significant time delay from crew activity to system performance. Adaptive software may be a solution to better anticipate system changes and to alter production rates to maintain system balance.

• Both compressors had, on average, less than 6% negative impact on the 4BMS

performance. • A modified 4BMS heater ramp control algorithm was tested and resulted in power

savings, however gaps in CO2 delivery occurred. The prospect of power improvements is likely and future testing of modifications to the heater schedule is warranted.

• Additional work is required to prevent TSAC exposure to humidity from room air by

implementing isolation mechanisms. • Additional refinements to the overall control software are required for better

communication between the 4BMS, TSAC and Sabatier. • The TSAC and 4BMS need sufficient communications to synchronize their half

cycles and to signal each other when shutdowns are initiated. • The current compressor operation/control logic appears to support a wide range of

test conditions, but modifications may need to be made in order to reduce starvation during the low EP cases as well as reduce the number of brief operation cycles during high EP loading.

• Also, the impact of increased cycles on the 4BMS vacuum vent valve should be

evaluated to determine if these operating rules could be improved. • The data collected over the course of integrated testing is currently being compared

with predictions from existing models to validate the model against test data. The model is being adjusted as required to duplicate test results. Thus far it has been determined that the current compressor model does not adequately predict flowrate through the compressor at low suction pressures. A curve fit has been added to the compressor model based on test results. In addition, the impact of vacuum circuit in-leakage has become very evident upon comparison of test results with model

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predictions. Efforts are underway to estimate the current bed leak rates and incorporate them into the model as a “worst case”. An operational flight system, once leakage due to sorbent dusting is eliminated, is expected to have a much lower leak rate.

• The impact of in-leakage on the system and its operating rules cannot be ignored

since in-leakage results in increased compressor run time as well as decreased Sabatier efficiency. While it may be difficult to implement, any future plans regarding the integration of a flight CDRA with a CRA should also involve re-evaluating existing protocols for verifying CDRA as well as CRA leak rates. As observed in this test, current CDRA/4BMS leak test procedures could result in significant in-leakage that impacts CRA performance.

• The dynamic transients expected in a Lunar EVA scenario (TP 5) provided insight on

the delayed response of both the 4BMS and TSAC. Consideration of adaptive software to better utilize large influxes of CO2 is suggested.

• Large variations between half-cycles were noted during the Lunar EVA scenario. The

specific causes for this trend need to be understood and rectified. • The TSAC had, on average, less than 5% negative impact on the 4BMS performance.

However, much higher values were measured at about 2.6 torr inlet pp CO2, and bear further review.

• A 4BMS heater ramp control algorithm can save about 50 watts (time-averaged

power). However, refinements to the TSAC operation will be required to prevent gaps in CO2 production to the Sabatier.

• Additional work is required to prevent TSAC exposure to room air. An isolation

valve, or other appropriate solution, should be implemented and tested. • Additional refinements to the overall control software are required for better

communication between the 4BMS, TSAC, and Sabatier. • An adjustment to the Sabatier control is needed to prevent separator-triggered

shutdowns following standby mode. • 4BMS performance was well above requirements for the range of inlet CO2

concentrations tested. • In general, the current TSAC operation/control logic appears to support a range of test

conditions, but a more robust test matrix should be explored in future. • Upgraded components within the Sabatier EDU performed as expected.

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• Lessons learned from this test can, should, and will be incorporated into future revisions of the CDRS hardware.

3.3 Lessons Learned

3.3.1 Lessons Learned from the Integration Testing

This section documents the Lessons Learned, Anomalies and Resolutions that were implemented as part of the integrated testing.

• Hydrogen flow rate inconsistent across various measurement means, system mass balance not in check. Sabatier water production efficiency calculation is based on hydrogen flow rate.

o Critical parameters that are used to evaluate system performance against requirements must be accurate and verified against accepted standards.

• Loss of network communication from the Sabatier system led to a crash of the overall control computer, which in turn led to shutdown of the other subsystems.

o Control systems need to be designed such that subsystems can continue to operate independently if they lose contact with the main controller. In the case of the ARS, the CDRA is considered critical life support and needs to have the capability to continue operation in the absence of higher level commands. The Sabatier software must be designed to not propagate errors outside its boundaries.

• The Sabatier system rapidly cycled from Process to Standby during operation with the TSAC compressor during low CO2 production rates. The transition was keyed off of CO2 supply pressure limits. The Sabatier operating bands designed initially for the mechanical compressor operation were too tight for TSAC operation. Pressure bands were widened to allow smoother, slower mode transitions and avoid rapid cycling.

o System triggers that initiate logic decisions (such as changing operating mode, activating control loops, etc) must be examined and exercised over the widest range of operating conditions possible. The problem during the testing was resolved by changing the set points for the transition commands. These type of set points should also be variable in the control software so they can be adjusted to optimize operation.

• The Sabatier phase separator pump attempted to pump water out of the system when in standby while the pressure was very low. The pump could not overcome the differential pressure to pump out water when the system pressure was so low.

o The Sabatier flight software was designed to prevent the separator from pumping water during any low-pressure conditions. The software also performs a pump-out prior to transitioning to Standby while there is still pressure in the system to aid the pumping.

• The Sabatier system rapidly between Standby and Process such that the Standby evacuation was not completed. Valves were chattering during the transition. The

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action of the valves cause pressure changes that in turn changed status in the software that caused the valves to change position again. This was another artifact of control ranges set too close together. The transitions were taking place prior to completion of purge steps and the software ended up caught in an indeterminate state.

o Software logic should be designed such that sequences are completed before subsequent operating state changes are allowed to occur. Checks should be incorporated to verify that procedures (such as purges) are completed.

• If the Sabatier had gone through a shutdown and was still hot, upon restart it would go directly to Process without performing the required purge in Standby first. Apparently the temperature requirement was met and the software did not wait for the purge requirement to be met.

o Software must be written to ensure that all requirements are met, not just the first requirement. Careful testing is often needed to flush out these types of errors in code, as it is often only a unique set of circumstances will create the right conditions for these anomalies.

• Sabatier reactor thermal soak back – when flow to the reactor stops (as in Process

to Standby transition) the heat of the reactor soaks back to the inlet. This was accommodated in the Sabatier EDU by increasing high temperature shutdown limits. The flight reactor design also acknowledged this phenomenon and designed the inlet end instrumentation to tolerate high temperature.

o Component and controls design must consider all conditions, including non-operational conditions.

• 4MBS heater ramp rate – during the TSAC testing, the 4BMS heater control was

modified from a fixed temperature setpoint control to a ramp rate in which the temperature linearly increased from 60 to 400 F. The result of this test was a savings of 50 W time averaged over the desorption cycle, however, less CO2 was desorbed from the 4BMS to the TSAC during the cycle. The overall integration result was starvation of the Sabatier reactor for steadily increasing durations. Due to the potential power savings, further evaluation of modified desorption schedules is warranted.

• TSAC sensitivity to leaks – during testing, the TSAC was inadvertently exposed

to room air several times. Since the adsorbent material is very sensitive to humidity, the TSAC had to be taken offline and purged for an extended period of time before resuming testing.

o Future integrated designs must include means of isolating the TSAC to prevent accidental exposure to cabin air. Subsystem design must consider operating and non-operating states that may be damaging to the hardware.

• Integrated TSAC / Sabatier control pressure – as a result of the testing, it was determined that a minimum of 3 psid is needed for the Sabatier setpoints for CO2 pressure. When the Sabatier transitions to Process, the initial draw of CO2 lowers

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the TSAC pressure by more than 2 psid. If the transition setpoints are too close together, the systems will cycle rapidly between Process and Standby.

• Air effects on Sabatier performance – temperature anomalies were noted in the

Sabatier profile during the mechanical compressor testing. It was concluded that the temperature spike at the reactor inlet was due to higher than normal concentration of air during a 4BMS bed switching event. The Sabatier reactor is robust to the presence of air and its known temperature profile proved to be a good indicator of altered operating conditions.

o A future test item would be to determine if the reconfigured Sabatier reactor temperature sensors are as sensitive to detecting air inclusion as the EDU Sabatier.

• Sabatier Phase Separator operation at vacuum – testing determined that the rotary

phase separator cannot pump water out when the gas pressure is at vacuum. The flight operating control is configured to empty the separator at the beginning of a Standby transition when the gas pressure in the system is still relatively high.

• CDRA leak check – A significant observation made during integrated testing was

that hardware leakage could be masked if the hardware is leak checked while not in operation. For example, during initial integration testing, the 4BMS passed leakage testing, yet significant air in-leakage was observed during testing. The root cause was a selector valve that was cold-soaked during operation that caused the soft goods to shrink and allow leak paths. The valve was not cold during the static system leak check, and therefore passed the test.

o Systems need to be leak checked in their operating environment to ensure trouble free operation.

3.3.2 Lessons Learned from the Sabatier Flight Program

This section documents Lessons Learned that were incorporated into the flight Sabatier design as a result of the integration testing.

3.3.2.1 Hardware Changes Required

• Hydrogen Vent Tee – the space station OGS rack was initially designed with a

scar for the Sabatier Assembly to be added at a later date to the Oxygen Generation Assembly, but the Sabatier design was not very far advanced at the time the rack was launched. The initial plan was for the Sabatier to vent in the same line as the CDRA. This was later changed to having the Sabatier use the hydrogen vent from the OGA instead.

o The implementation of this change required the addition of a tee line that would be inserted at the interface panel quick disconnect. The change also

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imposed restrictions on the rate of discharge of the Sabatier to meet the restrictions of the shared vent line.

3.3.2.2 Software Changes Required

• CDRA Control Software – the flight CDRA software did not have provisions for interface commands related to a Sabatier system. The software had to be modified to keep the bulkhead vent valve closed so that the Sabatier could extract the CO2 from the desorbing CDRA beds. The CDRA venting logic, as noted earlier, is different for the flight system than the ground test system. Once the flight system bed pressure exceeds 8 psi, indicating that the compressor has not been activated, the vacuum vent valve is opened and left opened for the remainder of the desorption cycle. The loss of recovered CO2 is acceptable at this point since the accumulator is likely full or the system is not operational. This modification keeps the total number of cycles on the vacuum vent valve the same as that for which they were originally designed.

• OGA Evacuation Check – the OGA will check the pressure in the Sabatier hydrogen

delivery line before opening the valve to deliver hydrogen. If the pressure is high, the Sabatier could potentially have air in it. The OGA will not deliver if the pressure is too high to avoid a potentially hazardous condition. The pressure limit was initially 0.3 psia. This limit was too low, as the Sabatier pressure would at least be that of the vapor pressure of water in the phase separator, plus any instrumentation error in the pressure sensor. The limit was raised to 3.0 psia and the change made to the OGA software.

• Phase separator pumpout – as a result of the integrated testing, the flight Sabatier

software included provisions to pump out the phase separator at the very beginning of a transition to Standby while there is still sufficient gas pressure in the separator. The software then does not allow the separator to pump out any other time in Standby.

3.4 Recommendations for Subsystem Modification if Designing

a New System

• CDRA/TSAC combined design

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Can there be weight/power/volume savings if the CDRA and TSAC were designed as a single system? LPCOR

• CDRA / OGA cycle mismatch The ARS system on ISS is designed with the OGA operating on a 90 minute diurnal cycle, which matches the station orbit. The OGA would be powered and producing hydrogen during the “day” when power is plentiful and in standby during the “night” when power is scarce. The CDRA operated on a 144 minute half cycle. The mismatch in cycle times requires the use of storage volume to collect CO2 when hydrogen is not available to process. This would be a good area to investigate in the future, either through modeling or testing, to see if matched cycles results in less starvation or smaller accumulator volume.

• CDRA Power Usage – Desorption Rate The current design of the 4MBS has the heaters turn on full power during

the desorption phase if the station is in the daylight portion of the orbit. Testing with both compressors has shown that the 4BMS can retain CO2 in the bed for a significant period of time as long as the bed is evacuated to space vacuum for the final 10 minutes of the cycle. The 4BMS may possibly be operated such that the bed is pressure controlled instead of temperature controlled to save power when the compressor is not ready to receive CO2. This would prevent venting of the CO2 from the 4BMS to space vacuum.

Investigate by modeling or testing.

• CO2 tank proof pressure During the period of time leading up to the Integration Test program, the OGA for the International Space Station was designed and built. Coincidental development of the Sabatier led to incorporation of accumulator tanks into the OGS rack prior to its launch. The volume available for these tanks was smaller than desired, but development testing of the mechanical compressor showed that the compressor could meet the higher pressure demand required to offset the smaller volume. Although these tanks were designed and manufactured to accommodate very high pressures, they were only proof tested to 160 psia. The application of sensor inaccuracies and control bands to the operating system requirements resulted in a usable maximum operating pressure of only 115 psia. In practice, this lower operating pressure will result in greater venting of CO2 overboard and likely associated Sabatier starvation. Interfacing systems should be proofed to as high a pressure as possible per the results of trade studies. The CO2 accumulator for ISS was proofed to 145 psig (160 psia), but the application of sensor accuracies to overpressure protection reduces the actual maximum operating pressure to 100 psig (115 psia).

• Shared Vent Lines - Restriction on flow, temperature, MDP, In the ISS design, the Sabatier shares the vent line with the OGA. The vent

line was sized and proof tested to meet the requirements of the OGA alone. During integrated operation, there are times when both systems must be able to vent gases

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through this line at the same time. The line is not sized to accept this much flow without creating excessive back pressure. The Sabatier must therefore restrict the rate at which it allows venting gases to flow into the line.

Future integrated designs must consider all operating scenarios, including startup and shutdown, as input to designing interfacing systems (i.e. vent line).

• Coolant Interface The coolant temperature directly affects the percent of water recovery of the Sabatier system by setting the dew point temperature at the phase separator. Coolant temperature should certainly be included in any trade study for future ARS designs. The additional water recovery would have to be traded against issues of external condensation on coolant lines if installed in a habitable volume of the spacecraft or habitat.

• OGA Interface – Pressure Check The design of the ISS controls requires that the OGA verify that the Sabatier had been vented prior to allowing hydrogen to flow to the system. This is done for system safety to prevent introduction of hydrogen to the Sabatier if it was full of air. The target pressure value had been set to 0.1 psia to verify evacuation. However, this value is not achievable when the Sabatier system has water in the phase separator. When evacuated, the inlet pressure will be something more than the vapor pressure of water at the phase separator temperature. For ISS installation, a modification will have to be made to the OGA software to raise the pressure limit used for the interface check. This system check also requires that the Sabatier be evacuated during every standby. This results in some product water loss. The water recovery gained by not venting would have to be traded against other methods of preventing flammable mixtures.

• Waste Water Bus MDP The waste water bus on ISS has a MDP of about 90 psig. The Sabatier system was designed with an MDP of 268 psig to provide containment as a final means of protection against damage due to detonation. The interface of the phase separator to the waste water bus was an area of concern due to the possibility of transmitting a pressure wave through the water lines. I will get the details on how this was resolved.

• Location in Habitable Volume The ISS ARS is designed with all components in the habitable volume. This then requires that all of the components that contain flammable gas have either secondary containment (the OGA dome) or be operated at sub-ambient pressure to prevent leakage of gas out into the cabin. The sub-ambient operation results in a water recovery penalty, as the lower system pressure increases the volume fraction of water vapor that is vented with the methane product gas. For exploration systems, locating the flammable gas components outside the habitable area would allow operation at higher pressure, and therefore increase water recovery. There may be other benefits of volume and mass savings achieved by operating at higher pressure.

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• Acoustics and EMI Restrictions Acoustics and EMI are not insurmountable requirements, but add weight and volume to systems for attenuation. Location of the system outside the habitable volume may lessen the burden of acoustic and EMI requirements.

4 Recommendations

4.1 Recommended Future Testing

This integrated test program has shown that a closed loop Air Revitalization System is achievable and practical. However, there is insufficient data from either integrated test to draw conclusions about the long term effects of each compressor on the 4BMS operation, and vice-versa. The testing uncovered possible areas for improvement, and areas where more information is needed. The testing has shown that the systems can be integrated with acceptable reduction of performance of the 4BMS and the resulting water recovered is as much as 90% of what is theoretically possible. Long duration experiments under controlled conditions, in terms of 4BMS loading, TSAC loading, compressed CO2 production, CO2 purity, vacuum levels, etc.., should be performed to better understand long term performance.

4.1.1 Recommended Test Objective

Any future development should focus on improving the systems’ equivalent system mass (ESM - weight, power and volume), efficiency and reliability. Many observations were made of potential improvements in ESM and reliability. These potential improvements should be the focus of follow on testing or modeling work. Due to software control limitations, the integrated tests to date were performed at preset operating schedules. Upon adding a more sophisticated and flexible control system, the integrated systems should be tested under dynamic operating conditions where the system parameters such as CO2 inlet, cycle time, standby time, etc are varied in a non-uniform pattern (that are realistic to mission-specific scenarios).

4.1.2 Specific Recommended Tests

The following specific test recommendations are made with a focus on discovering potential areas for improvement to system weight, power, volume, efficiency or reliability.

• Test integrated combinations of compressors and the 4BMS with different lengths of vacuum desorb time and different desroption temperatures to determine if the

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4BMS CO2 removal efficiency can be improved. The integrated testing showed an average loss of CO2 removal efficiency of about 4-5%. This loss may be recovered by modifying operating times.

• Test adaptive software for the overall ARS system to better match CO2 and hydrogen availability. This would lead to minimizing instances of Sabatier starvation and improved overall water recovery.

• Test variations of heater ramp algorithms to determine if power savings can be achieved in both 4BMS and TSAC components.

• Test the TSAC with lower pressure cooling air (as might be a design requirement for a Lunar base or future spacecraft) or with alternate cooling medium (liquid) as might be available in future application. Each will have design impacts on the cooling rate and overall efficiency.

• Use the ground based hardware to verify protocols for evaluating leakage rates of in-flight hardware to improve flight system reliability.

• Further test variable loads, such as the Lunar EVA scenario tested here, to flush out the reason for the large variations noted between half cycles. This will lead to better understanding of the system operations and ultimately improve efficiency and reliability.

• Investigate the large performance impact noted at 2.6 torr inlet CO2 pressure and not at other CO2 concentrations during TSAC/4BMS testing. Perform addition tests if warranted. It remains unknown whether this stems from a testing anomaly, analysis error, or is indicative of a true performance sensitivity. Additional testing will provide a basis for overall system repeatability and measurement accuracy.

• Review test results to determine specific combinations of factors that cause subsystem shutdowns and make necessary control modifications. An example is the Sabatier separator attempt to empty at vacuum pressure. This protocol was corrected in the Sabatier flight software.

• Perform testing over a more robust range of operating conditions. The wider the acceptable operating range, the more flexibility for future loop closure.

4.2 Recommended Future Hardware Development

4.2.1 Subsystem Development

These are some possible development tasks that would result in improvements in ESM and reliability based on the results of the completed testing. Additional improvements may be discovered as a result of additional future testing outlined above.

• Develop a heater ramp algorithm for the 4BMS that will save power, yet accomplish the CO2 desorption needed.

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• Develop isolation mechanism and associated control to prevent room air humidity from entering TSAC beds.

• Improve heat transfer design of the TSAC and the 4BMS in order to reduce power usage by investigating the following factors:

o Arrangement of heaters and cooling ducts to minimize the thermal mass; o New adsorbents or adsorbent structures with reduced thermal resistance; o Improved package insulation; and o Flexibility in design to allow utilization of waste heat.

• Design TSAC for moisture management which may include system isolation, moisture sensing and on-line regeneration.

• Improve TSAC controls which allow flexibility in startup, operation and shutdown, and allow better subsystem communication and synchronization.

• Implement adaptive software which will allow optimization of product delivery based on previous cycle loading, purge control, compression time, and available power.

• Develop subsystems that are modular, that operate more efficiently at reduced loading and can be stacked for higher loading.

• Develop low volume, lightweight, high temperature components. • Continue development of the LPCOR system that combines the CO2 removal and

CO2 compression functions of the 4BMS and TSAC. • Through modeling or testing, evaluate the impact of different cycle times for the

4BMS and Sabatier. Determine if there is an optimum cycle time for each that minimizes the accumulator volume and/or overall system power.

• Evaluate the impact of powering the 4BMS heaters to control bed pressure rather than temperature.

• Evaluate the length of vacuum desorb time needed to fully clear the 4BMS beds if the bed is pressure controlled prior to desorption.

• Determine the water recovery cost/benefit as a result of higher or lower Sabatier operating pressure, and the associated system level impacts.

4.2.2 Component Development

• Consider all operating and non-operating conditions (such as temperature and pressure extremes) when designing components.

• Test flight-like Sabatier reactor to determine if the temperature sensors are sensitive enough to detect excessive air in the CO2 as was noted with the EDU reactor.

• Develop a liquid cooled Sabatier phase separator for maximum water recovery.

4.2.3 Controls Development

• Improve communication links between integrated subsystems for synchronizing cycles and reporting system anomalies and shutdowns.

• Improve mechanical compressor operating logic to minimize short cycles and reduce starvation at low CO2 loading.

