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Produced by the NASA Center for Aerospace Information (CASI)
Eo33/R. A. Burns
NASA TECHNICAL
MEMORANDUM
NASA TM-82493
+ (b ASA-IM- dl ,4 y 3) VAitlABLE RELUCTANLe, NdJ-1UVlyVhullmlTY SENSURS t'UR CRWILNIC VALVLNUS11'lUN 1NJILAIlUn (NAJA) 50 PHL AJJ/nr AU1 LSC1. 1J1 UncldS
cJ/37 J54^03
VARIABLE RELUCTANCE PROXIMITY S-NSORS FOR
CRYOGENIC VALVE POSITION INDICATION
By R. A. CloydStructures and Propulsion Laboratory
rfj' ^^`T
July 1982 cv hq .^ ^Yy
L ^^^F1f,
NASA
Ge^^ro-e C. Marshall Space Flight Center
Marshall Space Flight Center, Alabama
WFC - Form 3190 (Rev ! r 1971)
1
1
E
TECHNICAL REPORT STANDARD TITLE PAGE1. REPORT NO, ^r
NASA TM-82893F757ERNPXNT ACCESSION NO 3, RECIPIENTS CATALOG N0.
4, TITLE AND SUBTITLE r
Variable Reluctance Proximity Sensors for CryogerAc5. REPORT DATE
July 1982Valve Position Indication s, PERFORMING ORGANIZATION CODE
7, AUTHOR(S) 8, PERFORMING ORGANIZATION REPAR F #
R. A. Cloyd9, PERFORMING ORGANIZATION NAME AND ADDRESS 10, WORK UNIT, NO.
George C. Marshall Space Flight Center RTOP: 985-15-3211. CONTRACT OR GRANT NO.Marshall Space Flight Center, Alabama 35812
13, TYPE OF REPORT & PERIOD COVERED12, SPONSORING AGENCY NAME AND ADDRESS
National Aeronautics and Space Administration Technical MemorandumWashington, D. C. 20546
14, SPONSORING AGENCY CODE
15, SUPPLEMENTARY NOTES
Prepared by Structuz ,es and Propulsion Laboratory, Science and Engineering
18, ABSTRACT
This test was conducted to determine the performance of a variable reluctanceproximity sensor system when installed in an External Tank ventlrelinf valve. The.sensors were used as position indicators. The valve and sensors were cycled througha series of thermal transients; while the valve was being opened and closed pneu-matically, the sensor's performance was being monitored. During these thermaltransients, the vent valve was cooled 10 times by liquid nitrogen: and 2 times byliquid hydrogen. It was concluded that the sensors were acceptable replacements Mfor the existing mechanical switches. However, the sensors need a mechanical over-ride for the target similar to what is presently used with the mechanical switches.This override could insure contact between sensor and target and eliminate anyproblems of actuation gap growth caused by thermal gradients.
17, KEY WORDS 18, DISTRIBUTION STATEMENT
Thermal shock testsThermal cycle tests Unclassified - UnlimitedProximity SensorsCryogenic Valves
19, SECURITY CLASSIF. (of this roportlUnclassified
20, SECURITY CLASSIF. (of this page)Unclassified
21, NO. OF PAGES50
22. PRICE
NTIS
=1 -
,MENE, ,
MSFC - Form 3292 ( May 1969)For sale by National Technical Information Service, Springfield, Virginia 22161
i
I
TABLE OIL CONTENTS
Page
I. INTRODUCTION ...................................................... 1
II. APPROACH ........................................................... 1
Iii. TEST PLAN FOR CRYOGENIC TESTING OF PROXIMITYPOSITION INDICATORS .............................................. 2
IV. TEST ARRANGEMENT ................................................ 3
A. Thermal Cycle Tests .............................................. 3B. Thermal Shock Test .............................................. 4
V. TEST DISCUSSION ................................................... 4
A. Thermal Cycle No. 1 ............................................. 4B. 'Thermal Cycle No. 2 ....... ..................................... 5C. Thermal Cycle Nos. 3 through 6 .................................. 5D. Thermal Cycle No. 7 ............................................ 5E. Thermal Cycle No. 8 ..... .... ................................... 6F. Thermal Cycle No. 9 ............................................. 6G. Thermal Cycle No. 10 ............................................ 6H. LH 2Thermal Cycle No. 1 ......................................... 6
I. LH 2Thermal Cycle No. 2 ......................................... 6
J. Thermal Shock Test .............................................. 6
VI. TEST GRAPHICS AND TEMPERATURE DATA... ....................... 7
VII. CONCLUSIONS AND RECOMMENDATION ............................... 7
BIBLIOGRAPHY ............................................................ 44
d.
