CIRA-UM-04-008 CIRA PWT USER MANUAL
Contents
1. Experimental Hall as shown in Fig 3 CIRA UM 04 008 CIRA PWT USER MANUAL TEST HALL AREA PWT ENTRANCE Fig 3 Experimental Hall floor The facility can use various Conical Nozzles for different test conditions These interchangeable components are stored inside a parking area into the Experimental Hall A Hoist System for handling of heavy bodies as nozzles sections models supports etc is fixed to the building ceiling The main building has the function to host the operating team the users offices and the facility control system room The control room is located on the first floor where the Experimental Hall can be viewed through a large window The control room equipment see fig 4 includes the video camera monitors the video recording facility operator console s and the engineering and data acquisition systems that provide complete information about the test and model conditions Page 3 of 23 CIRA UM 04 008 CIRA PWT USER MANUAL 4 1 SCIROCCO PLASMA WIND TUNNEL aero thermodynamic perfor mances Th2. Ena DEPARTMENT DIPARTIMENTO LMSS NO OFPAGES N PAGINE PROJECT PROGETTO ARCHIVE POSITION ARCHIVIO POSIZIONE okk CIRA UM 04 008 CIRA PWT USER MANUAL JOB COMMESSA 30 9024 0000 FILE NAME PWT UM DOC DISTRIBUTION STATEMENT NATURA DOCUMENTO SOFTWARE MICROSOFT WORD 2000 TITLE TITOLO CIRA PWT USER MANUAL PREPARED REVIEWED APPROVED AUTHORIZED PREPARATO VERIFICATO APPROVATO AUTORIZZATO EDITOR C Purpura F De Filippis S Caristia S Caristia E E Trifoni Craps A Pani A Del Vecchio SZ DATE DATA DATE DATA DATE DATA DATE DATA BY THE TERMS OF THE LAW IN FORCE ON COPYRIGHT THE REPRODUCTION DISTRIBUTION OR USE OF THIS DOCUMENT WITHOUT SPECIFIC WRITTEN AUTHORIZATION IS STRICTLY FORBIDDEN A NORMA DELLE VIGENTI LEGGI SUI DIRITTI DI AUTORE QUESTO DOCUMENTO E DI PROPRIETA CIRA E NON POTRA ESSERE UTILIZZATO RIPRODOTTO O COMUNICATO A TERZI SENZA AUTORIZZAZIONE CIRA CIRA UM 04 008 CIRA PWT USER MANUAL AUTHORS C PURPURA CIRA PWT USER MANUAL ABSTRACT The present document describes the characteristics and the procedures of the new CIRA Plasma Wind Tunnel SCIROCCO The PWT performance and the main dimension are described The PWT auxiliary systems have been described with their mechanical interfaces The time schedule requirements and the support requirement have been also outlined in order to give a guideline to PWT test organization a
3. ISSUES o cooncccccoccononcconanoconanonananonananonananonannrcnnanrrnnanenanana 15 12 CIRA SITE LOGISTIC cia da dd 15 13 PWT TEST REQUEST PROCEDURE ccscccssseccnssesensseeeesseeeseeensseeenssesenees 15 14 CONTACT POINT WE 16 Ee tee EE E eebe 16 Page 1 of 23 Kna 1 0 INTRODUCTION CIRA the Italian Aerospace Research Centre has recently built a 70 MW Plasma Wind Tunnel arc jet kind named SCIROCCO The facility primary mission is to simulate the thermo fluid dynamic conditions on Thermal Protection System of space vehicles re entering the earth atmosphere on models in scale 1 1 The CIRA Plasma Wind Tunnel PWT SCIROCCO is a high enthalpy hypersonic wind tunnel at the boundaries of state of art technology This document describes the wind tunnel technical characteristics and performances its instrumentation and the typical operative procedures The facility is located in Capua CE Italy about 50 km north of Naples The Plasma Wind Tunnel is part of a grand new complex which includes ground testing facilities and dedicated service utilities making up the Italian Aerospace Research Centre The picture in Fig 1 shows an aerial view of the facility e Ka 2 0 LIST OF ACRONYMS AC Alternate Current CPA Calibration Probe Arms DAS Data Acquisition System DDM Detailed Dynamc Model DeNOx Nitrogen Oxides abatement ENEL National Electrical Energy Agency ESA European Space Agency ESP Pressure Scanner Me
4. air washing phase starts with cold dry process air that continues to be supplied to the Arc Heater after the end of the test and continues with atmospheric air that is sucked CIRA UM 04 008 CIRA PWT USER MANUAL Fig 7 Test Chamber 6 0 ARC HEATER AND NOZZLE SYSTEMS The arc heater is located in the Test Hall between the Compressed Air System and the Conical Nozzle The arc heater is shown in fig 8 through 10 and it is the generator of high temperature air Plasma necessary to simulate aerothermal flight condition of re entry vehicles The increase of temperature 10000 K of the incoming process air takes place through the transformation of electric energy into thermal and kinetic energy by means of an electric arc discharge between the electrodes The gas after being heated in the arc heater is accelerated through the nozzle where the gas thermal energy is converted in kinetic energy The arc heater has been designed in according to the following process data in by the fan MIN MAX After few minutes from the beginning of the air washing phase a fan is activated A small Air pressure Bar 1 0 16 7 mass flow of internal Test Chamber air is sent Air mass flow rate Kg sec 0 1 3 5 to an analyser to measure the content of 02 03 and H only when the level of the monitored Plasma enthalpy MJ kg 2 5 45 0 gases is under the prescribed limits the Electric power MW 1 0 70 0 managing LCU2 ends the washing operation D