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• Improve operating rules for 4BMS vent valve to minimize cycles on the valve. • Develop protocols for verification of accuracy of key measurement sensors. • Develop software protocols that prevent propagation of failures to other systems,

and the ability to operate independently if needed. • Evaluate system triggers that initiate logic decisions and exercise them over the

widest practical range of operating conditions. This will prevent issues such as rapidly cycling caused by pressure dead bands.

• Develop controls protocols that can be adjusted by crew intervention or by “smart” controls. This will allow a system to acclimate to its environment (for example, microgravity) and make necessary adjustments.

• Design software logic such that sequences are completed before subsequent operating state changes are allowed to occur. Checks should be incorporated to verify that procedures (such as purges) are completed.

• Design software such that all conditions are met before transitions occur. Careful testing over a wide range of operating conditions is needed to locate errors in code.

• Optimize Sabatier/TSAC pressure control logic and operating limits for transitions between Process and Standby that are based on TSAC delivery pressure.

• Develop protocols for leak checking components in their operating environment so that so that non-operating conditions (temperature or pressure) do not mask the detection of leakage.

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5 Appendices

Calculations This section details the calculations used to evaluate the performance of the subsystems during the Integrated Test Program. Raw Data – Sensor for Mechanical test only in green, for TSAC test only in red, for both tests in black. Tag Name Units CDPGas124 4BMS Inlet Air CO2 Concentration %CO2 CDPGas125 4BMS Outlet Air CO2 Concentration %CO2 AFCGas126 Lab Air CO2 Concentration %CO2 CDPDP_120 4BMS Inlet Air Dewpoint F CDPDP_121 4BMS Outlet Air Dewpoint F AFcDP_120 Lab Air Dewpoint F CDPTmp120 4BMS Inlet Air Temperature F CDPTmp121 4BMS Outlet Air Temperature F AFcTmp120 Lab Air Temp. Middle F CDPmt13 5A Bed 308 Heater Temp A F CDPmt14 5A Bed 308 Heater Temp B CDPmt16 5A Bed 309 Heater Temp A F MSAFlw022 Lab CO2 Inject Flowrate SLPM CDPMpde 4BMS Operating Mode

0OF 1SH 2A1 3A2 4A3 5B1 6B2 7B3 8WP CDPmw12 5A Bed 308 Primary Heater Power Watt CDPmw13 5A Bed 309 Primary Heater Power Watt CDPmw14 5A Bed 308 Secondary Heater Power Watt CDPmw15 5A Bed 309 Secondary Heater Power Watt CDPFlw121 4BMS Inlet Air Flowrate (TSI Meter) SCFM CDPTmp086 4BMS Precool Inlet H2O Temp F CDPFlw080 4BMS Precooler Inlet H2O Flow GPM CDPPrs120 4BMS Inlet Air Pressure PSIA CDPPrs122 4BMS Outlet Air Pressure PSIA CDPDP_023 Dessicant Bed Outlet Air Dewpt F MSAMas020 Facility CO2 Tank Weight Lbs CDPPrs021 Fac Vacuum Tank Air Inlet Pressure Torr CDPPrs023 CDPPrs022 Fac Vacuum Tank Air Pressure Torr CDPPrs024 CDPmt11 Desiccant Bed Outlet Temperature F THCFlw120 THC CHX Outlet Air Flowrate SCFM VenFlw120 CDPPrs123 Sorbent bed 308 pressure PSIA CDPTmp125 Desiccant bed 104 Outlet Air Temp F CDPFlw120 4BMS Inlet Air Flowrate (Sierra Meter) SCFM CDPFacClk 4BMS cycle Elapsed Time CDPmdns 4BMS Day/Night Status AfcPrs120 Lab Pressure PSIA MSAFlw023 Lab High CO2 Inject Flowrate LBS/HR CDPPrs121 Precooler Outlet to Ambient PSIA CDPTemp133 Precooler Inlet Air Temp Deg F MSA3WV020 0 is Inlet 1 is THC CDPmp12 Pump Inlet Air Pressure PSIA CDPVlt120 2-Stage Pump (Air Save) Voltage Volts CDPCur120 2-Stage Pump (Air Save) Current Amps CDPmp10 Blower Delta Pressure In H2O CDPmz16 CDPTmp640

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Tag Name Units CDPSpr003 MEDDP_020 Mechanical Compressor Outlet Dewpoint F MEDFlw020 Compressor Outlet Flow after DP lb/hr MEDPrs020 Compressor Inlet Pressure PSIA MEDTmp020 Manifold Outlet or Crankcase HX inlet F MEDTmp021 Crankcase HX Outlet or CP HX inlet F MEDTmp022 Manifold Inlet F MEDTmp023 Cold Plate Outlet F MEDTmp024 Crankcase External Motor End F MEDTmp025 Lower Guide Cylinder Stage 1 Motor End F MEDTmp026 Crossover Head Stage 1 Motor End F MEDTmp027 Crossover Head Stage 2 F SEDCO2 cmd Sabatier CO2 Command SLPM MEDFlw021 Sabatier CO2 Flow SLPM SEDMFM006 SEDCompressor Compressor command 1=on 0=off TSAF prod TSAC outlet CO2 flowrate Sccm TSAP1 Bed A Internal pressure Torr TSAP2 Bed B internal pressure Torr TSAExtWalA Bed A External Wall Temperature C TSAHA1 Bed A Heater 1 Temperature C TSAHA3 Bed A Heater 3 Temperature C TSATouchA Bed A Touch Temperature C TSAExtWalB Bed B External Wall Temperature C TSATouchB Bed B Touch Temperature C TSAHB1 Bed B Heater 1 Temperature C TSAHB3 Bed B Heater 3 Temperature C TSAPower Heater power for Bed A and Bed B Watts TSAF cdra TSAC Inlet CO2 flowrate Sccm TSAAirInA Bed A Cooling Air Inlet Temperature C TSAAirInB Bed b Cooling Air Outlet Temperature C TSAAirOutA Bed A Cooling Air Inlet Temperature C TSAAirOutB Bed A Cooling Air Outlet Temperature C TSAP cdra Inlet pressure Torr SEDP106 H2 Inlet pressure Psia SEDH2_SP_ent OGA H2 setpoint SEDP002 CDRA pressure psia SEDCRA READY Status 1=on 0=off SEDCurrent Current from OGA 0-4095 counts 0-100 Amps SEDDP405 Reactor Delta Pressure PSID SEDDP409 Separator Delta Pressure "H2O

PSID SEDEOGAREADY Ethernet write 1=on 0=off SEDH2 cmd SLPM SEDHtr A 1=on 0=off (Y20) SEDHtr B 1=on 0=off (Y21) SEDMas020 Sabatier EDU Water Grams SEDMFC H2 Mass Flow SLPM SEDMolar User selected molar ratio SEDOGA READY Status 1=on 0=off SEDP000 Compressor suction Pressure PSIA

CDRA Pressure MEDPrs021 Accumulator Pressure or CO2 inlet PSIA SEDP006 Reactor inlet pressure PSIA SEDP206 Nitrogen inlet pressure PSIA SEDP304 Product water pressure PSIA SEDP601 Reactor outlet pressure PSIA SEDProcess Process Mode (C102) SEDPUMP301 Water pump 1=on 0=off SEDSEP_run SEDPurge Purge Mode SEDstby_purge SEDReactCool 501 Cooling Air Valve 1=closed 0=open SEDSVO501 SEDShutdown Shutdown Mode SEDStandby Standby Mode

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Tag Name Units SEDStop Stop Mode SEDASD SEDT CHXout A Heat Exchanger Outlet Temperature degF SEDT407-1 SEDT CHXout B Heat Exchanger Outlet Temperature degF SEDT407-2 SEDT React A Reactor Hot Zone degF SEDT403_1 Reacto Temperature 1 SEDT React B Reactor Hot Zone degF SEDT403_2 Reacto Temperature 2 SEDT React C Reactor Inlet degF SEDT403_3 Reacto Temperature 3 SEDT React D Reactor Inlet degF SEDT403_4 Reacto Temperature 4 SEDT React Out Reactor Outlet degF SEDT404_1 CDPSV_160 Vacuum Solenoid CDPSV_640 (0 Closed 1 Open) TSAC CDPSV_641 (0 Closed 1 Open) Space Vacuum CDPSV_642 (0 Closed 1 Open) MPC CDPmz16 Valve Pos. 209 (T = Ener. = B Pos.) Volt CDPTmp640 Re-positional Instr. Cluster Temp F CDPSpr003 Sabatier Inlet Hydrogen Flowrate SLPM SEDFCV003_cmd CO2 flow command SLPM SEDsep_spd Separator speed Rpm SEDfan Cooling fan status SEDMFC103_cmd H2 flow command SEDH402_1 Heater status SEDsep_curr Separator current Amps SEDMas020 Sabatier EDU Water Grams SEDMFC103 Actual hydrogen flow SLPM SEDmolar_ratio User selected molar ration

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Calculated Data for Mechanical Compressor Test Name Units Calculation

(current time – initial time) *24 Time Hours (inlet air CO2 concentration/100 * inlet air pressure) *760/14.7 mmHg FMG62 4BMS Inlet Air

CO2 Pressure (inlet CO2 pressure/air pressure) * (flow*60) * 14.7*144 *44 / (R * (T+460)) CO2 in lb/hr (outlet air CO2 concentration/100 * inlet air pressure) *760/14.7 FFG69 4BMS Outlet Air

CO2 Pressure mmHg

(outlet CO2 pressure/air pressure) * (flow*60) * 14.7*144 *44 / (R * (T+460)) CO2 out lb/hr CO2 rate in – CO2 rate out 4BMS CO2 Removal

Rate lb/hr

(lab air CO2 concentration/100 * inlet air pressure) *760/14.7 FMG10 Lab Air CO2 Pressure

mmHg

1-CO2 out/CO2 in 4BMS CO2 Removal Fraction

Sum of 4 heaters, bed 308, 309 primary and secondary Total Heater Power Watts Total Watts Sum of 4 heaters plus air save pump power

Dew point converted to saturation pressure FMD13 Desiccant bed outlet

mmHg

Air flow rate * sat pressure * 18 * 14.7 * 144 / (760 * R * (T +460)) H2O lost lb/min Pump voltage * current (> 0) Air-Save Pump Power, Watts CO2 injection (slpm) * 0.035315 CO2 Injection scfm (CO2 injection flow * (1- outlet CO2 %))/((inlet – outlet CO2%)/100) Flow Rate from CO2

injection Scfm

Pump inlet air pressure / 2 CDPmp12 Pump Inlet Air Pressure corrected

torr

Bed 308 pressure psi * 760 / 14.7 CDPPrs123 Sorbent bed 308 pressure

torr

Pump inlet pressure psi *760 / 14.7 CDPmp12 Pump Inlet Air Pressure

torr

Dewpoint degrees F converted to C CDPDP_023 Dessicant Bed Outlet Air Dewpt

C

Dewpoint degrees F converted to C CDPDP_120 4BMS Inlet Air Dewpoint

C

Dewpoint degrees F converted to C CDPTmp120 4BMS Inlet Air Temperature

C

CRA ready status + 10 CRA Ready (11=on 10=off)

SEDH2_SP_ent / 10 OGA Current/10 TSAPower / 10 TSAC Power/10 OGA ready status + 8 OGA Ready (9=on 8=off) Compressor status + 12 Compressor Status

(13=on 12=off)

Corrected H2 flow / Sabatier CO2 flow Calc MR from Actual Flow

Recorded data * slope + offset H2 Rate adjusted, (@0°C)

SLPM

H2 flow/ 22.4 / 2 * 18 * timestep + previous summed value Calc H2O Prod @ 100% Eff

gram

Calculated 100% efficient water * 0.9 Calc H2O Prod @ 90% Eff

gram

Calculated 100% efficient water * 0.8 Calc H2O Prod @ 80% Eff

gram

Actual water produced / calculated 100% efficient water * 100 H2O Prod Efficiency (valid with W/D calc)

%

Current mass water (scale) – initial mass water H2O Production grams H2 flow * timestep + previous summed value H2 Useage Rate Liters Day night status + 6 Day/Night Status (7=day,

6=night)

H2 flow / selected molar ratio Desired CO2 Flow (SLPM) =1 when OGA ready is true and Sabatier is standby Starvation (Standby

when OGA Ready)

=1 if 4BMS mode is 3 and pump inlet pressure > 11.5 4BMS CO2 Dump in A2 (mp12>7.95 and segment=A2)

89

Name Units Calculation 4BMS CO2 Dump in A2 (mp12>7.95 and segment=B2)

=1 if 4BMS mode = 6 and pump inlet pressure > 11.5

CEDU Cycle Counter (flag step changes)

Checks for change in CEDU status from one time step to next

Water Dump Event Checks for water mass change > 17 grams from one time step to next

Subsystem Efficiency Calculations 4BMS 4BMS CO2 Removal Rate (lb/hr) = CO2 Inlet (lb/hr) – CO2 Outlet (lb/hr) 4BMS CO2 Removal Efficiency = 1- CO2 Inlet (lb/hr)/CO2 Outlet (lb/hr) Sabatier H2 Usage = Average H2 Flow * Total time of test Theoretical Water Production Rate = H2 Usage / 22.4 / 2 * 18 Actual Water Production Rate = Scale reading at end of test – scale reading at beginning of test Sabatier Water Recovery Efficiency = Actual Water Production / Theoretical Water Production *100

90

5.2

App

endi

x D

ata

Plot

s

5.2

.....

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

..... 5

-1

App

endi

x D

ata

Plot

s5.

2.1

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

.... 5

-6

Intro

duct

ion

5.2.

2 ...

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

16

4BM

S B

asel

ine

Cas

e5.

2.3

.....

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

... 2

8 A

dditi

onal

4B

MS

Bas

elin

e C

ase

5.2.

4 ...

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

. 31

Mec

hani

cal C

ompr

esso

r Sta

nd A

lone

Cas

e5.

2.5

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

... 4

0 4B

MS/

CED

U B

asel

ine

Cas

e5.

2.6

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

.....

48

Saba

tier S

tand

alon

e B

asel

ine

Cas

e5.

2.7

.....

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

. 67

4BM

S/C

EDU

/Sab

atie

r Ful

ly In

tegr

ated

Cas

e5.

2.8

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

. 81

4BM

S/TS

AC

/Sab

atie

r Ful

ly In

tegr

ated

Cas

e Fi

gure

1 -

Det

aile

d Sc

hem

atic

of 4

BM

S w

ith se

nsor

loca

tions

iden

tifie

d. ...

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

. 5-7

Fi

gure

2 -

Det

aile

d Sc

hem

atic

of S

abat

ier E

DU

use

d in

Mec

hani

cal C

ompr

esso

r Tes

t with

sens

or lo

catio

ns id

entif

ied.

.....

......

......

.... 5

-8

Figu

re 3

- Sc

hem

atic

of I

nteg

rate

d Te

st w

ith M

echa

nica

l Com

pres

sor w

ith se

nsor

loca

tions

iden

tifie

d. ..

......

......

......

......

......

......

......

.. 5-9

Fi

gure

4 -

Sche

mat

ic o

f Sab

atie

r ED

U u

sed

with

TSA

C te

stin

g w

ith se

nsor

loca

tions

iden

tifie

d. ...

......

......

......

......

......

......

......

......

.... 5

-10

Figu

re 5

- Sc

hem

atic

of I

nteg

rate

d Te

st w

ith T

SAC

with

sens

or lo

catio

ns in

dent

ified

. ....

......

......

......

......

......

......

......

......

......

......

......

. 5-1

1 Ta

ble

1 –

Sens

ors i

n th

e 4B

MS .

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

.... 1

2 Ta

ble

2 - S

enso

rs in

the

Saba

tier E

DU

.....

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

13

Tabl

e 3

- Sen

sors

in th

e M

echa

nica

l Com

pres

sor ..

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

.... 1

4 Ta

ble

4 - S

enso

rs in

the

Tem

pera

ture

Sw

ing

Ads

orpt

ion

Com

pres

sor ..

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

......

... 1

4

5.2.

1 In

trod

uctio

n Th

is d

ocum

ent d

escr

ibes

the

test

dat

a co

llect

ed fr

om th

e in

tegr

ated

test

pro

gram

. Dat

a w

as c

olle

cted

from

all

of th

e op

erat

ing

syst

ems.

Diff

eren

t dat

a se

ts a

re p

lotte

d fo

r diff

eren

t com

bina

tions

of s

yste

ms.

The

follo

win

g gr

aphs

are

repr

esen

tativ

e da

ta se

ts fr

om th

e di

ffer

ent c

ases

that

wer

e ru

n.

91

P T DPCO2

Cabi

nAt

mos

pher

e

CO 2

VENT

P

T

T

RESI

DUAL

AIR

RET

URN

LINE

CHEC

KVA

LVE

DESI

CCAN

T

OUTL

ET

VAL

VE

DESI

CCAN

T BE

D

INLE

T AI

RSE

LECT

ORVA

LVE

GE

L S

ILIC

A

s T s T

s T s T

P

BLOW

ERP

T

ACCU

MUL

ATO

R CO

2

P 2

CO

PU

MP

CO SELE

CTOR

VALV

E

2

CO S

ORBE

NT B

ED

2 EL

ECTR

ICAL

HEAT

ER

HX

PRE-

COOL

ER

WAT

ER

T T

T S

CO S

ORBE

NT B

ED

2

T

P T

TO V

ACU

UM

S

P

T S AI

R IN

LET

POIS

T FO

UR B

ED M

OLEC

ULAR

SIE

VE

P =

PRES

SURE

SEN

SOR

DP=

DEW

POI

NT S

ENSO

RT

= TE

MPE

RATU

RE S

ENSO

RS

= SA

MPL

E PO

RT

= SE

LECT

OR V

ALVE

= CA

RBON

DIO

XIDE

SEN

SOR

308

309

DPDP

CO2

CO2 CO

2

AIR

RETU

RN

DESI

CCAN

T BE

D

CDP-

Gas

124

CD

PGas

125

AFc

Gas

126

CDPD

P_12

0 CDPD

P_12

1,12

2

AFc

DP_1

20

CDP-

Tmp1

20

T CD

PTm

p121

AFc

Tmp1

20

CDPT

mp0

86

P

CDP-

Prs1

20

AFcP

rs12

0

CDPD

P_02

3

CDP-

mt1

1

CD

PPrs1

23

CDPT

mp1

25

CDP-

mt1

2

MSA

Flw

022

Lab

CO

2 In

ject

ion

Flow

rate

CDPP

rs022

Vac

m T

nk In

let P

ress

CDPP

rs02

3 V

acm

Tnk

Pre

ss

MSA

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020

CO

2 Ta

nk W

eight

CO2

Inje

ctio

n

MSA

Flw

023

La

b C

O2

Inje

ctio

n Fl

owra

te

Cycl

e Inf

o

CDPm

dns

Day

/Nig

ht S

tatu

sCD

Pfcd

ck

Cycl

e Ela

psd

Tim

e

Proc

ess A

ir Fl

owra

te

CD

PFlw

120

Inle

t Air

Flow

rate

(Sie

rra)

CDPF

lw12

1 In

let A

ir Fl

owra

te (T

SI)

Pre

Cool

er W

ater

Flo

wrate

CDPF

lw08

0

Pre

Cool

er W

ater

Flo

wrat

e

Com

pone

nt P

ower

CDPm

w10

Vac

uum

Pum

p Po

wer

CDPm

w12

30

8 Be

d Pr

imar

y H

eate

r Pow

erCD

Pmw

13

309

Bed

Prim

ary

Hea

ter P

ower

CDPm

w14

308

Bed

Sec

onda

ry H

eate

r Pow

erCD

Pmw

15 3

09 B

ed S

econ

dary

Hea

ter P

ower

P

T

CDP-

Tmp0

87

CDPT

mp1

27

CDP-

Tmp1

28

CDPT

mp1

30CD

PTm

p129

CDPm

t-13,

14,1

5

CDPm

t 16,

17, 1

8

CDPm

p10

CDP-

mp1

1

516

514

515

513

512

CDP-

mp1

2CD

P-m

t92

511

CDP-

mp1

3CDPm

p14

CDPm

t91

F=

FLOW

MET

ER

FF

CD

PTm

p133

CDPF

lw12

0

517

CDPm

z11

CDP-

mz1

0

CDPm

z12

CDP-

mz1

3

CDP-

mz1

4

CDPm

z16

CDP-

mz1

5

F CD

PFlw

080

CDPF

lw12

1

DP P CDPm

t10

CDPP

rs122

CDPP

rs121

CDPT

mp1

26

Figu

re 1

- D

etai

led

Sche

mat

ic o

f 4B

MS

with

sens

or lo

catio

ns id

entif

ied.