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LIST OF ILLUSTRATIONS
Figure Title Page
1. External Tank vent/relief valve .................................... 8
2. Modified vent/relief valve with proximity sensors ................... 9
3. Proximity sensor mounting detail .................................... 10n
4. Specimen after thermal cycle test ................................... 11
5. Thermal cycle test schematic ....................................... 12
6. Test specimen a firing thermal cycle test ............................ 133
7. Specimen after thermal cycle test ................................... 14
8. Thermal shock test schematic .................... . .................. 15
9. Test specimen after thermal shock test ............................. 16
F
iv
n
FIST Or TABLES
Table Titles
Page
1. Thermal Cycle No. 1 Graph and Temperature Data .......I
i2. Thermal Cycle No. 2 Graph and Temperature Data ................... 20
3. Thermal Cycle No. 3 Graph and Temperature Data ................... 22Z
a 4. Thermal Cycle No. 4 Graph and Temperature Data ................... 24s
5. Thermal Cycle No. 5 Graph and Temperature Data ................... 26
6. Thermal Cycle No. 6 Graph and Temperature Data ................... 28i
7. Thermal Cycle No. 7 Graph and Temperature Data ................... 30i
8. Thermal Cycle No. 8 Graph and Temperature Data ................... 32
9. Thermal Cycle No. 9 Graph and Temperature Data ................... 34
10. Thermal Cycle No. 10 Graph and Temperature Data ................... 36
11. Liquid Hydrogen Thermal Cycle No. 1 Graph and Temperature Data .. 38
12. Liquid Hydrogen Thermal Cycle No. 2 Graph and Temperature Data .. 40
13. Thermal Shock Test Graph and Temperature Data .................... 42
.i
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v
I
TECHNICAL, MEMORANDUM
VARIABLE RELUCTANCE PROXIMITY SENSORS FORCRYOGENIC VALVE POSITION INDICATION
I. INTRODUCTION
The purpose of this test was to determine the feasibility of installing proximityindicators on the Shuttle External Tank vent and relief valves. Variable reluctanceproximity indicators are being considered for replacement of the mechanical positionswitches currently used in the vent valves. Mechanical switches have demonstratedvarious malfunctions during the Apollo program such as diaphragm cracks, oxidationof the contacts, internal mechanical fail?zre, and others.
The Eldec proximity indicator was selected because similar Eldec sensors arecurrently used in multiple Orbiter applications such as landing gear and payload baydoors. The Eldec sensors are also used in diverse applications on the B-1 bomberand other military and civilian aircraft. The latest generation of Eldec sensors hasalready been tested in cryogenics and successfully met all general requirements forcryogenic service. The intent of this test was to determine the performance reli-ability of the sensors when operationally installed in a vent and relief valve.
II. APPROACH
A spare External Tank vent and relief valve was acquired for a test bed (Fig.1) . The position indicators, their installation, and all associated functions areidentical to valvas currently being produced and flown on the External Tank. Theexisting Honeywell I HM 25 mechanical position indicator switches were remc ved andreplaced by Eldec SCD 8-020-10 proximity sensors (Digs. 2 through 4) . Targets forthe sensors were installed on each side of the valve's main piston (rig. 3) . Allmodifications were made by making as few changes to the original valve as possibleso that design and manufacturing impact would be minimized in the event the prox-imity sensors are adopted for use.
The vent valve was first cooled with liquid nitrogen to simulate conditions onthe liquid oxygen tank. Liquid nitrogen is slightly colder than the ullage normallyvented through the valve, but was used for safety reasons instead of liquid oxygen.Upon completion of the nitrogen testing, the valve was cooled with liquid hydrogento simulate conditions during venting of the liquid hydrogen fuel tank.
01
II1. TEST PLAN FOR CRYOGENIC TESTING OFPROXIMITY POSITION INDICATORS
OBJECTIVE: To verify the operation of position indicators in open and closedpositions under cryogenic conditions.
REQUIREMENTS:
1. Provide 115 V, 400 ti for GFE electronics.
2. Provide gaseous helium for valve actuation (N 125 psi operating pressure).Gaseous nitrogen may be used for the tests with liquid nitrogen.
3. Temperature to be maintained within limits specified.
4. Temperature readings obtained at each probe for each valve cycle.
5. Notation of indicator performance for each valve cycle.
G. If there is an indication that the proximity switch failed, verify that thevalve did in fact open or close.
f
7.l
Provide photographs of test setup.d
TEST PROCEDURE:
1. Test is to consist of a total of 12 thermal cycles, 10 cycles using LN2(temperature requirement of -300°F maximum) and 2 cycles using LH2(temperature requirement of - 400°F maximum) .
2, Each thermal cycle is to consist of the lowering of temperature fromambient.
3. 500 valve cycles are to be completed during each thermal cycle, brokendown as follows:
a. 50 valve cycles at ambient temperature fi
b. 50 valve cycles during the transitionM
c. 400 valve cycles at the cryogenic state.
4. Testing of the valve proximity sensor to include reducing the temperaturewith liquid nitrogen from ambient to approximately -300°F and monitoringthe probes and temperature during the test duration.
THERMAL SHOCK TEST
PURPOSE:
This test is being condheted to subject the proximity sensors to a rapid thermaltransient shock and to evaluate their performance during this period.
2
RE UIREMENTS :
The sensors shall be mounted in the vent valve specimen with the boost openpiston and cap and actuating piston removed.
A stationary target will be in place under both sensors. The target will be incontact with both sensor faces.
The >ansors shall be subjected to a thermal shock by purging with GN2-300°F directly on their sensing faces.
TE,MPF.RAT URE :,r
The Nos. 1, 2, and 3 thermocouples should be stabilized at their respectivelowest temperature and remain there for 1 min (ambient to approximately-300°F).
Monitor temperature and proximity sensor actuation signal during the test.
IV. TEST ARRANGEMENT
A. Thermal Cycle '.Pests
The test specimen, a modified vent and relief valve, MMC PIN PD4700187-029was mounted by its inlet to an aluminum plate and the y, an end cap placed over itsoutlet. The valve was instrumented with four thermocouples located as shown inFigure 2; there is a thermocouple on each sensor spacer and between the proximitysensors and another on the valve body. The temperature from the four thermo-couples were recorded every 15 sec for the duration of the tests. A liquid nitrogenor liq p aid hydrogen purge from the dewar was routed through the mounting plate andup near the proximity sensors. The liquid was vented down through the mountplate and carried a safe distance and then vented to the atmosphere (Figs. 5 through7) .
The proximity sensors were connected to the Eldec 8-242-09 SIN 4, 10 channelelectronics, which outputs either a target near or target far indication. This 10channel electronics package was modified by Eldec t:7 perform as the recommendedpackage would with these SC08-020-10 proximity sensors. The electronics packageused was a qualification test hardware specimen for another type of Eldec sensor forthe Space Shuttle and was modified as an economic consideration. The output indi-cation of the electronics package was recorded throughout the test by the oscillograph.
The helium supply, which operates the specimen valve, was manifolded to a125 psi regulator and routed through a solenoid valve to the helium inlet on thespecimen valve (Figs. 1 and 5). The solenoid valve was operated by an electrictimer which cycled the valve from the closed to the fully open position every 10 sec.The timer output was recorded by the oscillograph during the thermal cycle tests.There was a pressure transducer, coneected to the helium supply line close to thespecimen valve, which served as verification of proper helium pressure. The pressuretransducer's output was recorded by the oscillograph during the thermal cycle tests.
3
B. Thermal Shack Test
The thermal shock test setup was similar to the 'thermal cycle setup exceptthe main piston and pneumatic actuating piston were removed. Liquid nitrogen fromthe dewar was purged onto the proximity sensor faces through the new opening madeby the removal of the pneumatic actuator (Fig. 8).
A target rod was held in place along the centerline of the sensors by a large"C" clamp. This assured that the target was held fast against the sensors duringthe vigorous nitrogen purge of the sensor faces (Fig. J).
The temperatures from the four thermocouples were recorded as before, butwere recorded at 3-sec intervals. The oscillograph recorded only the proximitysensor performance during this test.
V. TEST DISCUSSION
A. Thermal Cycle No. 1
The following is a discussion of the first thermal cycle. Since it was typicalof the other 12 thermal cycles, they will not be discussed on an individual basis.Any anomalies which occurred in other thermal cycles will be discussed individually.
The test began by cycling the specimen valve open and closed 50 times usingpressurized helium. The proximity sensors were monitored for performance duringthe ambient temperature test. There were no sensor anomalies during the 50 cycleambient test.
The next phase of the thermal cycle test was 50 valve cycles (minimum) duringthe thermal transient condition from ambient to cryogenic temperatures. Duringinitial ehilldown the No. 2 sensor (nearest valve body, Fig. 2) did not operate forfour valve cycles and then began operating properly. The No. 2 sensor signalstopped at 32°F and began again at -77°F; performance throughout the rest of thetransient test was nominal.