92

SAB

ATIE

RR

EAC

TOR

CO

ND

ENSI

NG

HEA

TEX

CH

ANG

ER

T

P

CG

CG

CO

NTR

OLL

ERA

ND

EIB

N2

IN

CO

2 IN

H2

IN

CH

4 VE

NT

H2O

OU

T

LF CV

MFC

PP

P

T

T

Δ P

MV2

02

SVO

203

CV

204

F201

F001

P00

2FC

V003

CV

004

MFM

MFM

005

P006

F101

SVC

102

MFC

103

CV1

04

R40

1

H40

2

T403

DP

405

T404 SVO

501

FAN

502

T407 ST

408

DP4

09

PUM

P30

1

SVC

303

P304

P601

RV

602

SVO

604

RV6

03SV

O60

5

BPR

606

FR60

7

SVO

608

CG

411

CG

412

P206

FR20

5

HX4

06

TTT

RV4

10

SVC

007

P

T

Δ P

MV

609

Saba

tier E

ngin

eerin

g D

evel

opm

ent U

nit

SVL1

8383

MV

105

6/25

/04

CV

305

F406

SAB

ATIE

RR

EAC

TOR

CO

ND

ENSI

NG

HEA

TEX

CH

ANG

ER

T

P

CG

CG

CO

NTR

OLL

ERA

ND

EIB

N2

IN

CO

2 IN

H2

IN

CH

4 VE

NT

H2O

OU

T

LF CV

MFC

PP

P

T

T

Δ P

MV2

02

SVO

203

CV

204

F201

F001

P00

2FC

V003

CV

004

MFM

MFM

005

MFM

MFM

005

MFM

MFM

005

P006

F101

SVC

102

MFC

103

CV1

04

R40

1

H40

2

T403

DP

405

T404 SVO

501

FAN

502

T407 ST

408

DP4

09

PUM

P30

1

SVC

303

P304

P601

RV

602

SVO

604

RV6

03SV

O60

5

BPR

606

FR60

7

SVO

608

CG

411

CG

412

P206

FR20

5

HX4

06

TTT

RV4

10

SVC

007

SVC

007

P

T

Δ P

MV

609

Saba

tier E

ngin

eerin

g D

evel

opm

ent U

nit

SVL1

8383

MV

105

6/25

/04

CV

305

F406

Fi

gure

2 -

Det

aile

d Sc

hem

atic

of S

abat

ier

ED

U u

sed

in M

echa

nica

l Com

pres

sor

Tes

t with

sens

or lo

catio

ns id

entif

ied.

93

CD

RA

To V

acuu

mV20

9A

ir Sa

veV

200

LMS

Spac

e V

acuu

mSi

mul

ator

PT

TP1

V2

V3

Acc

um

Faci

lity

Ven

tD

ew

Poin

t

HV

1

HV

2

BPR

V1

FM1

TP2 H

V3

CO

2B

ottle

Sab

ED

U

HV

4

BPR

V2

SVC

007

PTP0

02

N2

H2O

pro

duct

to w

eigh

t sc

ale

Vac

uum

ven

t

RV

@15

0 ps

ia HV

5

PG

Ven

turi

Vac

Ven

t

H2

Bottl

e/re

gula

tor

H2

Bottl

e/re

gula

tor

CO

2

Coo

lant

in/o

ut

FM2

Coo

lant

in/o

ut

FM2

HV

6

P000

CD

RA

To V

acuu

mV20

9A

ir Sa

veV

200

LMS

Spac

e V

acuu

mSi

mul

ator

PTPT

TP1

TP1

V2

V3

Acc

umA

ccum

Faci

lity

Ven

tD

ew

Poin

t

HV

1

HV

2

BPR

V1

FM1

TP2

TP2 H

V3

CO

2B

ottle

Sab

ED

U

HV

4

BPR

V2

SVC

007

PTPTP0

02

N2

H2O

pro

duct

to w

eigh

t sc

ale

Vac

uum

ven

t

RV

@15

0 ps

ia HV

5

PGPG

Ven

turi

Vac

Ven

t

H2

Bottl

e/re

gula

tor

H2

Bottl

e/re

gula

tor

CO

2

Coo

lant

in/o

ut

FM2

Coo

lant

in/o

ut

FM2

HV

6

P000

Fi

gure

3 -

Sche

mat

ic o

f Int

egra

ted

Tes

t with

Mec

hani

cal C

ompr

esso

r w

ith se

nsor

loca

tions

iden

tifie

d.

94

SAB

ATIE

RR

EAC

TOR

CO

ND

ENSI

NG

HEA

TEX

CH

ANG

ER

T

P

CG

CG

CO

NTR

OLL

ERA

ND

EIB

N2

IN

CO

2 IN

H2

IN

CH

4 VE

NT

H2O

OUT

MFC

PP

P

MFM

T

ΔP

MV2

02

SVO

203

CV2

04F2

01

F001

P002

FCV

003

CV0

04

MFM

005

P006

-1

F101

SVC

102

MFC

103 CV1

04

R40

1

H40

2

T403

-1,-8

DP4

05

T404

-1,-2

SVO

501

FAN

502

T407

-1,-2

DP4

09-1

,-2

CV3

05

P304

P601SV

O60

4

BPR

606

SVO

608

CG

411

CG

412

P206

FR20

5H

X406

TSV

C00

7P

ΔP

MV1

05

ΔP

DR

UM

SEPA

RAT

OR

AN

DPU

MP

L

SVC

303

TT

CO

LD P

LATE

CO

OLA

NTIN

/OU

T

T

PP106

P006

-2

Man

ual F

ill P

ort

RV2

07

RV0

09

RV1

07

P L602

CP3

01

T413

-1,-2

SEP

411

FR60

7

TT

TT

TT

TT

NN

414

TTT4

10-1

,-2

Gas

Sam

ple

Por

t

BED

412

Gas

Sam

ple

Por

t

SAB

ATIE

RR

EAC

TOR

CO

ND

ENSI

NG

HEA

TEX

CH

ANG

ER

T

P

CG

CG

CO

NTR

OLL

ERA

ND

EIB

N2

IN

CO

2 IN

H2

IN

CH

4 VE

NT

H2O

OUT

MFC

PP

P

MFM

T

ΔP

MV2

02

SVO

203

CV2

04F2

01

F001

P002

FCV

003

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04

MFM

005

P006

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F101

SVC

102

MFC

103 CV1

04

R40

1

H40

2

T403

-1,-8

DP4

05

T404

-1,-2

SVO

501

FAN

502

T407

-1,-2

DP4

09-1

,-2

CV3

05

P304

P601SV

O60

4

BPR

606

SVO

608

CG

411

CG

412

P206

FR20

5H

X406

TSV

C00

7P

ΔP

MV1

05

ΔP

DR

UM

SEPA

RAT

OR

AN

DPU

MP

L

SVC

303

TT

CO

LD P

LATE

CO

OLA

NTIN

/OU

T

T

PP106

P006

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Man

ual F

ill P

ort

RV2

07

RV0

09

RV1

07

P L602

CP3

01

T413

-1,-2

SEP

411

FR60

7

TT

TT

TT

TT

NN

414

TTT4

10-1

,-2

Gas

Sam

ple

Por

t

BED

412

Gas

Sam

ple

Por

t

Fi

gure

4 -

Sche

mat

ic o

f Sab

atie

r E

DU

use

d w

ith T

SAC

test

ing

with

sens

or lo

catio

ns id

entif

ied.

95

CD

RA

To V

acuu

mV20

9A

ir Sa

veV

200

LMS

Spac

e V

acuu

mSi

mul

ator

V2

Faci

lity

Ven

tSab

ED

U

N2

H2O

pro

duct

to w

eigh

t sc

ale

Vac

uum

ven

t PG

Ven

turi

Vac

Ven

t

H2

Bottl

e/re

gula

tor

H2

Bottl

e/re

gula

tor

CO

2 in

let

TSA

C

CD

RA

To V

acuu

mV20

9A

ir Sa

veV

200

LMS

Spac

e V

acuu

mSi

mul

ator

V2

Faci

lity

Ven

tSab

ED

U

N2

H2O

pro

duct

to w

eigh

t sc

ale

Vac

uum

ven

t PGPG

Ven

turi

Vac

Ven

t

H2

Bottl

e/re

gula

tor

H2

Bottl

e/re

gula

tor

CO

2 in

let

TSA

C

Fi

gure

5 -

Sche

mat

ic o

f Int

egra

ted

Tes

t with

TSA

C w

ith se

nsor

loca

tions

inde

ntifi

ed.

96

Tab

le 1

– S

enso

rs in

the

4BM

S Se

nsor

D

esig

natio

n Se

nsor

Des

crip

tion

Sens

or

Des

igna

tion

Sens

or D

escr

iptio

n C

DPT

mp1

26

Port

514

Inte

rnal

Des

icca

nt B

ed 1

Te

mp.

C

DPD

P_02

3 D

essi

cant

Bed

Out

let A

ir D

ewpt

C

DPT

mp1

27

Port

515

Inte

rnal

Des

icca

nt B

ed 1

Te

mp.

C

DPD

P_12

0 4B

MS

Inle

t Air

Dew

poin

t C

DPF

lw08

0 4B

MS

Prec

oole

r Inl

et H

2O F

low

C

DPT

mp1

28

Port

516

(mt9

8) D

esic

cant

Bed

1

CD

PFlw

120

4BM

S In

let A

ir Fl

owra

te (S

ierr

a)

CD

PTm

p129

Po

rt 50

3 So

rben

t Bed

Inte

rnal

Tem

p.

CD

PFlw

121

4BM

S In

let A

ir Fl

owra

te (T

SI)

CD

PTm

p130

Po

rt 50

4 So

rben

t Bed

Inte

rnal

Tem

p.

CD

Pmw

12

5A B

ed 3

08 P

rim. H

eate

r Pow

er

CD

PTm

p133

Pr

ecoo

ler I

nlet

Air

Tem

p C

DPm

w13

5A

Bed

309

Prim

. Hea

ter P

ower

M

SAFT

_022

To

tal C

O2

Add

ed L

C

DPm

w14

5A

Bed

308

Sec

. Hea

ter P

ower

M

SAFT

_023

To

taliz

e C

DPF

lw02

3 C

DPm

w15

5A

Bed

309

Sec

. Hea

ter P

ower

A

FcD

P_12

0 La

b A

ir D

ewpo

int (

1)

CD

PPrs

021

Fac

Vac

uum

Tan

k C

O2

Inle

t Pre

ssur

e C

DPP

rs02

0 fe

edba

ck d

elta

pre

ssur

e C

DPP

rs02

2 Fa

c V

acuu

m T

ank

CO

2 Pr

essu

re

CD

PTm

p020

Sp

ace

Sim

ulat

or T

ank

In

CD

PPrs

120

4BM

S In

let A

ir Pr

essu

re

THC

Tmp0

84

THC

HX

Chi

ll In

C

DPP

rs12

1 Pr

ecoo

ler O

utle

t to

Am

bien

t TH

CTm

p085

TH

C H

X C

hill

Out

C

DPP

rs12

2 4B

MS

Out

let A

ir Pr

essu

re

THC

Tmp1

20

THC

CH

X In

let A

ir Te

mp.

C

DPT

mp0

86

4BM

S Pr

ecoo

ler I

nlet

H2O

Tem

p TH

CTm

p121

TH

C C

HX

Out

let A

ir Te

mp.

C

DPT

mp1

20

4BM

S In

let A

ir Te

mp.

A

FcPr

s120

M

odul

e Pr

essu

re (1

) M

SAFl

w02

2 La

b Lo

w C

O2

Inje

ct F

low

rate

A

FcTm

p120

La

b A

ir Te

mp.

Mid

dle

(1)

MSA

Flw

023

Lab

Hig

h C

O2

Inje

ct F

low

rate

A

FcTm

p121

C

AB

IN F

RO

NT

TEM

P (1

) M

SAM

as02

0 Fa

cilit

y C

O2

Tank

Wei

ght

AFc

Tmp1

22

CA

BIN

BA

CK

TEM

P (1

) TH

CFl

w12

0 TH

C C

HX

Out

let A

ir Fl

owra

te

HB

_Prs

220

Hig

h B

ay P

ress

ure

(1)

CD

PTm

p121

4B

MS

Out

let A

ir Te

mp.

H

B_T

mp2

20

Hig

h B

ay T

emp.

(1)

AFc

Tmp1

20

Lab

Air

Tem

p. M

iddl

e (1

)

CD

PCur

120

CO

2 Pu

mp

Cur

rent

C

DPV

lt120

C

O2

Pum

p V

olta

ge

CD

Pmp1

0 D

iff. F

an 3

03

CD

PPrs

123

Sorb

ent b

ed 3

08 p

ress

ure

CD

PTm

p087

C

DR

A C

hill

H2O

Out

C

DPT

mp1

21

4BM

S O

utle

t Air

Tem

p.

CD

PTm

p125

D

esic

cant

bed

104

Out

let A

ir Te

mp

97

Sens

or D

esig

natio

n Se

nsor

Des

crip

tion

Tab

le 2

- Se

nsor

s in

the

Saba

tier

ED

U

Sens

or D

esig

natio

n Se

nsor

Des

crip

tion

SED

PUM

P301

W

ater

pum

p 1=

on 0

=off

(Y22

) SE

DPu

rge

Purg

e M

ode

(C10

4)

SED

CO

2_cm

d_00

3 C

O2

Com

man

d 0-

4095

cou

nts

Coo

ling

Air

Val

ve 1

=clo

sed

0=op

en (Y

31)

SED

CO

2_Fl

ow_0

05

CO

2 M

ass F

low

(V14

14)

SED

Rea

ctC

ool_

501

Com

pres

sor c

omm

and

1=on

0=

off (

Y24

) SE

DC

ompr

esso

r SE

DSh

utdo

wn

Shut

dow

n M

ode

(C10

0)

SED

Stan

dby

Stan

dby

Mod

e (C

101)

SE

DC

RA

REA

DY

C

RA

Sta

tus 1

=on

0=of

f (Y

23)

SED

Stop

St

op M

ode

(C10

3)

SED

CR

AR

EAD

Y

CR

A S

tatu

s 1=o

n 0=

off (

C13

1)3

Hea

t Exc

hang

er O

utle

t Te

mpe

ratu

re (V

1435

) SE

DC

urre

nt f

OG

A

0-40

95 c

ount

s 0-1

00 A

mps

(V

1551

) SE

DT

CH

Xou

t_A

H

eat E

xcha

nger

Out

let

Tem

pera

ture

(V14

36)

SED

DP4

05

Rea

ctor

Del

ta P

ress

ure

(V14

00)

SED

T C

HX

out_

B

SED

DP4

09

Sepa

rato

r Del

ta P

ress

ure

(V14

01)

SED

T R

eact

_A

Rea

ctor

Hot

Zon

e (V

1430

) SE

DEO

GA

REA

DY

Et

hern

et w

rite

1=on

0=o

ff (C

135)

SE

DT

Rea

ct_B

R

eact

or H

ot Z

one

(V14

31)

H2

Com

man

d 0-

4095

cou

nts

(V14

20)

SED

H2_

cmd_

103

SED

T R

eact

_C

Rea

ctor

Inle

t (V

1432

) SE

DT

Rea

ct_D

R

eact

or In

let (

V14

33)

SED

Htr_

A

Hea

ter A

1=o

n 0=

off (

Y20

) SE

DT

Rea

ct_O

ut

Rea

ctor

Out

let (

V14

34)

SED

Htr_

B

Hea

ter B

1=o

n 0=

off (

Y21

)

Prod

uct w

ater

wei

ght s

cale

SE

DM

as02

0 Sa

batie

r ED

U W

ater

SED

MFC

_103

_dat

a H

2 M

ass F

low

(V14

15)

SED

Mol

ar ra

tio__

U

ser s

elec

ted

mol

ar ra

tio (V

1660

) SE

DO

GA

REA

DY

O

GA

Sta

tus 1

=on

0=of

f (X

104)

SE

DO

GA

REA

DY

O

GA

Sta

tus 1

=on

0=of

f (C

130)

C

ompr

esso

r suc

tion

Pres

sure

(V

1554

) SE

DP0

00

Acc

umul

ator

Pre

ssur

e or

CO

2 in

let (

V14

02)

SED

P002

SE

DP0

06

Rea

ctor

inle

t pre

ssur

e (V

1403

) SE

DP2

06

Nitr

ogen

inle

t pre

ssur

e (V

1404

) SE

DP3

04

Prod

uct w

ater

pre

ssur

e (V

1405

) SE

DP6

01

Rea

ctor

out

let p

ress

ure

(V14

06)

SED

Proc

ess

Proc

ess M

ode

(C10

2)

98

Tab

le 3

- Se

nsor

s in

the

Mec

hani

cal C

ompr

esso

r

Sens

or D

esig

natio

n Se

nsor

Des

crip

tion

MED

DP_

020

Mec

hani

cal C

ompr

esso

r O

utle

t Dew

poin

t, F

MED

Flw

020

Com

pres

sor O

utle

t Flo

w

afte

r DP,

lb/h

r M

EDPr

s020

C

ompr

esso

r Inl

et P

ress

ure,

PS

IG

MED

Tmp0

20

Man

ifold

Out

let o

r C

rank

case

HX

inle

t, F

MED

Tmp0

21

Cra

nkca

se H

X O

utle

t or C

P H

X in

let,

F M

EDTm

p022

M

anifo

ld In

let,

F M

EDTm

p023

C

old

Plat

e O

utle

t, F

MED

Tmp0

24

Cra

nkca

se E

xter

nal M

otor

En

d, F

M

EDTm

p025

Lo

wer

Gui

de C

ylin

der

Stag

e 1

Mot

or E

nd, F

M

EDTm

p026

C

ross

over

Hea

d St

age

1 M

otor

End

, F

MED

Tmp0

27

Cro

ssov

er H

ead

Stag

e 2,

F

Tab

le 4

- Se

nsor

s in

the

Tem

pera

ture

Sw

ing

Ads

orpt

ion

Com

pres

sor

TSA

F pr

od

TSA

C o

utle

t CO

2 flo

wra

te

TSA

P1

Bed

A In

tern

al p

ress

ure

TSA

P2

Bed

B in

tern

al p

ress

ure

TSA

ExtW

alA

B

ed A

Ext

erna

l Wal

l Te

mpe

ratu

re

TSA

HA

1 B

ed A

Hea

ter 1

Te

mpe

ratu

re

TSA

HA

3 B

ed A

Hea

ter 3

Te

mpe

ratu

re

TSA

Touc

hA

Bed

A T

ouch

Tem

pera

ture

TS

AEx

tWal

B

Bed

B E

xter

nal W

all

Tem

pera

ture

TS

ATo

uchB

B

ed B

Tou

ch T

empe

ratu

re

TSA

HB

1 B

ed B

Hea

ter 1

Te

mpe

ratu

re

TSA

HB

3 B

ed B

Hea

ter 3

Te

mpe

ratu

re

TSA

Pow

er

Hea

ter p

ower

for B

ed A

an

d B

ed B

TS

AF

cdra

TS

AC

Inle

t CO

2 flo

wra

te

TSA

AirI

nA

Bed

A C

oolin

g A

ir In

let

Tem

pera

ture

TS

AA

irInB

B

ed b

Coo

ling

Air

Out

let

Tem

pera

ture

TS

AA

irOut

A

Bed

A C

oolin

g A

ir In

let

Tem

pera

ture

TS

AA

irOut

B

Bed

A C

oolin

g A

ir O

utle

t Te

mpe

ratu

re

TSA

P cd

ra

Inle

t pre

ssur

e

99

4BM

S B

asel

ine

Cas

e Te

st D

ay 5

8

6

/27/

05

Page

11

Add

ition

al 4

BM

S C

ase

Te

st D

ay 1

7

2/6

/05

Page

23

Mec

hani

cal C

ompr

esso

r Sta

nd A

lone

Cas

e Te

st D

ay 4

11

/2/0

4 Pa

ge 2

7 4B

MS/

CED

U B

asel

ine

Cas

e Te

st D

ay 9

12

/1/0

4 Pa

ge 3

6 Sa

batie

r Sta

ndal

one

Cas

e Te

st D

ay 1

6 2/

4/05

Pa

ge 4

4 4B

MS/

TSA

C B

asel

ine

Cas

e

11/2

0/05

Pa

ge 5

7 4B

MS/

CED

U/S

abat

ier F

ully

Inte

grat

ed C

ase

Test

Day

16

2/4/

05

Page

63

4BM

S/TS

AC

/Sab

atie

r Ful

ly In

tegr

ated

Cas

e

1/27

/06

Page

77

100

5.2.

2 4B

MS

Bas

elin

e C

ase

PO

IST

4BM

S/C

ompr

esso

r ED

U T

estin

g - 4

BM

S B

/L w

ith T

P1 C

ondi

tions

- El

apse

d Ti

me

from

6/2

7 --

Tes

t D

ay 5

8 20

05

Plot

1 --

Sta

tus

for 4

BMS,

CRA

, OG

A an

d Co

mpr

esso

r (of

fset

for c

larit

y)

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

status

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A R

eady

(9=o

n 8=

off)

Com

pres

sor S

tatu

s (1

3=on

12=

off)

Th

is p

lot g

ives

the

stat

us o

f eac

h of

the

oper

atin

g sy

stem

s aga

inst

a ti

mel

ine.

For

this

cas

e, o

nly

the

4BM

S is

ope

ratin

g. T

he in

tege

r va

lues

cor

resp

ond

to th

e di

ffer

ent p

roce

ssin

g cy

cles

of t

he 4

BM

S. 0

=Off

, 1=S

H??

, 2=B

ed A

Air

Save

, 3=B

ed A

Des

orb,

4=B

ed A

V

acuu

m V

ent,

5=B

ed B

Air

Save

, 6=B

ed B

Des

orb,

7=B

ed B

Vac

uum

Ven

t. Th

e co

mpr

esso

r and

Sab

atie

r are

bot

h of

f.

101

Plot

2 --

Car

bon

Diox

ide

Parti

al P

ress

ures

at 4

BMS

Inle

t, 4B

MS

Out

let,

and

in L

ab

Mod

ule

Sim

ulat

or

0246810121416

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

mmHg

FMG

62 4

BMS

Inle

t Air

CO2

Pres

sure

mm

HgFF

G69

4BM

S O

utle

t Air

CO2

Pres

sure

mm

Hg

FMG

10 L

ab A

ir CO

2 Pr

essu

re m

mHg

This

plo

t sho

ws t

he C

O2

conc

entra

tion

in a

nd o

ut o

f the

4B

MS.

The

out

let c

once

ntra

tion

spik

es e

very

tim

e th

e be

ds sw

itch

beca

use

ther

e is

resi

dual

CO

2 in

the

lines

from

the

deso

rbin

g be

d th

at g

oes t

o th

e 4B

MS

outle

t onc

e th

at d

esor

bing

bed

com

es o

n-lin

e an

d ai

r st

arts

flow

ing

thro

ugh

it ag

ain.

102

Plot

3 --

Air

Dew

poin

t at 4

BMS

Inle

t, 4B

MS

Out

let,

and

in L

ab M

odul

e Si

mul

ator

-40

-30

-20

-100102030405060

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Temperature, degrees F

CDPD

P_12

0 4

BMS

Inle

t Air

Dew

poin

t #1

F

CD

PDP_

121

4BM

S O

utle

t Air

Dew

poin

t #1

F

AFc

DP_1

20 L

ab A

ir De

wpo

int F

This

plo

t sho

ws t

he d

ew p

oint

of t

he a

ir en

terin

g th

e 4B

MS

and

the

bulk

air

in th

e La

b M

odul

e si

mul

ator

. The

out

let d

ew p

oint

sens

or

was

not

wor

king

dur

ing

the

test

.

103

Plot

4 --

Air

Tem

pera

ture

at 4

BMS

Inle

t, 4B

MS

Out

let,

in L

ab M

odul

e Si

mul

ator

, and

W

ater

Tem

pera

ture

at P

reco

oler

Inle

t

020406080100

120

140

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPT

mp1

21 4

BMS

Out

let A

ir Te

mpe

ratu

re F

AFc

Tmp1

20 L

ab A

ir Te

mp.

Mid

dle

F

CD

PTm

p086

4BM

S Pr

ecoo

l Inle

t H2O

Tem

p #1

F

Th

is p

lot s

how

s air

tem

pera

ture

s thr

ough

out t

he 4

BM

S. A

t the

star

t of a

bed

cha

nge

(at 2

5.5

hour

s abo

ve) t

he p

revi

ousl

y de

sorb

ed b

ed

that

is st

ill h

ot b

ecom

es th

e ad

sorb

ing

bed.

The

air

flow

ing

thro

ugh

the

bed

pick

s up

the

heat

from

the

bed,

topp

ing

out a

t abo

ut 1

30 F

. Th

is h

ot a

ir th

en fl

ows t

hrou

gh th

e sp

ent d

esic

cant

bed

and

rege

nera

tes i

t by

pick

ing

up th

e w

ater

and

retu

rnin

g it

to th

e ca

bin.

104

Plot

5 --

Sor

bent

Bed

Hea

ter T

empe

ratu

res

050100

150

200

250

300

350

400

450

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPm

t13

5A

Bed

308

Hea

ter T

emp

A F

CD

Pmt1

6 5

A B

ed 3

09 H

eate

r Tem

p A

F

This

plo

t sho

ws t

he te

mpe

ratu

res o

f the

mol

ecul

ar si

eve

beds

. The

des

orbi

ng b

ed h

eate

rs a

re fu

lly o

n un

til th

e te

mpe

ratu

re re

ache

s 400

F

and

then

an

ON

/OFF

con

trol i

s use

d to

mai

ntai

n th

e te

mpe

ratu

re a

t 400

unt

il th

e en

d of

the

cycl

e.

105

Plot

6 --

Des

icca

nt B

ed In

let a

nd O

utle

t Air

Tem

pera

ture

s

0102030405060708090100

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPm

t11

Des

icca

nt B

ed O

utle

t Tem

pera

ture

F

This

plo

t sho

ws t

he te

mpe

ratu

res o

f the

des

icca

nt b

ed. T

he a

ir le

avin

g th

e de

sicc

ant i

s war

med

by

the

heat

of a

dsor

ptio

n of

wat

er o

nto

the

desi

ccan

t mat

eria

l.

106

Plot

7 --

Des

icca

nt B

ed O

utle

t Air

Dew

poin

t Tem

pera

ture

-40

-30

-20

-10010203040

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPD

P_02

3 D

essi

cant

Bed

Out

let A

ir De

wpt

F

This

plo

t sho

ws h

ow th

e de

w p

oint

of t

he a

ir le

avin

g th

e de

sicc

ant a

nd e

nter

ing

the

mol

ecul

ar si

eve

bed

rem

ains

ver

y dr

y. W

ater

will

co

ntam

inat

e th

e m

olec

ular

siev

e an

d re

quire

hig

h te

mpe

ratu

re re

gene

ratio

n. T

he sp

ikes

in th

e de

w p

oint

sign

al a

re d

ue to

cal

ibra

tions

of

the

sens

or.

107

Plot

8 --

4BM

S Pr

oces

s Ai

r Flo

w R

ate

051015202530

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

SCFM

CDPF

lw12

0 4

BMS

Inle

t Air

Flow

rate

SCF

M (S

ierr

a)

CDPF

lw12

1 4

BMS

Inle

t Air

Flow

rate

SCF

M (T

SI)

Two

diff

eren

t air

flow

inst

rum

ents

wer

e us

ed to

mon

itor t

he p

roce

ss a

ir flo

w.

108

Plot

9 --

4BM

S Va

cuum

Sys

tem

Pre

ssur

es

02468101214161820

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA/Torr

CDPP

rs12

3 S

orbe

nt b

ed 3

08 p

ress

ure

PSIA

CDPm

p12

Pum

p In

let A

ir Pr

essu

re P

SIA

CDPP

rs02

1 F

ac V

acuu

m T

ank

Air

Inle

t Pre

ssur

e To

rr

CD

PPrs

022

Fac

Vac

uum

Tan

k A

ir Pr

essu

re T

orr

Th

is p

lot s

how

s the

pre

ssur

es th

roug

hout

the

4BM

S. T

he b

ed p

ress

ure

(red

squa

re w

ave

show

n in

PSI

A) c

ycle

s bet

wee

n am

bien

t pr

essu

re d

urin

g ad

sorp

tion

and

vacu

um d

urin

g de

sorp

tion.

The

vac

uum

syst

em p

ress

ures

spik

e up

initi

ally

whe

n th

e be

d be

gins

de

sorb

ing

and

then

retu

rns t

o va

cuum

leve

ls a

s the

CO

2 is

exh

aust

ed fr

om th

e be

d.

109

Plot

10

-- 4B

MS

Com

pone

nt P

ower

0

100

200

300

400

500

600

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Watts

CDPm

w12

5A

Bed

308

Prim

. Hea

ter P

ower

Wat

t

CDPm

w13

5A

Bed

309

Prim

. Hea

ter P

ower

Wat

t

CDPm

w14

5A

Bed

308

Sec

. Hea

ter P

ower

Wat

t

CDPm

w15

5A

Bed

309

Sec

. Hea

ter P

ower

Wat

t

Air-

Save

Pum

p Po

wer

, Wat

ts

Th

is p

lot s

how

s the

pow

er su

mm

ary

for t

he sy

stem

. The

prim

ary

and

seco

ndar

y he

ater

s are

on

full

until

the

bed

reac

hes 4

00 F

and

th

en c

ycle

to m

aint

ain

the

tem

pera

ture

. The

air

save

pum

p is

act

ivat

ed fo

r 10

min

utes

of e

ach

half

cycl

e.

110

Plot

11

-- 4B

MS

CO2

Inje

ctio

n an

d Co

olan

t Wat

er F

low

Rat

e

0

0.51

1.52

2.53

3.5

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

SLPM/GPM

050100

150

200

250

300

350

LBS

MSA

Flw

022

Lab

CO

2 In

ject

Flo

wra

te S

LPM

CDPF

lw08

0 4

BMS

Prec

oole

r Inl

et H

2O F

low

GPM

MSA

Flw

023

Lab

High

CO

2 In

ject

Flo

wra

te L

BS/H

R

MSA

Mas

020

Fac

ility

CO2

Tank

Wei

ght L

bs

Th

is p

lot s

how

s the

CO

2 in

ject

ion

rate

into

the

4BM

S. T

he C

O2

inje

ctio

n ra

te is

bas

ed o

n a

clos

ed lo

op a

lgor

ithm

to m

aint

ain

a co

nsta

nt C

O2

conc

entra

tion

at th

e in

let o

f the

4B

MS

as sh

own

in p

lot 2

and

plo

t 12.

The

CO

2 ta

nk w

eigh

t is a

mea

ns o

f per

form

ing

a m

ass b

alan

ce o

n C

O2

to v

erify

the

accu

racy

of t

he m

easu

rem

ents

.

111

Plot

12

-- Pe

rcen

t Car

bon

Diox

ide

at 4

BMS

Inle

t, 4B

MS

Out

let,

and

in L

ab M

odul

e Si

mul

ator

0

0.51

1.52

2.5

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

%

CDPG

as12

4 4

BMS

Inle

t Air

CO2

Conc

entra

tion

%CO

2

CDPG

as12

5 4

BMS

Out

let A

ir CO

2 Co

ncen

tratio

n %

CO2

AFC

Gas

126

Lab

Air

CO2

Conc

entra

tion

%CO

2

Th

is p

lot i

s the

sam

e as

Plo

t 2 e

xcep

t it i

s rep

orte

d in

% c

once

ntra

tion

inst

ead

of m

mH

g.

112

5.2.

3 A

dditi

onal

4B

MS

Bas

elin

e C

ase

Ano

ther

exa

mpl

e of

4B

MS

Bas

elin

e te

st c

ondi

tions

:

POIS

T 4B

MS/

Com

pres

sor E

DU

Tes

ting

- 4B

MS

Bas

elin

e - E

laps

ed T

ime

from

2/6

-- T

est D

ay 1

7 20

05

Pl

ot 1

-- S

tatu

s fo

r 4BM

S, C

RA, O

GA

and

Com

pres

sor (

offs

et fo

r cl

arity

)

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

status

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A R

eady

(9=o

n 8=

off)

Com

pres

sor S

tatu

s (1

3=on

12=

off)

Plot

2 --

Car

bon

Diox

ide

Par

tial P

ress

ures

at 4

BMS

Inle

t, 4B

MS

Out

let,

and

in L

ab

Mod

ule

Sim

ulat

or

024681012141618

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

mmHg

FMG

62 4

BMS

Inle

t Air

CO2

Pres

sure

mm

HgFF

G69

4BM

S O

utle

t Air

CO2

Pres

sure

mm

Hg

FMG

10 L

ab A

ir CO

2 Pr

essu

re m

mHg

Plot

3 --

Air

Dew

poin

t at 4

BMS

Inle

t, 4B

MS

Out

let,

and

in L

ab M

odul

e Si

mul

ator

0102030405060

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPD

P_12

0 4

BMS

Inle

t Air

Dew

poin

t #1

F

CD

PDP_

121

4BM

S O

utle

t Air

Dew

poin

t #1

F

Pl

ot 4

-- A

ir Te

mpe

ratu

re a

t 4BM

S In

let,

4BM

S O

utle

t, in

Lab

Mod

ule

Sim

ulat

or, a

nd

Wat

er T

empe

ratu

re a

t Pre

cool

er In

let

020406080100

120

140

160

180

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPT

mp1

21 4

BMS

Out

let A

ir Te

mpe

ratu

re F

AFc

Tmp1

20 L

ab A

ir Te

mp.

Mid

dle

F

CD

PTm

p086

4BM

S Pr

ecoo

l Inle

t H2O

Tem

p #1

F

113

Plot

6 --

Des

icca

nt B

ed In

let a

nd O

utle

t Air

Tem

pera

ture

s

0102030405060708090100

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPm

t11

Des

icca

nt B

ed O

utle

t Tem

pera

ture

F

Plot

5 --

Sor

bent

Bed

Hea

ter T

empe

ratu

res

050100

150

200

250

300

350

400

450

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPm

t13

5A

Bed

308

Hea

ter T

emp

A F

CD

Pmt1

6 5

A B

ed 3

09 H

eate

r Tem

p A

F

Pl

ot 7

-- D

esic

cant

Bed

Out

let A

ir De

wpo

int T

empe

ratu

re

-100-8

0

-60

-40

-2002040

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPD

P_02

3 D

essi

cant

Bed

Out

let A

ir De

wpt

F

Plot

8 --

4BM

S Pr

oces

s Ai

r Flo

w R

ate

05101520253035

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

SCFM

CDPF

lw12

0 4

BMS

Inle

t Air

Flow

rate

SCF

M (S

ierr

a)

CDPF

lw12

1 4

BMS

Inle

t Air

Flow

rate

SCF

M (T

SI)

114

Plot

10

-- 4B

MS

Com

pone

nt P

ower

0

100

200

300

400

500

600

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Watts

CDPm

w12

5A

Bed

308

Prim

. Hea

ter P

ower

Wat

t

CDPm

w13

5A

Bed

309

Prim

. Hea

ter P

ower

Wat

t

CDPm

w14

5A

Bed

308

Sec

. Hea

ter P

ower

Wat

t

CDPm

w15

5A

Bed

309

Sec

. Hea

ter P

ower

Wat

t

Air-

Save

Pum

p Po

wer

, Wat

ts

Plot

9 --

4BM

S Va

cuum

Sys

tem

Pre

ssur

es

020406080100

120

140

160

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA/Torr

CDPP

rs12

3 S

orbe

nt b

ed 3

08 p

ress

ure

PSIA

CDPm

p12

Pum

p In

let A

ir Pr

essu

re P

SIA

CDPP

rs02

1 F

ac V

acuu

m T

ank

Air

Inle

t Pre

ssur

e To

rr

CD

PPrs

022

Fac

Vac

uum

Tan

k A

ir Pr

essu

re T

orr

Plot

11

-- 4B

MS

CO2

Inje

ctio

n an

d Co

olan

t Wat

er F

low

Rat

e

0

0.51

1.52

2.53

3.54

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

SLPM/GPM

330

332

334

336

338

340

342

LBSM

SAFl

w02

2 L

ab C

O2

Inje

ct F

low

rate

SLP

M

CD

PFlw

080

4BM

S Pr

ecoo

ler I

nlet

H2O

Flo

w G

PM

MSA

Flw

023

Lab

High

CO

2 In

ject

Flo

wra

te L

BS/H

R

MSA

Mas

020

Fac

ility

CO2

Tank

Wei

ght L

bs

Plot

12

-- P

erce

nt C

arbo

n Di

oxid

e at

4BM

S In

let,

4BM

S O

utle

t, an

d in

Lab

Mod

ule

Sim

ulat

or

0

0.51

1.52

2.5

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

%

CDPG

as12

4 4

BMS

Inle

t Air

CO2

Conc

entra

tion

%CO

2

CDPG

as12

5 4

BMS

Out

let A

ir CO

2 Co

ncen

tratio

n %

CO2

AFC

Gas

126

Lab

Air

CO2

Conc

entra

tion

%CO

2

115

5.2.

4 M

echa

nica

l Com

pres

sor S

tand

Alo

ne C

ase

PO

IST

4BM

S/C

ompr

esso

r ED

U T

estin

g –

CED

U B

asel

ine

- Ela

psed

Tim

e fr

om 1

1/22

-- T

est D

ay 4

200

4

Plot

1 --

Sta

tus

for 4

BMS,

CRA

, OG

A an

d Co

mpr

esso

r (of

fset

for c

larit

y)

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

status

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A R

eady

(9=o

n 8=

off)

Com

pres

sor S

tatu

s (1

3=on

12=

off)

Th

is p

lot i

s the

sam

e as

the

stat

us p

lot f

or th

e 4B

MS

stan

d al

one

test

. Eac

h lin

e re

pres

ents

the

stat

us o

f eac

h pi

ece

of e

quip

men

t. Th

e 4-

bed

mol

siev

e w

as o

pera

ted

unde

r its

nor

mal

ope

ratin

g m

ode,

and

the

com

pres

sor w

as o

nly

activ

ated

thre

e tim

es. T

he S

abat

ier a

nd

OG

A w

ere

not i

nvol

ved

in th

is te

st.

116

Plot

2 --

CED

U O

verv

iew

-1012345678

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Suction Press (PSIA), Flow

(Lb/hr), On/Off, Day/Night

-20

020406080100

120

140

Discharge Press (PSIA)

Day/

Nigh

t Sta

tus

(7=d

ay, 6

=nig

ht)

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

MED

Flw

020

Com

pres

sor O

utle

t Flo

w a

fter D

P lb

/hr

M

EDPr

s020

Com

pres

sor I

nlet

Pre

ssur

e PS

IA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

Th

is p

lot s

how

s mul

tiple

dat

a ite

ms o

n on

e pl

ot: c

ompr

esso

r flo

w, i

nlet

and

out

let p

ress

ure

and

the

com

pres

sor c

omm

and.

The

se sa

me

data

are

show

n in

sepa

rate

plo

ts fo

llow

ing

for b

ette

r cla

rity.

117

Plot

3 --

CED

U O

utle

t Flo

w R

ate,

On/

Off

-1

-0.50

0.51

1.52

2.53

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

lb/hr

012

1=On/ 0=Off

MED

Flw

020

Com

pres

sor O

utle

t Flo

w a

fter D

P lb

/hr

SE

DCom

pres

sor c

omm

and

1=on

0=o

ff

Th

is p

lot s

how

s the

flow

rate

at t

he c

ompr

esso

r exi

t. Th

is d

ata,

alo

ng w

ith th

e in

let a

nd o

utle

t pre

ssur

e, is

use

d to

ver

ify th

e flo

w ra

te

mod

el o

f the

com

pres

sor.

118

Plot

4 --

CED

U In

let P

ress

ure

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA

012

1=On / 0=Off

MED

Prs0

20 C

ompr

esso

r Inl

et P

ress

ure

PSIA

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

This

plo

t sho

ws t

he c

ompr

esso

r inl

et p

ress

ure.

The

inle

t pre

ssur

e va

ries a

s the

4-b

ed m

ol si

eve

is tr

ansi

tioni

ng th

roug

h its

ope

ratin

g m

odes

.

119

Plot

5 --

CED

U O

utle

t Dew

Poi

nt

-40

-20020406080

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


012

1 = On / 0 = Off

MED

DP_0

20 M

echa

nica

l Com

pres

sor O

utle

t Dew

poin

t F

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

This

plo

t sho

ws t

he o

utle

t dew

poi

nt o

f the

com

pres

sor.

The

dew

poi

nt w

as a

ntic

ipat

ed to

be

high

eno

ugh

to c

ause

con

dens

atio

n in

the

com

pres

sor,

but a

s sho

wn

in th

e pl

ot, t

he d

ew p

oint

rem

aine

d lo

w th

roug

hout

the

test

.

120

Plot

6 --

CED

U O

utle

t Pre

ssur

e

020406080100

120

140

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA

012

1 = On / 0 = Off

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

ASE

DCom

pres

sor c

omm

and

1=on

0=o

ff

Th

is p

lot s

how

s the

com

pres

sor d

isch

arge

pre

ssur

e. T

he c

ompr

esso

r was

test

ed a

t var

ying

dis

char

ge p

ress

ures

by

inco

rpor

atin

g a

pres

sure

regu

lato

r int

o th

e do

wns

tream

plu

mbi

ng.

121

Plot

7 --

CED

U T

empe

ratu

res

(1 o

f 3)

0102030405060708090100

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


012

1 = On / 0 = Off

MED

Tmp0

20 M

anifo

ld O

utle

t or C

rank

case

HX

inle

t F

MED

Tmp0

21 C

rank

case

HX

Out

let o

r CP

HX in

let F

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

This

plo

t and

the

next

two

show

the

tem

pera

ture

s at v

ario

us lo

catio

ns w

ithin

the

com

pres

sor.

The

tem

pera

ture

s are

mea

sure

d in

the

cool

ing

wat

er th

roug

hout

the

com

pres

sor.

The

larg

e te

mpe

ratu

re in

crea

se a

t 14-

15 h

ours

was

due

to th

erm

ocou

ples

bei

ng re

mov

ed

from

the

cool

ant a

nd n

ot re

leva

nt to

the

spec

ific

test

resu

lts.

122

Plot

8 --

CED

U T

empe

ratu

res

(2 o

f 3)

0102030405060708090100

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


012

1 = On / 0 = Off

MED

Tmp0

22 M

anifo

ld In

let F

M

EDTm

p023

Col

d Pl

ate

Out

let F

MED

Tmp0

24 C

rank

case

Ext

erna

l Mot

or E

nd F

SE

DCom

pres

sor c

omm

and

1=on

0=o

ff

123

Plot

9 --

CED

U T

empe

ratu

res

(3 o

f 3)

020406080100

120

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


012

1 = On / 0 = Off

MED

Tmp0

25 L

ower

Gui

de C

ylin

der S

tage

1 M

otor

End

F

MED

Tmp0

26 C

ross

over

Hea

d St

age

1 M

otor

End

F

MED

Tmp0

27 C

ross

over

Hea

d St

age

2 F

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

124

5.2.