The temporary loss of signal from sensor No. 2 was due to one of two reasonsor a combination of both. The first possibility is rapid localized cooling whichcreated a large thermal gradient and enlarged the gap between the sensor face andtarget ring on the main piston (Figs. 2 and 3) . The gap at ambient temperature is0.027, which is the recommended gap for this sensor in the slide by mode of opera-tion. To cause sensor failure, the gap would have to open up to approximately0. 054.
The second reason for loss of signal is a large thermal gradient in the prox-imity sensor itself which could cause the sensor to read target far when actuallythe target was near. Under normal o;)eration, there are two matched coils in thesensor, one in the sensing face and a reference coil further up in the sensor.When a ferromagnetic target is passed close to the sensor face, the electricalresistance of the coil at the face is lowered relative to the reference coil. Theassociated electronics monitor the resistance of both coils and give a target nearsignal when the balance between the two coils is disturbed. This design allows
4=I
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operation over a wide range of temperaturo because both coils would be affectedequally by surrounding environment, However, during this test the :face of thesensor was cooled very rapidly, and the rest of the sensor was somewhat thermally
r isolated due to the method of mounting with low thermal conductivity flourocarbonseals. This would cause the resistance in the sensing coil to rise and give a targetfor indication even though the target was actually under the sensor. Then, as thethermal gradient between the two coils decreased, the bridge would be out of balanceonce again and give the correct target near indication.
The next phase of the thermal cycle was 400 valve cycles at the cryogenictemperature state (lowest temperatures possible with the specimen valve using liquidnitrogen as the cryogen). During this portion of testing the temperature of thevalve and sensors were monitored and sensor performance was recorded. Duringcycle 345, the No. 1 sensor stopped working, the technician realized that theactuating helium pressure had dropped off from a nominal 125 to 90 psi. This wasnot enough pressure to allow the valve to travel to the fully open position and alignthe target under the No. 1 sensor, Another helium bottle was added into the mani-fold which raised the supply pressure to the required level and sensor No. 1Immediately began operating nominally.
13. Thermal Cycle No. 2
During the transient portion of thermal cycle No. 2, the thermal gradientproblem again caused a temporary loss of signal from proximity sensor No. 2 at theho[ginning^ of ehilldown, The sitpial loss was from 58.7 to 17.1 0F. The signalreturned and then dropped out again at 13.2°F and returned at -180°F. The sensorsoperated properly for the rest of the transient cycles and the 400 cryogenic cycles.There were no other irregularities during thermal cycle No. 2.
C. 'Thermal Cycle Nos. 3 through G
There were no anomalies during thermal cycle Nos. 3 through G,
D. Thermal Cycle No. 7
At initial chilldown, the No. 1 proximity sensor lost signal; the temperatureswere from 48 to -48 0r. This was the first and only time sensor No, 1 was apparentlyaffected by the thermal gradient situation. All other anomalies associated withsensor No, 1 have been due to low helium actuation pressure which was easilydetected by a very noticeable change in the pressure transducer curves on the stripcharts. However, in this case, the helium pressure was nominal so it was assumedthe anomaly was due to the thermal gradient situation.
Sensor No. 2 had a loss of signal during the transient cycles as did No. 1,which was due to the thermal gradient. The No. 2 sensor lost signal at 75 0E andreturned to service tit • 209°F.
During the 400 cryogenic cycles, the low helium actuation pressure situationoccurred again which resulted in the momentary loss of the No. 1 sensor. Theproblem v ,s quickly corrected and sensor No. 1 returned to service.
5
i:;
1 , Thermal Cycle No. 8
There were no anomalies during thermal cycle No. B.
F. Thermal Cycle No. 0
The No. 2 proximity sensor nVnin went out of service tit the beginning of thetransient portion of the test because of the gradient problem. The sensor failed tosignal Pit 40 OF and became operational again tit 4 1790F, Thcl,e were no other anomaliesduring this thermal cycle.
G. Thermal Cycle No. 10
There were
no anomalies during cycle No. 10.
fl. L11 2 'Thermal Cycle No, 1
The thermal cycle tests run with liquid hydrogen as the coolant were conductedusing the same procedure as the other thermal cycles; that is, 50 cycles at ambient,50 cycles during the transition from ambient to cryogenic, and 400 cycles at approxi-mately -400°F.
There were no sensor anomalies during LH 2 thermal cycle No. 1.
I. LI-I 2 Thermal Cycle No. 2
There were no proximity sensor anomalies during the 50 cycle ambient test.
Well into the transient cycles there was a loss of signal from sensor No. 1 dueto low helium actuation pressure, which was corrected. The signal was interruptedfor only one valve cycle tit a temperature of -257°F.