5 4B

MS/

CED

U B

asel

ine

Cas

e

POIS

T 4B

MS/

Com

pres

sor E

DU

Tes

ting

– C

EDU

/4B

MS

BL

#5 -

Elap

sed

Tim

e fr

om 1

2/1

-- T

est D

ay 9

200

4

Plot

1 --

Car

bon

Dio

xide

Par

tial P

ress

ures

at 4

BM

S In

let a

nd 4

BM

S O

utle

t, an

d 4B

MS,

CED

U a

nd S

EDU

Sta

tus

0246810121416

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

mmHg

0246810121416

Status

FMG

62 4

BMS

Inle

t Air

CO2

Pres

sure

mm

HgFF

G69

4BM

S O

utle

t Air

CO2

Pres

sure

mm

Hg

CRA

Rea

dy (1

1=on

10=

off)

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

Com

pres

sor S

tatu

s (1

3=on

12=

off)

This

plo

t sho

ws t

he st

atus

of t

he 4

BM

S an

d th

e co

mpr

esso

r and

the

carb

on d

ioxi

de c

once

ntra

tion

into

and

out

of t

he C

O2

rem

oval

sy

stem

. The

com

pres

sor w

as o

pera

ted

in th

e m

iddl

e pa

rt of

the

day

for t

his t

est s

erie

s, as

indi

cate

d by

the

purp

le li

ne c

hang

ing

from

12

to 1

3. F

or th

is te

st, t

he in

let C

O2

conc

entra

tion

(indi

cate

d by

the

red

line

abov

e) w

as se

t to

3 m

mH

g fo

r hal

f of t

he te

st a

nd 1

.5 m

mH

g fo

r the

rem

aind

er.

125

Plot

2 --

CED

U S

tatu

s

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Suction Press (PSIA), Flow (lb/hr), On/Off, Day, Night

020406080100

120

140

Day/

Nigh

t Sta

tus

(7=d

ay, 6

=nig

ht)

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

MED

Flw

020

Com

pres

sor O

utle

t Flo

w a

fter D

P lb

/hr

M

EDPr

s020

Com

pres

sor I

nlet

Pre

ssur

e PS

IA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

This

plo

t sho

ws s

ome

of th

e ke

y da

ta fo

r the

mec

hani

cal c

ompr

esso

r. Th

e in

let a

nd o

utle

t pre

ssur

es a

re b

oth

show

n on

this

plo

t alo

ng

with

flow

and

the

com

pres

sor c

omm

and.

The

follo

win

g pl

ot sh

ows t

he sa

me

data

on

a m

agni

fied

time

scal

e.

126

Plot

2 --

CED

U S

tatu

s

02468101214

1516

1718


020406080100

120

140

Day/

Nigh

t Sta

tus

(7=d

ay, 6

=nig

ht)

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

MED

Flw

020

Com

pres

sor O

utle

t Flo

w a

fter D

P lb

/hr

M

EDPr

s020

Com

pres

sor I

nlet

Pre

ssur

e PS

IA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

This

plo

t sho

ws t

he m

agni

fied

time

scal

e of

the

prev

ious

plo

t. Th

e lig

ht b

lue

line

abov

e is

the

com

pres

sor i

nlet

pre

ssur

e, w

hich

is th

e sa

me

as th

e m

olec

ular

siev

e be

d pr

essu

re a

s it i

s bei

ng d

esor

bed.

The

pur

ple

line

is th

e ac

cum

ulat

or p

ress

ure

into

whi

ch th

e co

mpr

esso

r is p

umpi

ng th

e C

O2.

The

gre

en li

ne sh

ows t

he m

ass f

low

rate

of C

O2

from

the

com

pres

sor.

127

Plot

3 --

4B

MS

Vacu

um S

yste

m P

ress

ures

02468101214161820

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA/Torr

CDPP

rs12

3 S

orbe

nt b

ed 3

08 p

ress

ure

PSIA

CDPm

p12

Pum

p In

let A

ir Pr

essu

re P

SIA

CDPP

rs02

1 F

ac V

acuu

m T

ank

Air

Inle

t Pre

ssur

e To

rr

CD

PPrs

022

Fac

Vac

uum

Tan

k A

ir Pr

essu

re T

orr

Th

is p

lot s

umm

ariz

es th

e va

cuum

syst

em p

ress

ures

for t

he in

tegr

ated

test

. The

vac

uum

pre

ssur

es in

dica

te w

hen

the

4BM

S is

ven

ting

to v

acuu

m. T

he p

lot i

s sho

wn

agai

n w

ith a

mag

nifie

d tim

e lin

e on

the

next

pag

e.

128

Plot

3 --

4B

MS

Vacu

um S

yste

m P

ress

ures

02468101214161820

1516

1718

Tim

e, H

ours

PSIA/Torr

CDPP

rs12

3 S

orbe

nt b

ed 3

08 p

ress

ure

PSIA

CDPm

p12

Pum

p In

let A

ir Pr

essu

re P

SIA

CDPP

rs02

1 F

ac V

acuu

m T

ank

Air

Inle

t Pre

ssur

e To

rr

CD

PPrs

022

Fac

Vac

uum

Tan

k A

ir Pr

essu

re T

orr

Th

is p

lot d

etai

ls th

e sy

stem

vac

uum

pre

ssur

es in

mor

e de

tail.

The

red

and

blue

line

s are

the

bed

pres

sure

and

com

pres

sor i

nlet

pr

essu

re, r

espe

ctiv

ely.

The

pre

ssur

es a

re b

asic

ally

the

sam

e du

ring

the

deso

rptio

n ph

ase.

The

gre

en a

nd b

row

n lin

es a

re th

e va

cuum

pr

essu

res.

The

bed

is d

esor

bed

dire

ctly

to th

e sp

ace

vacu

um si

mul

ator

dur

ing

the

last

10

min

utes

of t

he d

esor

ptio

n cy

cle,

as i

ndic

ated

by

the

incr

ease

in th

e tw

o va

cuum

pre

ssur

es. D

urin

g in

tegr

ated

test

ing,

ther

e ar

e oc

casi

ons w

hen

the

accu

mul

ator

is fu

ll, a

nd th

e be

d m

ust t

here

fore

des

orb

to sp

ace

vacu

um in

stea

d of

act

ivat

ing

the

com

pres

sor.

129

Plot

4 --

CED

U In

et a

nd O

utle

t Pre

ssur

es, O

utle

t Dew

Poi

nt

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Inlet (PSIA)

-60

-40

-20

020406080100

120

140

Outlet (PSIA), Dew Point (deg F)

MED

Prs0

20 C

ompr

esso

r Inl

et P

ress

ure

PSIA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

MED

DP_0

20 M

echa

nica

l Com

pres

sor O

utle

t Dew

poin

t F

This

plo

t aga

in sh

ows t

he c

ompr

esso

r inl

et a

nd o

utle

t pre

ssur

e, a

nd a

lso

the

dew

poi

nt o

f the

pro

duct

CO

2. T

he d

ata

show

s tha

t the

de

w p

oint

nev

er e

xcee

ds 3

0 F,

eve

n at

hig

h ac

cum

ulat

or p

ress

ure.

The

re is

, the

refo

re, l

ittle

risk

of c

onde

nsat

ion

in e

ither

the

com

pres

sor o

r the

acc

umul

ator

.

130

Plot

5 --

Sor

bent

Bed

Hea

ter T

empe

ratu

res

050100

150

200

250

300

350

400

450

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPm

t13

5A

Bed

308

Hea

ter T

emp

A F

CD

Pmt1

6 5

A B

ed 3

09 H

eate

r Tem

p A

F

This

plo

t sho

ws t

he te

mpe

ratu

re o

f the

two

mol

ecul

ar si

eve

beds

. The

hea

ter f

or th

e de

sorb

ing

bed

is tu

rned

on

full

pow

er u

ntil

the

bed

reac

hes 4

00 F

. The

hea

ter i

s the

n cy

cled

to m

aint

ain

the

bed

tem

pera

ture

whi

le th

e C

O2

is d

esor

bed.

131

Plot

6 --

Des

icca

nt B

ed O

utle

t Air

Dew

poin

t Tem

pera

ture

-100-8

0

-60

-40

-2002040

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPD

P_02

3 D

essi

cant

Bed

Out

let A

ir De

wpt

F

132

5.2.

6 Sa

batie

r Sta

ndal

one

Bas

elin

e C

ase

POIS

T 4B

MS/

Com

pres

sor E

DU

Tes

ting

– Sa

batie

r Bas

elin

e Pt

#1

- Ela

psed

Tim

e fr

om 2

/4 --

Tes

t Day

16

2005

Plot

1 --

Sta

tus

for 4

BMS,

CRA

, OG

A an

d Co

mpr

esso

r (of

fset

for c

larit

y)

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

status

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A R

eady

(9=o

n 8=

off)

Com

pres

sor S

tatu

s (1

3=on

12=

off)

This

plo

t sho

ws t

he o

pera

ting

stat

us o

f the

com

pone

nts.

In th

is te

st, t

he S

abat

ier w

as o

pera

ted

alon

e.

133

Plot

2 --

SED

U R

eact

or C

oolin

g C

ontro

l

0

200

400

600

800

1000

1200

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Temperature (F)

0246810

Open/Closed, Flow (SLPM)

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

SEDR

eact

Cool

501

Coo

ling

Air

Val

ve 1

=clo

sed

0=op

enM

EDFl

w02

1 Sa

batie

r CO

2 Fl

ow S

LPM

H2 R

ate

adju

sted

, SLP

M (@

0°C)

Th

is p

lot s

how

s the

hyd

roge

n an

d ca

rbon

dio

xide

flow

rate

s alo

ng w

ith th

e te

mpe

ratu

res o

f the

reac

tor.

This

cas

e w

as ru

n at

full

flow

, 9

slpm

hyd

roge

n an

d 2.

7 sl

pm C

O2,

in c

yclic

ope

ratio

n. T

he re

acta

nt fl

ow is

on

for a

bout

53

min

utes

and

off

for 3

7 m

inut

es. T

he h

ot

zone

of t

he re

acto

r pea

ks o

ut a

t 100

0 F

whi

le re

acta

nts a

re fl

owin

g an

d co

ols d

own

to a

bout

500

F w

hen

the

flow

is st

oppe

d. T

he

reac

tor o

utle

t flo

w is

bel

ow 2

00 F

dur

ing

the

entir

e ru

n.

134

Plot

3 --

SED

U S

epar

ator

Lev

el C

ontro

l

0123456

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

On/Off, Delta Pressure (IWC)

0200

400

600

800

1000

1200

1400

1600

Weight (grams)

SEDP

UMP3

01 W

ater

pum

p 1=

on 0

=off

SEDD

P409

Sep

arat

or D

elta

Pre

ssur

e"H2

OSE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

This

plo

t sho

ws t

he o

pera

tion

of th

e w

ater

col

lect

ion

tank

and

pum

p. T

he d

ata

is sh

own

mag

nifie

d in

the

next

plo

t.

135

Plot

3 --

SED

U S

epar

ator

Lev

el C

ontro

l

0123456

1112

1314

Tim

e, H

ours


0200

400

600

800

1000

1200

1400

1600

Weight (grams)

SEDP

UMP3

01 W

ater

pum

p 1=

on 0

=off

SEDD

P409

Sep

arat

or D

elta

Pre

ssur

e"H2

OSE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

Th

is p

lot s

how

s the

ope

ratio

n of

the

wat

er se

para

tor i

n m

ore

deta

il. T

he sa

w to

oth

line

is th

e le

vel i

n th

e se

para

tor a

s mea

sure

d w

ith a

di

ffer

entia

l pre

ssur

e se

nsor

. Whe

n th

e le

vel r

each

es a

hig

h lim

it, th

e pu

mp

is a

ctiv

ated

for a

bout

5 se

cond

s. Th

e da

ta c

olle

ctio

n fo

r th

ese

test

s was

one

read

ing

per m

inut

e. M

any

times

, the

read

ing

did

not c

atch

the

activ

atio

n of

the

pum

p, w

hich

is w

hy o

nly

a fe

w

activ

atio

ns a

re sh

own

on th

e gr

aph.

The

wat

er w

eigh

t is m

easu

red

with

an

elec

troni

c sc

ale.

The

tim

e pe

riod

arou

nd h

our 1

2 w

ith n

o in

crea

se in

wat

er w

eigh

t is a

Sta

ndby

per

iod

for t

he S

abat

ier s

yste

m.

136

Plot

4 --

SED

U S

yste

m P

ress

ures

02468101214161820

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA

00.5

11.5

22.5

33.5

44.5

5

PSID

SEDP

006

Reac

tor i

nlet

pre

ssur

e PS

IASE

DP60

1 Re

acto

r out

let p

ress

ure

PSIA

SEDD

P405

Rea

ctor

Del

ta P

ress

ure

PSID

SEDD

P409

Sep

arat

or D

elta

Pre

ssur

e"H2

O

Th

is p

lot s

how

s the

pre

ssur

es th

roug

hout

the

Saba

tier s

yste

m. T

he m

aroo

n, sp

iked

line

s are

the

sam

e se

para

tor d

iffer

entia

l pre

ssur

e re

adin

g sh

own

in th

e pr

evio

us p

lot.

The

red

and

blue

line

s are

the

reac

tor i

nlet

and

out

let p

ress

ures

, res

pect

ivel

y. T

he re

acto

r is

evac

uate

d to

low

pre

ssur

e (<

2 p

sia)

eve

ry ti

me

the

syst

em tr

ansi

tions

to S

tand

by. T

he g

reen

line

is th

e re

acto

r diff

eren

tial p

ress

ure.

Th

e di

ffer

entia

l pre

ssur

e is

rela

ted

to fl

ow ra

te, a

nd is

less

than

1 p

sid

at fu

ll flo

w.

137

Plot

5 --

SED

U S

yste

m E

ffici

ency

0

500

1000

1500

2000

2500

3000

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Weight (grams), Usage (lites)

Calc

H2O

Pro

d @

100

% E

ff, g

ram

Calc

H2O

Pro

d @

90%

Eff

, gra

mCa

lc H

2O P

rod

@ 8

0% E

ff, g

ram

H2O

Pro

duct

ion,

gra

ms

H2 U

seag

e Ra

te, L

iters

This

plo

t sho

ws t

he S

abat

ier w

ater

pro

duct

ion

rate

plo

tted

with

cal

cula

ted

effic

ienc

y ta

rget

s. Th

e ef

ficie

ncy

is c

alcu

late

d fr

om th

e us

age

rate

of h

ydro

gen.

Thi

s plo

t sho

ws t

he e

ffic

ienc

y to

be

abou

t 80%

. Thi

s plo

t is a

littl

e m

isle

adin

g fo

r eff

icie

ncy

beca

use

the

wat

er

wei

ght i

s not

reco

rded

unt

il th

e fir

st d

ump

out b

y th

e pu

mp,

and

ther

efor

e th

e in

vent

ory

of w

ater

in th

e sy

stem

is n

ot fu

lly a

ccou

nted

.

138

Plot

6 --

SED

U M

olar

Rat

io

012345678910

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

2425

26

Tim

e, H

ours

Flow (SLPM @ 0 C)

00.5

11.5

22.5

33.5

4

Molar Ratio

H2 R

ate

adju

sted

, SLP

M (@

0°C)

Calc

MR

from

Act

ual F

low

MED

Flw

021

Saba

tier C

O2

Flow

SLP

M

Th

is p

lot s

how

s the

hyd

roge

n an

d ca

rbon

dio

xide

flow

s to

the

Saba

tier r

eact

or a

nd th

e ca

lcul

ated

mol

ar ra

tio. T

he st

oich

iom

etric

ratio

fo

r the

reac

tion

is 4

mol

es h

ydro

gen

per m

ole

of c

arbo

n di

oxid

e. S

ince

the

ISS

life

supp

ort c

lose

d lo

op m

ass b

alan

ce is

car

bon

diox

ide

rich,

the

reac

tor i

s con

trolle

d to

a m

olar

ratio

of 3

.5 to

ens

ure

that

all

of th

e av

aila

ble

hydr

ogen

is u

sed

in th

e re

actio

n.

139

Plot

7 --

SED

U C

O2

and

H2

Flow

00.

511.

522.

533.

544.

55

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

CO2 Flow (SLPM)

012345678910

H2 Flow (SLPM)

MED

Flw

021

Saba

tier C

O2

Flow

SLP

MDe

sire

d CO

2 Fl

ow (S

LPM

)SE

DMFC

H2

Mas

s Fl

ow S

LPM

This

plo

t sho

ws t

he C

O2

and

H2

flow

feed

s to

the

reac

tor.

In th

is te

st, t

he S

abat

ier w

as o

pera

ted

in c

yclic

mod

e, th

eref

ore

the

flow

s ar

e tu

rned

on

and

off f

or e

very

Pro

cess

/Sta

ndby

mod

e.

140

Plot

8 --

SED

U T

empe

ratu

res

0

200

400

600

800

1000

1200

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Hot Zone and Inlet Temps

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

B R

eact

or H

ot Z

one

degF

SEDT

Rea

ct C

Rea

ctor

Inle

t deg

F

SEDT

Rea

ct D

Rea

ctor

Inle

t deg

FSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

This

plo

t det

ails

the

tem

pera

ture

s in

the

Saba

tier r

eact

or. T

empe

ratu

res A

and

B a

re in

the

hot z

one

of th

e re

acto

r, w

hich

is a

bout

thre

e in

ches

from

the

inle

t end

. Tem

pera

ture

s C a

nd D

are

clo

ser t

o th

e in

let e

nd a

nd in

tend

ed to

be

used

to d

etec

t the

pre

senc

e of

air

in th

e in

let C

O2

stre

am. W

hile

the

reac

tant

s are

flow

ing

into

the

reac

tor,

the

heat

from

the

reac

tion

is c

ontin

uous

ly p

ushe

d to

war

d th

e af

t end

of

the

reac

tor b

ed. W

hen

the

flow

s sto

p (a

roun

d 11

.75

hour

s, 13

.25

hour

s, 14

hou

rs, e

tc) t

he h

otte

st p

art o

f the

reac

tion

zone

star

ts to

co

ol d

own,

but

the

inle

t end

of t

he re

acto

r im

med

iate

ly st

arts

to h

eat u

p du

e to

con

duct

ion

of h

eat f

rom

the

hot z

one.

The

out

let o

f the

re

acto

r fol

low

s the

sam

e co

olin

g tre

nd a

s the

hot

zon

e w

hen

the

reac

tant

s are

rem

oved

.

141

Plot

9 --

SED

U W

ater

Pro

duct

ion

Rat

e

0

200

400

600

800

1000

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Rate (gm/hr)

012

Mode

H2O

Pro

duct

ion,

gra

ms

SEDS

tand

by S

tand

by M

ode

SEDP

roce

ss P

roce

ss M

ode

(C10

2)

Th

is p

lot d

etai

ls th

e w

ater

pro

duct

ion

rate

. The

wat

er p

rodu

ct is

reco

rded

on

a di

gita

l sca

le, w

hich

is in

crem

ente

d ev

ery

time

the

prod

uct w

ater

pum

p tu

rns o

n to

em

pty

the

sepa

rato

r. D

urin

g St

andb

y (w

hen

the

blue

line

is 1

and

the

gree

n lin

e is

0) t

here

is n

o ad

ditio

nal w

ater

pro

duct

ion,

and

the

red

line

is fl

at fo

r the

dur

atio

n. O

nce

Proc

ess m

ode

star

ts a

gain

, the

wat

er p

rodu

ctio

n st

arts

aga

in.

142

Plot

10

-- SE

DU

Ove

rvie

w

0

500

1000

1500

2000

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Temperature (F), Accum Pressure

(PSIA)

05101520

Reactor Pressure (psia)

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

ASE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

SEDP

601

Reac

tor o

utle

t pre

ssur

e PS

IA

Th

is p

lot i

s an

over

view

of t

he S

abat

ier s

yste

m o

pera

tion,

and

giv

es a

naly

sts a

qui

ck g

lanc

e at

the

stat

e of

the

syst

em. T

he re

acto

r pr

essu

re a

nd te

mpe

ratu

res s

how

read

ily th

at th

e sy

stem

is o

pera

ting

in a

cyc

lic m

ode,

sinc

e th

e te

mpe

ratu

re a

nd p

ress

ure

are

alte

rnat

ing.

The

wat

er p

rodu

ctio

n lin

e sh

ows t

hat t

he sy

stem

is o

pera

ting

wel

l, w

ith n

o m

ajor

pro

blem

s. Th

e C

O2

accu

mul

ator

pr

essu

re is

als

o lis

ted

on th

is g

raph

. In

this

test

cas

e, th

e C

O2

feed

was

ope

rate

d on

a fi

xed

25 p

sia

feed

sour

ce. F

or th

e in

tegr

ated

te

sts,

the

CO

2 pr

essu

re ri

ses a

nd fa

lls a

nd th

e co

mpr

esso

r fill

s the

acc

umul

ator

and

the

Saba

tier e

mpt

ies i

t.

143

Plot

11

-- SE

DU

Sta

tus

024681012

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Status

01020304050

Pressure (psia)

OG

A R

eady

(9=o

n 8=

off)

CRA

Rea

dy (1

1=on

10=

off)

SEDS

tand

by S

tand

by M

ode

SEDP

roce

ss P

roce

ss M

ode

(C10

2)

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

Th

is p

lot s

how

s the

stat

us o

f som

e of

the

syst

ems i

n th

e in

tegr

ated

test

. The

OG

A st

atus

(off

for t

his s

tand

alo

ne te

st) i

s giv

en a

long

w

ith th

e Sa

batie

r Pro

cess

or S

tand

by m

odes

. The

acc

umul

ator

pre

ssur

e is

giv

en h

ere

as w

ell,

whi

ch is

mor

e in

form

ativ

e fo

r the

in

tegr

ated

test

s.

144

Plot

12

-- SE

DU

CO

2 Fl

ow C

ontro

l Acc

urac

y

0

0.51

1.52

2.53

3.54

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Flow (SLPM), Reactor Press (psia)

051015202530

Accum Pressure (PSIA)

MED

Flw

021

Saba

tier C

O2

Flow

SLP

MDe

sire

d CO

2 Fl

ow (S

LPM

)

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

ASE

DP00

6 Re

acto

r inl

et p

ress

ure

PSIA

This

plo

t sho

ws t

he a

ccur

acy

of th

e C

O2

flow

con

trol.

The

Saba

tier r

equi

red

deve

lopm

ent o

f a fl

ow c

ontro

l for

spac

e fli

ght u

se. T

he

Saba

tier E

DU

inco

rpor

ated

a m

otor

driv

e co

ntro

l val

ve. T

his p

lot s

how

s tha

t the

act

ual f

low

met

the

desi

red

flow

ove

r the

rang

e of

in

let p

ress

ures

use

d fo

r thi

s tes

t.

145

4BM

S/TS

AC

Bas

elin

e C

ase

PO

IST

4BM

S/TS

AC

/Sab

atie

r Tes

ting

– 4B

MS-

TSA

C T

est #

4 - E

laps

ed T

ime

from

11/

20/2

005

Plot

1 --

Sta

tus

for

4BM

S an

d TS

AC

012345678

12

34

56

78

910

11

Tim

e, H

ours

status

-200

0200

400

600

800

1000

1200

sccm

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

TSA

Fpro

d TS

AC

Out

let C

O2

Flow

rate

scc

m

This

plo

t is,

agai

n, th

e fa

mili

ar st

atus

plo

t, w

hich

show

s the

ope

ratin

g m

ode

of th

e 4B

MS.

The

TSA

C d

oes n

ot h

ave

a m

ode

desi

gnat

ion

data

ele

men

t, bu

t the

plo

t of o

utpu

t flo

w g

ives

a g

ood

indi

catio

n of

the

oper

atin

g st

ate.

Eac

h be

d is

in a

“D

eliv

er”

stat

e w

hen

the

outp

ut fl

ow is

con

stan

t.

146

Plot

13

-- T

SAC

Inte

rnal

Pre

ssur

es

0

200

400

600

800

1000

1200

12

34

56

78

910

11

Tim

e, H

ours

Pressure, torr

TSA

P1 B

ed A

Inte

rnal

Pre

ssur

e to

rrTS

AP2

Bed

B In

tern

al P

ress

ure

torr

Th

is p

lot s

how

s the

pre

ssur

es o

f the

CO

2 pr

oduc

t in

each

of t

he tw

o TS

AC

bed

s. W

hen

the

beds

are

des

orbi

ng, t

he p

ress

ure

is

mai

ntai

ned

at 1

000

torr

for t

he d

urat

ion

of th

e de

sorb

cyc

le.

147

Plot

14

-- T

SAC

Bed

A T

empe

ratu

res

050100

150

200

250

300

350

12

34

56

78

910

11

Tim

e, H

ours

Temperature, °C

TSA

HA1

Bed

A H

eate

r 1 T

empe

ratu

re C

TSA

HA3

Bed

A H

eate

r 3 T

empe

ratu

re C

TSA

ExtW

alA

Bed

A E

xter

nal W

all T

empe

ratu

re C

TSA

Touc

hA B

ed A

Tou

ch T

empe

ratu

re

Th

is p

lot s

how

s the

tem

pera

ture

pro

file

for B

ed “

A”.

The

sign

ifica

nce

of th

e cu

rves

is e

xpla

ined

for p

lot n

umbe

r 16

whi

ch sh

ows

tem

pera

ture

s and

pre

ssur

es to

geth

er.

148

Plot

15

-- T

SAC

Bed

B T

empe

ratu

res

050100

150

200

250

300

12

34

56

78

910

11

Tim

e, H

ours

Temperature, °C

TSA

HB1

Bed

B He

ater

1 T

empe

ratu

re C

TSA

HB3

Bed

B He

ater

3 T

empe

ratu

re C

TSA

ExtW

alB

Bed

B Ex

tern

al W

all T

empe

ratu

re C

TSA

Touc

hB B

ed B

Tou

ch T

empe

ratu

re C

Th

is p

lot s

how

s the

tem

pera

ture

pro

file

for B

ed “

B”.

149

Plot

16

-- T

SAC

Bed

A P

ress

ures

and

Tem

pera

ture

s

0

200

400

600

800

1000

1200

12

34

56

78

910

11

Tim

e, H

ours

Pressure, torr

050100

150

200

250

300

350

Temperature, °C

TSA

P1 B

ed A

Inte

rnal

Pre

ssur

e to

rrTS

AA

irInA

Bed

A C

oolin

g A

ir In

let T

empe

ratu

re C

TSA

AirO

utA

Bed

A C

oolin

g A

ir O

utle

t Tem

pera

ture

CTS

AEx

tWal

A B

ed A

Ext

erna

l Wal

l Tem

pera

ture

C

TSA

HA1

Bed

A H

eate

r 1 T

empe

ratu

re C

TSA

HA3

Bed

A H

eate

r 3 T

empe

ratu

re C

Th

is p

lot s

how

s the

tem

pera

ture

s and

pre

ssur

es to

geth

er. W

hen

Bed

A tr

ansi

tions

into

des

orb

mod

e (a

bout

5.5

hou

rs o

n th

e pl

ot) t

he

heat

ers a

re tu

rned

on

and

the

tem

pera

ture

and

pre

ssur

e of

the

bed

quic

kly

rise.

Eve

n th

ough

the

bed

tem

pera

ture

and

pre

ssur

e ar

e no

t at

the

max

imum

at h

our 6

.0, t

he b

ed is

cap

able

of d

eliv

erin

g fu

ll flo

w a

t thi

s tim

e (s

ee p

lot 1

). Th

e te

mpe

ratu

re a

nd p

ress

ure

cont

inue

to

rise

unt

il th

e de

liver

y pr

essu

re o

f 100

0 to

rr is

reac

hed

and

deliv

ery

is in

itiat

ed. O

nce

the

deliv

ery

pres

sure

is m

et, t

he h

eate

r pow

er

is re

duce

d to

mai

ntai

n th

e pr

essu

re a

nd th

e te

mpe

ratu

re m

omen

taril

y dr

ops.

As C

O2

is d

raw

n of

f the

bed

, the

tem

pera

ture

is in

crea

sed

to m

aint

ain

pres

sure

unt

il th

e en

d of

the

cycl

e (h

our 8

.5 o

n th

e pl

ot).

Upo

n sw

itchi

ng b

eds,

the

bed

that

was

pre

viou

sly

deso

rbin

g is

is

olat

ed a

nd c

oole

d to

redu

ce th

e in

tern

al p

ress

ure,

pre

parin

g it

for a

dsor

ptio

n fr

om th

e 4B

MS,

150

Plot

18

-- T

SAC

Inle

t Flo

w R

ate

-5000

500

1000

1500

2000

2500

3000

3500

12

34

56

78

910

11

Tim

e, H

ours

CO2 flow, sccm

TSA

Fcdr

a TS

AC

Inle

t CO

2 Fl

owra

te s

ccm

Th

is p

lot s

how

s the

flow

rate

of C

O2

from

the

4BM

S in

to th

e TS

AC

. The

CO

2 co

mes

off

the

4BM

S in

a w

ave,

and

the

saw

toot

h flo

w

patte

rn a

t the

end

of e

ach

cycl

e is

due

to th

e os

cilla

ting

heat

er c

ontro

l in

the

4BM

S as

the

last

of t

he C

O2

is d

esor

bed

from

the

4BM

S be

d.

151

5.2.

7 4B

MS/

CED

U/S

abat

ier F

ully

Inte

grat

ed C

ase

PO

IST

4BM

S/C

EDU

/Sab

atie

r Tes

ting

– TP

3 –

Ela

psed

Tim

e fr

om 2

/4 –

Tes

t Day

16

2005

Plot

1 --

Sta

tus

for 4

BMS,

CRA

, OG

A an

d Co

mpr

esso

r (of

fset

for c

larit

y)

02468101214

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

status

CDPM

pde

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A R

eady

(9=o

n 8=

off)

Com

pres

sor S

tatu

s (1

3=on

12=

off)

Th

is fi

rst p

lot s

how

s the

stat

us o

f the

diff

eren

t sub

syst

ems.

In th

is te

st p

oint

, the

Sab

atie

r was

ope

rate

d cy

clic

ally

. The

re w

as n

o re

al

Oxy

gen

Gen

erat

ion

Ass

embl

y in

the

inte

grat

ed te

st, b

ut th

e te

st c

ontro

l sys

tem

sent

a si

gnal

to th

e Sa

batie

r rep

rese

ntin

g th

e O

GA

st

atus

, to

whi

ch th

e Sa

batie

r ope

ratio

n w

ould

resp

ond.

Whe

n th

e O

GA

sign

aled

that

it w

as O

ff, t

he S

abat

ier w

ent t

o St

andb

y or

Not

R

eady

stat

us. O

nce

the

Saba

tier h

ad c

ompl

eted

its h

ealth

che

cks i

t wou

ld re

turn

a R

eady

stat

us e

ven

thou

gh th

e O

GA

was

not

yet

on.

Th

e Sa

batie

r wou

ld w

ait f

or th

e O

GA

read

y si

gnal

bef

ore

goin

g ba

ck to

Pro

cess

mod

e. T

he 9

0 m

inut

e O

GA

cyc

le w

as c

ompl

etel

y in

depe

nden

t of t

he 4

BM

S 14

4 m

inut

e ha

lf cy

cle.

152

Plot

2 --

SED

U R

eact

or C

oolin

g C

ontro

l

0

200

400

600

800

1000

1200

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Temperature (F)

0123456

Open/Closed, Flow (SLPM)

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

SEDR

eact

Cool

501

Coo

ling

Air

Val

ve 1

=clo

sed

0=op

enM

EDFl

w02

1 Sa

batie

r CO

2 Fl

ow S

LPM

H2 R

ate

adju

sted

, SLP

M (@

0°C)

Th

is p

lot s

how

s the

reac

tor t

empe

ratu

res a

nd c

oolin

g co

ntro

l ope

ratio

n. T

he c

oolin

g ai

r val

ve w

as se

t to

open

to m

aint

ain

the

reac

tor

exit

tem

pera

ture

bel

ow 3

00 F

. Sin

ce th

is c

ase

was

cyc

lic o

pera

tion

at 3

cre

w ra

te o

f hyd

roge

n flo

w, t

he te

mpe

ratu

re w

as a

lway

s bel

ow

300

F an

d th

e co

olin

g ai

r val

ve w

as a

lway

s kep

t clo

sed.

As t

he S

abat

ier c

ycle

d fr

om P

roce

ss to

Sta

ndby

, the

hyd

roge

n an

d C

O2

flow

to

the

reac

tor w

as st

oppe

d an

d th

e re

acto

r wou

ld n

atur

ally

coo

l off

unt

il th

e ne

xt P

roce

ss c

ycle

beg

an a

nd th

e re

acto

r hea

ted

itsel

f up

agai

n.

153

Plot

3 --

SED

U S

epar

ator

Lev

el C

ontro

l

0123456

78

910

1112

Tim

e, H

ours


1000

1100

1200

1300

1400

1500

1600

Weight (grams)

SEDP

UMP3

01 W

ater

pum

p 1=

on 0

=off

SEDD

P409

Sep

arat

or D

elta

Pre

ssur

e"H2

OSE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

Th

is p

lot s

how

s the

leve

l con

trol i

n th

e ph

ase

sepa

rato

r of t

he S

abat

ier.

Sinc

e th

e sy

stem

is o

pera

ting

cycl

ical

ly, t

here

are

per

iods

whe

n th

e le

vel i

n th

e se

para

tor s

tops

incr

easi

ng. T

his i

s the

tim

e w

hen

the

Saba

tier i

s in

Stan

dby

and

wat

er g

ener

atio

n ce

ases

. The

gra

dual

ly

incr

easi

ng sl

ope

of th

e bl

ue li

ne is

whe

n w

ater

is g

ener

ated

at a

con

stan

t rat

e du

ring

Proc

ess m

ode.

The

shar

p ve

rtica

l lin

es a

re si

mpl

y irr

egul

ar d

ata

from

the

diff

eren

tial p

ress

ure

sens

or. T

he o

rang

e lin

e re

pres

ents

the

accu

mul

ated

wat

er p

rodu

ct th

at is

reco

rded

by

a di

gita

l sca

le. T

he to

tal i

ncre

ases

in st

eps a

s the

wat

er fr

om th

e se

para

tor i

s per

iodi

cally

pum

ped

out t

o th

e re

serv

oir o

n th

e sc

ale.

Eac

h tim

e th

e w

ater

is p

umpe

d ou

t, th

e le

vel d

ecre

ases

and

then

star

ts sl

owly

bui

ldin

g ag

ain.

The

dat

a co

llect

ion

is o

nce

per m

inut

e, a

nd th

e pu

mp

oper

atio

n on

ly la

sts 5

seco

nds,

so ra

rely

is th

e pu

mp

activ

ity c

aptu

red

by th

e da

ta st

ream

.

154

Plot

4 --

SED

U S

yste

m P

ress

ures

02468101214161820

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

PSIA

012345678910

PSID

SEDP

006

Reac

tor i

nlet

pre

ssur

e PS

IASE

DP60

1 Re

acto

r out

let p

ress

ure

PSIA

SEDD

P405

Rea

ctor

Del

ta P

ress

ure

PSID

SEDD

P409

Sep

arat

or D

elta

Pre

ssur

e"H2

O

This

plo

t sho

ws t

he d

iffer

ent p

ress

ures

with

in th

e Sa

batie

r sys

tem

. The

reac

tor i

nlet

and

out

let p

ress

ures

var

y fr

om 1

2 an

d 10

psi

a (r

espe

ctiv

ely)

dur

ing

the

Proc

ess m

ode

to a

bout

1 p

sia

durin

g th

e St

andb

y m

ode.

Dur

ing

each

Sta

ndby

per

iod,

the

reac

tor i

s eva

cuat

ed

to sp

ace

vacu

um to

exh

aust

the

pote

ntia

lly fl

amm

able

gas

es. W

hile

the

pres

sure

is lo

w, t

he sy

stem

doe

s a se

lf ch

eck

to d

eter

min

e if

ther

e ar

e an

y le

aks.

The

reac

tor d

iffer

entia

l pre

ssur

e is

abo

ut 1

psi

d w

hile

gas

is fl

owin

g, a

nd it

goe

s to

zero

dur

ing

the

Stan

dby

perio

d of

no

flow

.

155

Plot

5 --

SED

U S

yste

m E

ffici

ency

0

500

1000

1500

2000

2500

3000

3500

12

34

56

78

910

1112

1314

1516

1718

1920

2122

2324

Tim

e, H

ours

Weight (grams), Usage (lites)

Calc

H2O

Pro

d @

100

% E

ff, g

ram

Calc

H2O

Pro

d @

90%

Eff

, gra

mCa

lc H

2O P

rod

@ 8

0% E

ff, g

ram

H2O

Pro

duct

ion,

gra

ms

H2 U

seag

e Ra

te, L

iters

Th

is p

lot s

how

s the

act

ual w

ater

pro

duct

ion

and

the

calc

ulat

ed p

rodu

ctio

n ba

sed

on d

iffer

ent e

ffic

ienc

y ra

tes.

The

top

line

is th

e hy

drog

en u

sage

, and

it le

vels

off

eve

ry ti

me

the

syst

em sw

itche

s int

o st

andb

y. T

he H

2O P

rodu

ctio

n lin

e is

the

sam

e va

lue

from

the

digi

tal s

cale

as w

as sh

own

on th

e le

vel c

ontro

l plo

t (#3

). Th

e ca

lcul

ated

pro

duct

ion

valu

es a

re th

e am

ount

of w

ater

that

wou

ld b

e co

llect

ed if

the

syst

em o

pera

ted

at th

e st

ated

eff

icie

ncy.

For

100

% e

ffic

ienc

y, th

e w

ater

gen

erat

ion

rate

is 0

.4 g

ram

s wat

er p

er st

anda

rd

liter

of h

ydro

gen

cons

umed

.

156

Plot

6 --

SED

U M

olar

Rat

io

012345

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Flow (SLPM @ 0 C)

012345

Molar Ratio

H2 R

ate

adju

sted

, SLP

M (@

0°C)

MED

Flw

021

Saba

tier C

O2

Flow

SLP

MCa

lc M

R fr

om A

ctua

l Flo

w

This

plo

t sho

ws t

he fl

ow c

ontro

l of t

he h

ydro

gen

and

carb

on d

ioxi

de. T

he h

ydro

gen

is c

ontro

lled

by a

mas

s flo

w c

ontro

ller a

nd is

th

eref

ore

very

con

stan

t. Th

e C

O2

is c

ontro

lled

by a

mot

oriz

ed v

alve

and

mus

t res

pond

to th

e ch

angi

ng C

O2

accu

mul

ator

pre

ssur

e. T

he

CO

2 flo

w c

ontro

l is n

ot a

s con

stan

t as t

he h

ydro

gen,

but

the

mol

ar ra

tion

rem

ains

ver

y cl

ose

to 3

.5 th

roug

hout

the

test

.

157

Plot

8 --

SED

U T

empe

ratu

res

0

200

400

600

800

1000

1200

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Hot Zone and Inlet Temps

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

B R

eact

or H

ot Z

one

degF

SEDT

Rea

ct C

Rea

ctor

Inle

t deg

F

SEDT

Rea

ct D

Rea

ctor

Inle

t deg

FSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

Th

is p

lot s

how

s the

Sab

atie

r rea

ctor

tem

pera

ture

s dur

ing

test

ing.

It is

the

sam

e ch

arac

teris

tic a

s the

Sab

atie

r sta

nd a

lone

test

ing.

158

Plot

9 --

SED

U W

ater

Pro

duct

ion

Rat

e

0

200

400

600

800

1000

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Rate (gm/hr)

012

Mode

H2O

Pro

duct

ion,

gra

ms

SEDS

tand

by S

tand

by M

ode

SEDO

GA

REA

DY S

tatu

s 1=

on 0

=off

Th

is p

lot s

how

s the

wat

er p

rodu

ctio

n ra

te o

verla

id w

ith th

e Sa

batie

r Rea

dy st

atus

. The

wat

er c

olle

cted

incr

ease

s onl

y w

hile

the

syst

em

is in

Pro

cess

mod

e an

d no

t in

Stan

dby.

159

Plot

10

-- SE

DU

Ove

rvie

w

0

400

800

1200

1600

2000

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Temperature (F), Accum Pressure (PSIA)

02468101214161820

Reactor Pressure (psia)

SEDT

Rea

ct A

Rea

ctor

Hot

Zon

e de

gFSE

DT R

eact

Out

Rea

ctor

Out

let d

egF

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

ASE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

SEDP

601

Reac

tor o

utle

t pre

ssur

e PS

IA

Th

is p

lot i

s an

over

view

of t

he S

abat

ier s

yste

m o

pera

tion.

It sh

ows t

he a

ccum

ulat

or p

ress

ure,

syst

em p

ress

ure,

reac

tor t

empe

ratu

res

and

the

cum

ulat

ive

wat

er p

rodu

ct c

olle

cted

. With

this

one

plo

t, on

e ca

n te

ll th

at th

e sy

stem

is o

pera

ting

in c

yclic

mor

e, th

e te

mpe

ratu

res a

re st

able

and

the

outle

t tem

pera

ture

is c

ool e

noug

h to

not

nee

d co

olin

g ai

r. Th

e ac

cum

ulat

or p

ress

ure

is re

lativ

ely

low

(a

bout

50

psi)

thro

ugho

ut th

e cy

cles

.

160

Plot

11

-- SE

DU

Sta

tus

02468101214

23

45

67

8

Tim

e, H

ours

Status

010203040506070

Pressure (psia)

OG

A R

eady

(9=o

n 8=

off)

CRA

Rea

dy (1

1=on

10=

off)

SEDS

tand

by S

tand

by M

ode

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

This

plo

t sho

ws t

he st

atus

of t

he d

iffer

ent o

pera

ting

syst

ems a

nd th

e ac

cum

ulat

or p

ress

ure

with

the

time

scal

e m

agni

fied.