'There were no sensor anomalies during the 400 valve cycles tit the cryogenicte nil) ertittires.
J. Thermal Shock 'Pest
The Purpose of this test was to evaluate the performance of the arldec proximitysensors during » thermal shock. The arrangement of the test eli.sdnated the affectof irregular thermal contractions of the internal valve components that would increasethe sensor to target gap. The target wi s mounted directly on the face of bothsensors, thus eliminating the gap. Liquid nitrogen was rapidly purged on the sensorfaces. The sensors were monitored for output from ambient until the thermocoupleshad stabilized tit their lowest temperatures. The proximity sensors performedflawlessly during this test.
U
6
VI. ThS`J.' GRAPHICS AND TEMPERATURE, DATA
Tables 1 through L" are a compilation of thermocouple test data from all thermalcycles and the thermal shock test. The temperatures shown in these tables and theaccompanying graphs are in Fahrenheit degrees.
The graphs show data from thermocouples 1 and 2 which reflect each proximitysensor's temperature. The graph temperatures are shown in 5-min intervals. Thetemperature tables are correlated with the graphs by a T-0 indication. The tablesshow data from all four tliermoc'ouples (Fig. 2 gives locations). The temperatureswere given in l°rain intervals.
During; thermal cycles 1, 7, and LI1 2 thermal cycle 2 there was a loss of dosi.tion indication by the No. 1 proximity sensor due to low helium actuation pressure.This problem was discussed in detail in Section V. `1.'he signal interruptions causedby low helium pressure are not shown on the thermal cycle graphs because they werefacility problems and did not reflect sensor performance problems.
VII. CONCLUSIONS AND RECOMMENDATION
Throughout the duration of this test there were four cycle sequences - thermalcycles 1, 2, 7, and a - in which the proximity sensors did not function properly.However, in each instance, as the thermal cycle progressed the sensors regainedtheir ability to accurately identify the valve position. The anomalies are attributedto sz combination of two application design elements which did not place the sensorsin their optimum performance environment. The first contributing design elementwas the inability t• o control the gap between the sensor and target during rapidthermal transients. The second element is the small target size used for this test.Since the target was small, this enhanced the possibility of a thermal gradient betweenthe two sensor coils temporarily creating a false signal. These test bed designelements were driven by a desire to adapt the sensors to the External Tank vent andrelief valves with minimum impact.
It is concluded that the Eldec SC08-020-10 proximity sensor is an acceptablereplacement for the IIoneywell 1HM25 position indicator switch. however, the needfor an improved sensor mount became obvious because of the problems experiencedduring this test. Such an improvement would be a mechanical override that couldcontrol the actuation gap or insure contact between the sensor and target. Thiscontact and larger target worked flawlessly during the thermal shock test. Theoverride device could be similar in design to the existing switch actuation mechanisms,but would increase reliability because the sensor itself is inherently more reliablethan the mechanical switch.
For future use, the recommended mounting method world be to incorporate thesensor.- in the valve design either internally or in a sensing well. This could alloweven cooling of the sensor, and the head-on mode of operation could be employedrather than the slide-by mode. Head-on operation of the sensors allows a largeractuation gap. This integral design eliminates any mechanisms other than the valveparts themselves and employs the greatest advantage of the solid state proximitysensor.
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Figure 3. Proximity sensor mounting detail.
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16
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BIBLIOGRAPHY
Vaires , 11. B. : Technical Brief New Generation Two-Piece Voziable Reluctance Proxi-mity System. Doc. No. 74-708. Eldec Corporation, 1974.
See, E. C.: Position Indicators for Aerospace Components. Report No. MDC-60911.McDonnell Douglas Astronautics Corporation, May 1970.
Thomas, E. R.: Advancement of Position Indicator Technology Study Final Report.SD 72-SA-0191-2. Space Division North American Rockwell, 1,5 pec, 1972.
44
t
APPROVAL
VARIABLE RELUCTANCE PROXIMITY SENSORS FOR
CRYOGENIC VALVE POSITION INDICATION
By R. A. Cloyd
The information in this report has been reviewed for technical content. Reviewof any information concerning Department of Defense or nuclear energy activities orprograms has been made by the MSFC Security Classification Officer. This report,in its entirety, has been determined to be unclassified.
a^rH. M. SMYLYChief, Mechanical Systems Development Branch
C. D. LAMBChief, Mechanical Division
Vl' CA. A. McCOOLDirector, Structures and Propulsion Laboratory
*U.S. GOVERNMENT PRINTING OFFICE: 1982-546 .071/57 45