At a

bout

3.8

ho

urs,

the

pres

sure

in th

e ac

cum

ulat

or d

ips b

elow

20

psia

. The

Sab

atie

r has

to tr

ansi

tion

to S

tand

by m

ode

durin

g th

is ti

me

that

ther

e is

in

suff

icie

nt C

O2,

and

ther

efor

e th

e Sa

batie

r sta

tus i

s Not

Rea

dy. E

ach

time

the

com

pres

sor t

urns

on

(bot

tom

line

) the

pre

ssur

e in

the

accu

mul

ator

incr

ease

s. W

hen

the

OG

A is

ope

ratin

g an

d th

e Sa

batie

r is i

n Pr

oces

s (re

d lin

e) th

e pr

essu

re in

the

accu

mul

ator

dec

reas

es

as C

O2

is d

raw

n ou

t.

161

Plot

12

-- SE

DU

CO

2 Fl

ow C

ontro

l Acc

urac

y

0

0.51

1.52

2.53

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours

Flow (SLPM), Reactor Press (psia)

010203040506070

Accum Pressure (PSIA)

MED

Flw

021

Saba

tier C

O2

Flow

SLP

MDe

sire

d CO

2 Fl

ow (S

LPM

)

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

ASE

DP00

6 Re

acto

r inl

et p

ress

ure

PSIA

Th

is p

lot s

how

s the

con

trol a

ccur

acy

of th

e C

O2

mod

ulat

ing

valv

e. T

he a

ccum

ulat

or p

ress

ure

is th

e up

stre

am p

ress

ure

to th

e va

lve.

Th

e re

acto

r pre

ssur

e is

the

dow

nstre

am p

ress

ure.

The

val

ve m

ust c

ontro

l flo

w o

ver 4

:1 fl

ow tu

rndo

wn

and

6:1

pres

sure

turn

dow

n. T

he

dark

blu

e lin

e is

the

desi

red

flow

and

the

red

line

over

it is

the

actu

al fl

ow a

s mea

sure

d by

a m

ass f

low

met

er. T

he a

ctua

l flo

w is

with

in

4% o

f the

des

ired

flow

.

162

Plot

2 --

CED

U S

tatu

s

012345678

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24


010203040506070

Day/

Nigh

t Sta

tus

(7=d

ay, 6

=nig

ht)

SEDC

ompr

esso

r com

man

d 1=

on 0

=off

MED

Flw

020

Com

pres

sor O

utle

t Flo

w a

fter D

P lb

/hr

M

EDPr

s020

Com

pres

sor I

nlet

Pre

ssur

e PS

IA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

Th

is p

lot s

how

s the

stat

us o

f the

mec

hani

cal c

ompr

esso

r whe

n in

tegr

ated

with

the

4BM

S an

d Sa

batie

r. It

show

s the

com

pres

sor i

nlet

an

d ou

tlet p

ress

ures

and

flow

rate

. Thi

s inf

orm

atio

n is

use

d to

fine

tune

the

com

pres

sor o

pera

ting

logi

c to

min

imiz

e po

wer

and

m

axim

ize

CO

2 re

cove

ry.

163

Plot

4 --

CED

U In

et a

nd O

utle

t Pre

ssur

es, O

utle

t Dew

Poi

nt

0

0.51

1.52

2.53

3.54

4.5

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Inlet (PSIA)

-40

-20

020406080100

120

Outlet (PSIA), Dew Point (deg F)

MED

Prs0

20 C

ompr

esso

r Inl

et P

ress

ure

PSIA

MED

Prs0

21 A

ccum

ulat

or P

ress

ure

or C

O2

inle

t PSI

A

MED

DP_0

20 M

echa

nica

l Com

pres

sor O

utle

t Dew

poin

t F

Th

is p

lot a

dditi

onal

ly sh

ows t

he d

ew p

oint

of t

he C

O2

leav

ing

the

com

pres

sor.

The

tall

spik

es a

t 4.5

and

16.

4 ho

urs a

re c

alib

ratio

n ru

ns o

f the

dew

poi

nt se

nsor

. The

dew

poi

nt n

ever

exc

eeds

30

F, th

eref

ore

cond

ensa

tion

in th

e co

mpr

esso

r or a

ccum

ulat

or is

not

an

issu

e.

164

Plot

5 --

Sor

bent

Bed

Hea

ter T

empe

ratu

res

050100

150

200

250

300

350

400

450

01

23

45

67

89

1011

1213

1415

1617

1819

2021

2223

24

Tim

e, H

ours


CDPm

t13

5A

Bed

308

Hea

ter T

emp

A F

CD

Pmt1

6 5

A B

ed 3

09 H

eate

r Tem

p A

F

Th

is p

lot s

how

s the

var

iatio

n of

4B

MS

oper

atio

n w

hen

the

syst

em te

st is

sim

ulat

ing

a da

y/ni

ght c

ycle

. The

hea

ters

in th

e 4B

MS

are

turn

ed o

ff d

urin

g th

e ni

ght p

ortio

n of

the

cycl

e re

sulti

ng in

tem

pera

ture

dec

reas

e of

the

deso

rbin

g be

d. T

he c

ycle

at h

our 3

doe

s not

pr

oduc

e en

ough

CO

2 an

d re

sults

in a

shor

t per

iod

of C

O2

star

vatio

n fo

r the

Sab

atie

r (no

ted

in p

lot #

11

abov

e).

165

5.2.

8 4B

MS/

TSA

C/S

abat

ier F

ully

Inte

grat

ed C

ase

PO

IST

4BM

S/TS

AC

/Sab

atie

r Tes

ting

– Lu

nar N

ight

1C

– E

laps

ed T

ime

from

1/2

7/20

06

The

follo

win

g pl

ots a

re fr

om o

ne o

f the

test

s with

the

TSA

C a

nd th

e 4B

MS

and

Saba

tier.

The

cond

ition

s wer

e se

t to

sim

ulat

e a

Luna

r m

issi

on w

ith 4

cre

w a

ll le

avin

g fo

r EV

A to

geth

er a

nd re

turn

ing

toge

ther

. The

CO

2 fr

om 2

cre

w m

embe

rs is

rege

nera

ted

two

hour

s af

ter r

etur

n fr

om E

VA

, and

the

CO

2 fr

om th

e re

mai

ning

2 c

rew

mem

bers

is re

gene

rate

d th

e ne

xt d

ay.

Plot

1 --

Sta

tus

for

4BM

S, T

SAC

and

Sab

atie

r

024681012

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

status

-200

0200

400

600

800

1000

1200

1400

1600

1800

2000

sccm

CDPM

ode

0OF

1SH

2A1

3A2

4A3

5B1

6B2

7B3

8WP

CRA

Rea

dy (1

1=on

10=

off)

OG

A C

urre

nt/1

0TS

AFp

rod

TSA

C O

utle

t CO

2 Fl

owra

te s

ccm

Th

is p

lot s

how

s the

stat

us o

f the

diff

eren

t sub

syst

ems i

n th

e te

st. T

he L

unar

mis

sion

is a

ssum

ed to

be

in d

aylig

ht a

ll th

e tim

e, th

eref

ore

ther

e is

no

Day

/Nig

ht c

yclin

g as

in th

e IS

S M

issi

on sc

enar

ios u

sed

in th

e m

echa

nica

l com

pres

sor t

ests

. The

re a

re a

few

fals

e st

arts

at

the

begi

nnin

g of

the

test

, the

n at

hou

rs 2

2, 2

5 an

d 27

ther

e ar

e pe

riods

whe

re th

e Sa

batie

r sw

itche

d to

Sta

ndby

. Lat

er p

lots

will

show

th

at th

e m

issi

on sc

enar

io re

sulte

d in

per

iods

of C

O2

star

vatio

n fo

r the

Sab

atie

r sub

syst

em. A

roun

d 30

hou

rs, t

here

is a

per

iod

whe

re

the

Saba

tier r

apid

ly sw

itche

d fr

om P

roce

ss to

Sta

ndby

. Thi

s occ

urre

d be

caus

e th

e de

adba

nd o

n th

e pr

essu

re se

tpoi

nt to

turn

the

166

Saba

tier o

n an

d of

f was

too

narr

ow, a

nd th

e no

rmal

ope

ratio

n ca

used

the

pres

sure

to c

ross

that

span

qui

ckly

. One

of t

he

reco

mm

enda

tions

for f

utur

e m

odifi

catio

ns is

to b

road

en th

at d

eadb

and.

Plot

2 --

Car

bon

Dio

xide

Par

tial P

ress

ures

at 4

BM

S In

let,

4BM

S O

utle

t, an

d in

La

b M

odul

e Si

mul

ator

-505101520

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

mmHg

FMG

62 4

BMS

Inle

t Air

CO2

Pres

sure

mm

HgFF

G69

4BM

S O

utle

t Air

CO2

Pres

sure

mm

Hg

FMG

10 L

ab A

ir CO

2 Pr

essu

re m

mHg

Th

is p

lot s

how

s the

CO

2 co

ncen

tratio

n at

the

inle

t of t

he 4

BM

S. T

his c

once

ntra

tion

prof

ile w

as th

e ou

tput

resu

lt of

mod

elin

g th

e Lu

nar h

abita

t with

the

crew

act

iviti

es a

nd lo

catio

n. T

his p

rofil

e in

clud

es th

e 4

crew

mem

ber E

VA

with

the

stag

gere

d re

gene

ratio

n. T

he

outle

t CO

2 is

alm

ost z

ero

exce

pt fo

r the

shar

p sp

ikes

at t

he b

ed c

hang

es. T

here

is a

n in

crea

se in

CO

2 at

the

outp

ut b

etw

een

hour

s 35

and

40. T

his i

s the

tim

e pe

riod

whe

n th

e fir

st tw

o EV

A C

O2

pack

s are

rege

nera

ted

and

the

4BM

S in

the

habi

tat c

anno

t kee

p up

with

th

e ad

ditio

nal C

O2

load

dur

ing

rege

nera

tion.

Thi

s eff

ect i

s see

n ag

ain

betw

een

hour

s 60

and

65 w

hen

the

next

two

EVA

pac

ks a

re

rege

nera

ted.

167

Plot

3 --

Air

Dew

poin

t at 4

BM

S In

let a

nd in

Lab

Mod

ule

Sim

ulat

or

10203040506070

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours


CDPD

P_12

0 4

BMS

Inle

t Air

Dew

poin

t #1

F

A

FcDP

_120

Lab

Air

Dew

poin

t F

This

plo

t sho

ws d

ew p

oint

read

ings

at t

he 4

BM

S in

let a

nd in

the

Lab

Mod

ule

sim

ulat

or. T

he se

ctio

n be

twee

n ho

ur 3

0 to

50

is a

n ap

pare

nt b

ad se

nsor

read

ing.

The

tall

spik

es a

re c

alib

ratio

n ru

ns o

f the

sens

or. D

urin

g ea

ch c

ycle

, as t

he b

eds c

hang

e, a

dum

p of

hum

id

air f

rom

the

deso

rbin

g be

d is

retu

rned

to th

e in

let o

f the

con

dens

ing

heat

exc

hang

er, w

hich

in tu

rn fe

eds b

ack

to th

e in

let o

f the

4B

MS.

Th

e re

d lin

e sh

ows t

he sm

all s

pike

in in

let h

umid

ity a

t eac

h be

d ch

ange

, whi

ch is

then

redu

ced

as th

e cy

cle

com

plet

es it

s cou

rse.

The

bl

ue li

ne is

the

lab

mod

ule

aver

age

hum

idity

, whi

ch fo

llow

the

trend

of t

he in

let h

umid

ity. W

ater

is c

ontin

uous

ly in

ject

ed in

to th

e la

b m

odul

e to

mak

e up

for t

he w

ater

lost

to th

e va

cuum

sim

ulat

or. T

he in

let,

bein

g do

wns

tream

of t

he c

onde

nsin

g he

at e

xcha

nger

, is

typi

cally

at a

low

er d

ew p

oint

than

the

lab

mod

ule

aver

age.

168

Plot

4 --

Air

Tem

pera

ture

at 4

BM

S In

let,

4BM

S O

utle

t, in

Lab

Mod

ule

Sim

ulat

or,

and

Wat

er T

empe

ratu

re a

t Pre

cool

er In

let

050100

150

200

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPT

mp1

21 4

BMS

Out

let A

ir Te

mpe

ratu

re F

AFc

Tmp1

20 L

ab A

ir Te

mp.

Mid

dle

F

CD

PTm

p086

4BM

S Pr

ecoo

l Inle

t H2O

Tem

p #1

F

This

plo

t sho

ws t

he a

ir an

d co

olin

g w

ater

tem

pera

ture

s at t

he 4

BM

S. W

hen

the

beds

switc

h, th

e ai

r exi

ting

is in

itial

ly v

ery

high

te

mpe

ratu

re a

s it i

s flo

win

g th

roug

h th

e be

d th

at w

as ju

st re

cent

ly h

eate

d to

400

F. T

his h

ot a

ir is

use

d to

des

orb

the

desi

ccan

t bed

that

is

full

of w

ater

. The

air

tem

pera

ture

qui

ckly

retu

rns t

o no

rmal

tem

pera

ture

s as t

he b

ed c

ools

dow

n an

d be

gins

ads

orbi

ng C

O2.

The

air

inle

t tem

pera

ture

is c

oole

r tha

n th

e av

erag

e La

b M

odul

e te

mpe

ratu

re si

nce

it ha

s bee

n co

oled

by

the

cond

ensi

ng h

eat e

xcha

nger

.

169

Plot

5 --

Sor

bent

Bed

Hea

ter

Tem

pera

ture

s

050100

150

200

250

300

350

400

450

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours


CDPm

t14

5A

Bed

308

Hea

ter T

emp

B F

CDPm

t16

5A

Bed

309

Hea

ter T

emp

A F

This

plo

t sho

ws t

he 4

BM

S be

d he

ater

tem

pera

ture

s. Si

nce

the

sim

ulat

ion

is a

lway

s day

time,

the

heat

ers o

f the

4B

MS

are

kept

on

full

pow

er a

ccor

ding

to th

e no

rmal

pro

cess

ing

sche

dule

, i.e

., th

ere

is n

o po

wer

save

mod

e th

at tu

rns h

eate

rs o

ff. E

ach

bed

is h

eate

d to

400

F

to d

esor

b th

e C

O2.

170

Plot

6 --

Des

icca

nt B

ed In

let a

nd O

utle

t Air

Tem

pera

ture

s

0102030405060708090100

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours


CDPT

mp1

20 4

BMS

Inle

t Air

Tem

pera

ture

F

CDPm

t11

Des

icca

nt B

ed O

utle

t Tem

pera

ture

F

Th

is p

lot s

how

s the

tem

pera

ture

of t

he a

ir in

to a

nd o

ut o

f the

ads

orbi

ng d

esic

cant

bed

. The

tem

pera

ture

rise

s due

to th

e he

at o

f ad

sorp

tion

of w

ater

ont

o th

e de

scic

cant

.

171

Plot

7 --

Des

icca

nt B

ed O

utle

t Air

Dew

poin

t Tem

pera

ture

-95.

5

-95

-94.

5

-94

-93.

5

-93

-92.

5

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours


CDPD

P_02

3 D

essi

cant

Bed

Out

let A

ir De

wpt

F

Th

is p

lot s

how

s the

dew

poi

nt o

f the

air

leav

ing

the

desi

ccan

t and

ent

erin

g th

e C

O2

adso

rptio

n be

d. T

his d

ew p

oint

is m

onito

red

for

brea

kthr

ough

. Wat

er th

at e

scap

es th

e de

sicc

ant b

ed w

ill in

terf

ere

with

the

adso

rptio

n of

CO

2 on

to th

e C

O2

sorb

ent b

ed. T

he b

ed

wou

ld th

en h

ave

to b

e re

gene

rate

d at

hig

h te

mpe

ratu

re to

rem

ove

the

wat

er.

172

Plot

8 --

4B

MS

Proc

ess

Air

Flow

Rat

e, F

an d

P

05101520253035

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

SCFM

0510152025303540

CDPF

lw12

0 4

BMS

Inle

t Air

Flow

rate

SCF

M (S

ierr

a)

CDPF

lw12

1 4

BMS

Inle

t Air

Flow

rate

SCF

M (T

SI)

CDPm

p10

Blow

er D

elta

Pre

ssur

e in

H2O

Th

is p

lot s

how

s the

air

flow

rate

to th

e 4B

MS

and

the

blow

er p

ress

ure

drop

. The

pre

ssur

e dr

op ri

ses q

uick

ly w

hile

the

air t

empe

ratu

re

is h

igh

from

the

desi

ccan

t. (R

efer

bac

k to

plo

t 6).

The

air f

low

was

mea

sure

d w

ith tw

o di

ffer

ent d

evic

es, w

hich

show

ed v

ery

good

ag

reem

ent.

173

Plot

9 --

4B

MS

Vacu

um S

yste

m P

ress

ures

-20246810121416

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

PSIA/Torr

02468101214161820

CDPP

rs12

3 S

orbe

nt b

ed 3

08 p

ress

ure

PSIA

CDPm

p12

Pum

p In

let A

ir Pr

essu

re P

SIA

CDPP

rs02

3 F

ac V

acuu

m T

ank

Air

Inle

t Pre

ssur

e To

rr

CD

PPrs

024

Fac

Vac

uum

Tan

k A

ir Pr

essu

re T

orr

Th

is p

lot s

how

s vac

uum

pre

ssur

es o

f the

4B

MS.

The

4B

MS

deso

rbin

g be

d (b

ed 3

08) a

nd th

e TS

AC

inle

t pre

ssur

e (P

ump

Inle

t Air

Pres

sure

) are

alm

ost t

he sa

me

exce

pt fo

r the

pre

ssur

e dr

op b

etw

een

the

two

syst

ems.

The

spik

es in

the

Faci

lity

Vac

uum

pre

ssur

es

indi

cate

whe

n ei

ther

the

4BM

S is

per

form

ing

its 1

0 m

inut

e sp

ace

vacu

um d

esor

b, o

r the

bed

pre

ssur

e is

exc

essi

ve a

nd th

e 4B

MS

mus

t ve

nt e

arly

. Bet

wee

n ho

urs 3

5 an

d 40

, whe

n th

e EV

A C

O2

cani

ster

s are

rege

nera

ted,

ther

e is

exc

ess C

O2

in th

e ha

bita

t tha

t the

TSA

C

cann

ot d

eliv

er to

the

Saba

tier,

ther

efor

e, th

e 4B

MS

mus

t ven

t som

e of

the

CO

2 w

hen

its b

ed p

ress

ure

incr

ease

s. Th

is h

appe

ns a

gain

be

twee

n ho

urs 6

0 an

d 65

.

174

Plot

10

-- 4

BM

S C

ompo

nent

Pow

er

-1000

100

200

300

400

500

600

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Watts

CDPm

w12

5A

Bed

308

Prim

. Hea

ter P

ower

Wat

t

CDPm

w13

5A

Bed

309

Prim

. Hea

ter P

ower

Wat

t

CDPm

w14

5A

Bed

308

Sec

. Hea

ter P

ower

Wat

t

CDPm

w15

5A

Bed

309

Sec

. Hea

ter P

ower

Wat

t

Air-

Save

Pum

p Po

wer

, Wat

ts

This

plo

t sho

ws t

he p

ower

usa

ge o

f the

4B

MS.

The

thic

k ba

rs a

re th

e be

d he

ater

s cyc

ling

on a

nd o

ff w

hen

the

bed

is a

t tem

pera

ture

. Th

e he

ater

con

trol i

s on/

off c

ontro

l, w

hich

giv

es th

e te

mpe

ratu

re p

rofil

e th

e ch

arac

teris

tic sa

w to

oth

patte

rn.

175

Plot

11

-- 4

BM

S C

O2

Inje

ctio

n an

d C

oola

nt W

ater

Flo

w R

ate

00.

511.

522.

533.

54

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

SLPM/GPM

050100

150

200

250

300

350

400

LBS

MSA

Flw

022

Lab

CO

2 In

ject

Flo

wra

te S

LPM

CDPF

lw08

0 4

BMS

Prec

oole

r Inl

et H

2O F

low

GPM

MSA

Mas

020

Fac

ility

CO2

Tank

Wei

ght L

bs

This

plo

t sho

ws t

he C

O2

inje

ctio

n ra

te. T

his i

njec

tion

rate

is a

resu

lt of

the

Luna

r hab

itat m

odel

with

the

crew

act

ivity

, inc

ludi

ng th

e EV

A sc

enar

io p

revi

ousl

y di

scus

sed.

The

CO

2 ta

nk w

eigh

t is a

lso

reco

rded

as a

bac

kup

to th

e in

ject

ion

flow

rate

reco

rdin

g. T

he

cool

ant f

low

rate

, whi

ch is

con

stan

t at 0

.5 g

pm, i

s mon

itore

d fo

r sys

tem

hea

lth.

176

Plot

12

-- T

SAC

Pro

duct

Flo

w R

ate

-2000

200

400

600

800

1000

1200

1400

1600

1800

2000

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Flow Rate, sccm

TSA

Fpro

d TS

AC

Out

let C

O2

Flow

rate

scc

m

This

plo

t sho

ws t

he T

SAC

CO

2 de

liver

y flo

w ra

te to

the

Saba

tier.

The

deliv

ery

is fa

irly

cons

tant

unt

il th

e pe

riods

of s

tarv

atio

n be

gin

at h

our 2

2, 2

5 an

d 27

. The

n at

hou

r 30,

the

perio

d be

gins

whe

n th

e Sa

batie

r rep

eate

dly

tried

to st

art a

nd th

e pr

essu

re d

eadb

and

caus

ed

it to

shut

dow

n. A

t hou

r 55

the

hydr

ogen

flow

setp

oint

was

tem

pora

rily

set t

o tw

ice

the

norm

al ra

te. T

he T

SAC

was

mom

enta

rily

able

to

kee

p up

, but

then

late

r a p

erio

d of

star

vatio

n re

sulte

d at

hou

r 57.

177

Plot

13

-- T

SAC

Inte

rnal

Pre

ssur

es

0

200

400

600

800

1000

1200

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Pressure, torr

TSA

P1 B

ed A

Inte

rnal

Pre

ssur

e to

rrTS

AP2

Bed

B In

tern

al P

ress

ure

torr

Th

is p

lot s

how

s the

pre

ssur

es o

f the

TSA

C b

eds.

Dur

ing

perio

ds o

f sta

rvat

ion

(hou

r 30

to 3

5), t

he T

SAC

bed

pre

ssur

e fa

lls sh

ort

beca

use

ther

e w

as in

suff

icie

nt C

O2

avai

labl

e fr

om th

e 4B

MS.

Thi

s is s

een

agai

n at

hou

r 60-

65.

178

Plot

14

-- T

SAC

Bed

A T

empe

ratu

res

050100

150

200

250

300

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Temperature, °C

TSA

HA1

Bed

A H

eate

r 1 T

empe

ratu

re C

TSA

HA3

Bed

A H

eate

r 3 T

empe

ratu

re C

TSA

ExtW

alA

Bed

A E

xter

nal W

all T

empe

ratu

re C

TSA

Touc

hA B

ed A

Tou

ch T

empe

ratu

re

Th

is p

lot s

how

s the

tem

pera

ture

s of t

he T

SAC

Bed

A. T

he d

etai

led

desc

riptio

n is

giv

en fo

r plo

t 16.

179

Plot

15

-- T

SAC

Bed

B T

empe

ratu

res

050100

150

200

250

300

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Temperature, °C

TSA

HB1

Bed

B He

ater

1 T

empe

ratu

re C

TSA

HB3

Bed

B He

ater

3 T

empe

ratu

re C

TSA

ExtW

alB

Bed

B Ex

tern

al W

all T

empe

ratu

re C

TSA

Touc

hB B

ed B

Tou

ch T

empe

ratu

re C

This

plo

t giv

es th

e te

mpe

ratu

res f

or th

e TS

AC

Bed

B. T

he d

etai

led

desc

riptio

n is

giv

en fo

r plo

t 17.

180

Plot

16

-- T

SAC

Bed

A P

ress

ures

and

Tem

pera

ture

s

0

200

400

600

800

1000

1200

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Pressure, torr

050100

150

200

250

300

Temperature, °C

TSA

P1 B

ed A

Inte

rnal

Pre

ssur

e to

rrTS

AA

irInA

Bed

A C

oolin

g A

ir In

let T

empe

ratu

re C

TSA

AirO

utA

Bed

A C

oolin

g A

ir O

utle

t Tem

pera

ture

CTS

AEx

tWal

A B

ed A

Ext

erna

l Wal

l Tem

pera

ture

C

TSA

HA1

Bed

A H

eate

r 1 T

empe

ratu

re C

TSA

HA3

Bed

A H

eate

r 3 T

empe

ratu

re C

Th

is p

lot s

how

s the

pre

ssur

e an

d te

mpe

ratu

re p

rofil

e of

the

A b

ed. I

n ea

ch c

ycle

, the

bed

is h

eate

d un

til th

e de

liver

y pr

essu

re is

ac

hiev

ed. H

eatin

g co

ntin

ues a

s del

iver

y be

gins

unt

il th

e te

mpe

ratu

re re

ache

s a m

axim

um se

tpoi

nt. I

n th

e fir

st c

ycle

, pre

ssur

e is

m

aint

aine

d w

ith th

e be

d te

mpe

ratu

re b

elow

200

C. I

n th

e ne

xt c

ycle

, the

tem

pera

ture

is in

crea

sed

a lit

tle o

ver 2

00 C

and

in th

e th

ird

cycl

e th

e te

mpe

ratu

re re

ache

s the

max

imum

setp

oint

of 2

75 C

. In

each

of t

hese

cyc

les t

he C

O2

inpu

t fro

m th

e 4B

MS

was

less

and

le

ss, a

s not

ed in

Plo

t 18

belo

w. A

roun

d ho

ur 3

5-40

ther

e is

too

muc

h C

O2

from

the

4BM

S an

d th

e TS

AC

cou

ld n

ot d

eliv

er it

all

to th

e Sa

batie

r so

the

bed

star

ted

the

adso

rb c

ycle

hal

f ful

l. Th

is is

not

ed in

the

vacu

um sy

stem

pre

ssur

e pl

ot b

ack

on P

lot 9

.

181

Plot

17

-- T

SAC

Bed

B P

ress

ures

and

Tem

pera

ture

s

0

200

400

600

800

1000

1200

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Pressure, torr

050100

150

200

250

300

Temperature, °C

TSA

P2 B

ed B

Inte

rnal

Pre

ssur

e to

rrTS

AA

irInB

Bed

B C

oolin

g A

ir In

let T

empe

ratu

re C

TSA

AirO

utB

Bed

B Co

olin

g A

ir O

utle

t Tem

pera

ture

CTS

AEx

tWal

B Be

d B

Exte

rnal

Wal

l Tem

pera

ture

C

TSA

HB1

Bed

B He

ater

1 T

empe

ratu

re C

TSA

HB3

Bed

B He

ater

3 T

empe

ratu

re C

Th

is p

lot o

f Bed

B p

ress

ure

and

tem

pera

ture

show

s a c

oupl

e of

inst

ance

s of t

he T

SAC

runn

ing

out o

f CO

2 pr

essu

re fo

r del

iver

y to

Sa

batie

r. B

etw

een

hour

25

and

30, t

he b

ed lo

ses p

ress

ure

befo

re th

e en

d of

the

cycl

e. T

he fo

llow

ing

cycl

e th

e be

d pr

essu

re is

low

for

the

full

cycl

e, a

nd a

gain

the

next

cyc

le th

e be

d pr

essu

re fa

ll sh

ort b

efor

e th

e en

d of

the

cycl

e. T

his i

s the

resu

lt of

too

little

CO

2 av

aila

ble

from

the

4BM

S th

e pr

eced

ing

cycl

e.

182

Plot

18

-- T

SAC

Inle

t Flo

w R

ate

-300

0-2

000

-100

0010

0020

0030

0040

0050

0060

0070

00

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

CO2 flow, sccm

TSA

Fcdr

a TS

AC

Inle

t CO

2 Fl

owra

te s

ccm

Th

is p

lot s

how

s the

CO

2 flo

w ra

te fr

om th

e 4B

MS

to th

e TS

AC

. The

CO

2 co

mes

off

the

CO

2 ad

sorb

ent b

ed in

a w

ave.

Mos

t of t

he

flow

com

es o

ff a

s the

bed

tem

pera

ture

is c

limbi

ng. O

nce

the

bed

reac

hes i

ts se

tpoi

nt te

mpe

ratu

re, t

he h

eate

rs st

art t

urni

ng o

n an

d of

f to

mai

ntai

n th

e se

tpoi

nt. E

ach

time

the

heat

ers t

urn

on, m

ore

gas i

s rel

ease

d, a

nd w

hen

the

heat

ers t

urn

off,

the

flow

rate

dec

reas

es.

This

pro

file

coul

d po

tent

ially

be

impr

oved

with

a v

aria

ble

pow

er h

eate

r con

trol i

nste

ad o

f the

on/

off c

ontro

l.

183

Plot

19

-- S

EDU

Sep

arat

or L

evel

Con

trol

0123456789

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

On/Off, Delta Pressure (PSID)

0500

1000

1500

2000

2500

3000

3500

4000

Weight (grams)

SEDS

EP_r

un S

epar

ator

run

stat

us

SE

DDP4

09-1

Sep

arat

or D

P PS

ID

SE

DMas

020

Saba

tier E

DU W

ater

Gra

ms

Th

is p

lot s

how

s the

ope

ratio

n of

the

rota

ry p

hase

sepa

rato

r in

the

Saba

tier s

yste

m a

nd th

e w

ater

col

lect

ion

rate

. The

rota

ting

bow

l of

the

sepa

rato

r gra

dual

ly fi

lls w

ith w

ater

that

is c

onde

nsed

in th

e he

at e

xcha

nger

. The

diff

eren

tial p

ress

ure

betw

een

the

liqui

d at

the

botto

m o

f the

bow

l and

the

gas p

ress

ure

slow

ly ri

ses a

s mor

e liq

uid

is a

ccum

ulat

ed. W

hen

the

pres

sure

reac

hes a

setp

oint

, the

spee

d is

in

crea

sed

to p

ump

the

liqui

d ou

t, dr

oppi

ng th

e di

ffer

entia

l pre

ssur

e as

the

liqui

d is

rem

oved

. Dur

ing

this

test

, the

sepa

rato

r col

lect

ed

abou

t 140

gra

ms o

f wat

er b

etw

een

each

pum

pout

ove

r a ti

me

perio

d of

abo

ut 1

16 m

inut

es. T

his e

quat

es to

1.2

gra

ms/

min

ute

of w

ater

ge

nera

tion.

At t

he h

ydro

gen

inle

t flo

w ra

te o

f 3.2

6 sl

pm, t

he m

axim

um w

ater

reco

very

pos

sibl

e is

1.3

gra

ms/

min

ute.

The

Sab

atie

r ac

hiev

ed 9

2% re

cove

ry d

urin

g th

e st

eady

stat

e po

rtion

s of t

his t

est.

184

Plot

20

-- S

EDU

Sys

tem

Pre

ssur

es

024681012141618

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

PSIA

00.5

11.5

22.5

PSID

SEDP

006-

1 re

acto

r inl

et p

ress

ure

PSIA

SEDP

601

H2 v

ent p

ress

ure

PSIA

SEDD

P405

Rea

ctor

DP

PSI

D

This

plo

t sho

ws t

he S

abat

ier s

yste

m p

ress

ures

. Dur

ing

stea

dy st

ate

oper

atio

n, th

e re

acto

r pre

ssur

e is

abo

ut 1

0 ps

ia. O

pera

ting

at su

b-am

bien

t pre

ssur

e is

a sa

fety

feat

ure

of th

e sy

stem

that

pre

vent

s lea

kage

of f

lam

mab

le g

as to

the

cabi

n en

viro

nmen

t. A

ny ti

me

the

Saba

tier t

rans

ition

s to

Stan

dby

the

syst

em is

eva

cuat

ed to

vac

uum

to re

mov

e th

e ga

ses.

The

dow

nwar

d sp

ikes

in th

e pl

ot in

dica

te th

e tim

es th

at th

e Sa

batie

r wen

t to

Stan

dby

due

to st

arva

tion.

185

Plot

21

-- S

EDU

Sys

tem

Eff

icie

ncy

-100

00

1000

2000

3000

4000

5000

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Weight (grams)

02000

4000

6000

8000

1000

0

1200

0

H2 Usage (liters)

Calc

H2O

Pro

d @

100

% E

ff, g

ram

Calc

H2O

Pro

d @

90%

Eff

, gra

mCa

lc H

2O P

rod

@ 8

0% E

ff, g

ram

H2O

Pro

duct

ion,

gra

ms

H2 U

seag

e Ra

te, L

iters

Th

is p

lot s

how

s the

act

ual w

ater

col

lect

ion

com

pare

d to

the

theo

retic

pro

duct

ion

rate

. At 1

00%

reco

very

eff

icie

ncy,

the

Saba

tier

reac

tion

crea

ted

0.4

gram

s of w

ater

for e

ach

stan

dard

lite

r of h

ydro

gen

cons

umed

. The

ove

rall

wat

er g

ener

atio

n du

ring

this

ent

ire te

st

was

abo

ut 8

6%.

186

Plot

22

-- S

EDU

Mol

ar R

atio

024681012

4550

5560

Tim

e, H

ours

Flow (SLPM @ 0ºC)

00.5

11.5

22.5

33.5

44.5

5

Molar Ratio

SEDM

FM00

6 CO

2 flo

w ra

te S

LPM

Desi

red

CO2

Flow

(SLP

M)

H2 R

ate

adju

sted

, SLP

M (@

0°C)

Calc

MR

from

Act

ual F

low

Th

is p

lot s

how

s the

mol

ar ra

tio o

f hyd

roge

n to

CO

2 du

ring

the

test

. The

stoi

chio

met

ric ra

tio fo

r the

Sab

atie

r rea

ctio

n is

4 m

oles

hy

drog

en p

er m

ole

CO

2. T

he S

abat

ier i

s typ

ical

ly o

pera

ted

at a

mol

ar ra

tio o

f 3.5

bec

ause

ther

e is

usu

ally

exc

ess C

O2

avai

labl

e in

a

parti

ally

clo

sed

loop

Air

Rev

italiz

atio

n Sy

stem

. At o

ne p

oint

in th

e te

st (h

our 5

5) th

e hy

drog

en fl

ow ra

te w

as te

mpo

raril

y in

crea

sed

and

the

CO

2 flo

w in

crea

sed

to m

atch

it a

t the

sam

e ra

tio o

f 3.5

. The

mol

ar ra

tio v

alue

is u

ndef

ined

whe

n th

e hy

drog

en a

nd C

O2

flow

s ar

e bo

th z

ero.

187

Plot

23

-- S

EDU

Tem

pera

ture

s

0

200

400

600

800

1000

1200

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Hot Zone and Inlet Temps, degrees F SE

DT40

3_1

Reac

tor T

empe

ratu

re 1

deg

F

SE

DT40

3_2

Reac

tor T

empe

ratu

re 2

deg

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SEDT

403_

3 Re

acto

r Tem

pera

ture

3 d

eg F

SEDT

403_

4 Re

acto

r Tem

pera

ture

4 d

eg F

SEDT

404_

1R R

eact

or O

utle

t Tem

pera

ture

deg

F

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DT40

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t Exc

hang

er O

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t Tem

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ture

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eg F

This

plo

t sho

ws t

he S

abat

ier r

eact

or te

mpe

ratu

res d

urin

g th

e te

st. T

he to

p lin

e is

the

hot z

one

of th

e re

acto

r. Th

e re

acto

r coo

ls q

uick

ly

any

time

the

syst

em tr

ansi

tions

to S

tand

by. E

ach

time

the

reac

tor t

empe

ratu

re d

ips i

n th

e pl

ot is

an

indi

catio

n th

at th

ere

was

CO

2 st

arva

tion.

188

Plot

24

-- S

EDU

sta

tus

024681012

1015

2025

3035

4045

5055

6065

7075

Tim

e, H

ours

Status

0510152025

Pressure (PSIA)

OG

A C

urre

nt/1

0CR

A R

eady

(11=

on 1

0=of

f)

SEDS

TAND

BY_S

tat I

ndic

ator

0=F

ALS

E 1=

TRUE

SEDP

ROCE

SS_S

tat I

ndic

ator

0=F

ALS

E 1=

TRUE

SEDP

002

CO2

inle

t pre

ssur

e PS

IA

This

cha

rt sh

ows t

he st

atus

of t

he S

abat

ier s

yste

m a

nd th

e C

O2

inle

t pre

ssur

e. C

O2

avai

labi

lity

and

OG

A re

ady

are

the

two

key

indi

cato

rs th

at d

eter

min

e if

the

Saba

tier c

an o

pera

te. T

his m

issi

on sc

enar

io h

ad O

GA

read

y al

l the

tim

e, th

eref

ore

the

CO

2 in

let

pres

sure

was

the

caus

e fo

r the

Sab

atie

r bei

ng u

nabl

e to

ope

rate

.

189

References

Reference Papers presented at the International Conference on Environmental Systems (ICES) Ref No.

Paper No. Title Authors

[1] 2006-01-2271

Integrated Test and Evaluation of a 4-Bed Molecular Sieve, Temperature Swing Adsorption Compressor, and Sabatier Engineering Development Unit

James C. Knox Melissa Campbell Lee A. Miller Lila Mulloth Mini Varghese Bernadette Luna

[2] 2006-01-2133

Modeling and Analyses of an Integrated Air Revitalization System of a 4-Bed Molecular Sieve Carbon Dioxide Removal System (CDRA), Mechanical Compressor Engineering Development Unit (EDU) and Sabatier Engineering Development Unit

Frank F. Jeng Melissa Campbell Sao-Dung Lu Fred Smith James Knox

[3] 2006-01-2126

Performance Characterization of a Temperature-Swing Adsorption Compressor Based on Integrated Tests with Carbon Dioxide Removal and Reduction Assemblies

Lila Mulloth Micha Rosen Mini Varghese Bernadette Luna Bruce Webbon James C. Knox

[4] 2005-01-2864

Integrated Test and Evaluation of a 4-Bed Molecular Sieve (4BMS) Carbon Dioxide Removal System (CDRA), Mechanical Compressor Engineering Development Unit (EDU), and Sabatier Engineering Development Unit (EDU)

James C. Knox Melissa Campbell Karen Murdoch Lee A. Miller Frank Jeng

[5] 2004-01-

2496 Analysis of the Integration of Carbon Dioxide Removal Assembly, Compressor, Accumulator and Sabatier Carbon Dioxide Reduction Assembly

Frank F. Jeng Sharon Lafuse,

Frederick D. Smith Sao-Dung Lu James C. Knox Melissa L. Campbell,

Timothy D. Scull Steve Green

[6] 2004-01-2375

Integrated Testing of a 4-Bed Molecular Sieve and a Temperature-Swing Adsorption Compressor for Closed-Loop Air Revitalization

James C. Knox Lila M. Mulloth David L. Affleck

190

[7] 2004-01-2444

Measurement of Trace Water Vapor in a Carbon Dioxide Removal Assembly Product Stream

Joda Wormhoudt Joanne H. Shorter J. Barry McManus David D. Nelson Mark S. Zahniser Andrew Freedman Melissa Campbell Clarence T. Change Frederick D. Smith

[8] 2004-01-2374

Air Cooled Design of a Temperature-Swing Adsorption Compressor for Closed-Loop Air Revitalization Systems

Lila M. Mulloth Dave L. Affleck Micha Rosen Martin D. LeVan Yuan Wang Celio L. Cavalcante

[9] 2003-01-2627

Development of a Temperature-Swing Adsorption Compressor for Carbon Dioxide

Lila M. Mulloth David L. Affleck

[10] 2000-xx-xxxx

A Solid State Compressor for Integration of CO2 Removal and Reduction Assemblies

Lila M. Mulloth John E. Finn

[11] 2005-01-2942

Long-Duration Testing of a Temperature-Swing Adsorption Compressor for Carbon Dioxide for Closed-Loop Air Revitalization Systems

Lila M. Mulloth Micha Rosen Mini Varghese

Non-ICES Papers

[12] JSC-62218 CTSD-ADV-546

Test Plan and Requirements for the Integrated Evaluation of the 4-Bed Molecular Sieve (4BMS), Mechanical Compressor Engineering Development Unit (EDU), and Sabatier Engineering Development Unit (EDU)

Melissa Campbell

[13] Test Plan And Requirements For The Integrated Evaluation Of The 4-Bed Molecular Sieve (4BMS), Temperature Swing Adsorption Compressor (TSAC), And Sabatier Engineering Development Unit (EDU)

Melissa Campbell

[14] International Space Station Trace Contaminant Injection Test, Revision A, NASA Test Requirements Document, January 1997

J. D. Tatara J. L. Perry

191

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Integrated Evaluation of Closed Loop Air Revitalization System Components

K. Murdock

George C. Marshall Space Flight Center, Marshall Space Flight Center, AL 35812

Wolf Engineering, LLC, 24 Gulf Road, Somers, CT 06071

National Aeronautics and Space AdministationWashington, DC 20546–0001

Unclassified-UnlimitedSubject Category 54Availability: NASA CASI (443–757–5802)

Prepared for the Exploration and Space Operation Programs and Projects Office, Science and Missions Systems OfficeCOTR: Monserrate C. Roman

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01/11/04 to 03/31/06Contractor Report

NASA/CR—2010–216451

Environmental Control and Life Support Technologies, Air Revitalization System, Closed Loop Air Revitalization System, 4-Bed Modular Sieve, Mechanical Compressor Engineering Development Unit, Temperature Swing Adsorption Compressor, Sabatier Engineering and Development Unit

01–11–2010

UU 200U U U

NASA’s vision and mission statements include an emphasis on human exploration of space, which requires environmental control and life support technologies. This Contractor Report (CR) describes the development and evaluation of an Air Revitalization System, modeling and simulation of the compo-nents, and integrated hardware testing with the goal of better understanding the inherent capabilities and limitations of this closed loop system. Major components integrated and tested included a 4-Bed Modular Sieve, Mechanical Compressor Engineering Development Unit, Temperature Swing Adsorption Compressor, and a Sabatier Engineering and Development Unit. The requisite methodolgy and technical results are contained in this CR.

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