5. proven testing capability is 1run day 3runs week on a 8 hour single shift although 2runs day rates have been also performed Several on site activities are required to accomplish the tests on Customers Test Articles TA TA incoming inspection TA instrumentation and mechanical interfacing on facility Model Support System MSS TA installation checks test s execution post test TA inspection The two latter tasks are repeated in case of a test campaign on a single TA At the end of the testing activities the TA is dismounted and disconnected from the MSS Two separate Model Preparation Area are available to allow Customer s activities on TA before and after the test or test campaign execution CIRA UM 04 008 CIRA PWT USER MANUAL The time required for the TA installation and checks depends on its instrumetation complexity meaning both sensors number and types For a not instrumented model 4 hour is typical while for a heavely instrumented model 3 days could be required For the dismounting phase a mean time 1 day is typical If required pyrometers and or thermocamera setting and pointing activities follow the TA installation phase This task takes one additional work day typ All the above tasks are performed by LMSS technicians on the basis of Customer official Test Article installaltion data with Customer on site Engineer assistance The test execution is comprehensive of three phases facililty sta
6. the model is directly installed inside the Test Chamber on the MSS by means of the required performances to the facility for Nose Configuration and Leading edge Configuration dedicated interface 4 0 TUNNEL OPERATION REQUIREMENTS nose configuration Nominal Extreme Safety trajectory trajectory trajectory 10 75 10 75 75 175 mbar mbar mbar The hypersonic plasma jet usable for the PWT test achieves Mach numbers depending on the Conical Nozzle exit diameter Four nozzle configurations are available corresponding to Mach flow values of about 5 1 6 2 8 3 11 5 respectively Some deviations from the mentioned values can be observed during a test due to the variations of the air chemical composition of the exiting jet The Reynolds number per meter is shown to vary from 10 000 to 160 000 while the flow velocity varies from 2000 to 6000 m s independent from the used nozzle as predicted from the hypersonic theory C Ee tim 25 minutes 25 minutes 5 minutes Page 4 of 23 Ena REQUIREMENTS leading edge Nominal Extreme Safety trajectory trajectory _ trajectory 5 25 15 100 mbar mbar 1000 1250 1200 1400 1300 1600 C C C 25 minutes 25 minutes 5 minutes The above requirements have been translated in terms of pressure and heat flux at stagnation point for both Nose and Leading edge configuration This conversion has been carried out under the hypothesis of a model in Test Chamber of fully ca
7. 04 008 CIRA PWT USER MANUAL 12 CIRA SITE LOGISTIC CIRA is located in Capua a small city near Naples and Caserta located at about 200 kilometers south of Rome and about 50 Kilometers North of Naples Customers can arrange their trip to CIRA with a flight either to Rome Fiumicino Airport or to Naples Capodichino Airport 13 PWT TEST REQUEST PROCEDURE The hereinafter description will be focussed on technical aspects only All the contractual activities steps definitions and timings relevant to the request to test at PWT SCIROCCO facility will not be adressed The TPS testing is divided in three main phases typically a materials identification testing and selection b realization and test of a preliminary dummy model rated 1 N respect the real object c realization and test of the final model rated 1 N respect the real object The Scirocco PWT can be used for testing in all the above three phases although for phase a a small arc jet facility is more suitable The typical path that drives to the test campaign completion relevant to above phase b or c is as follows During a meeting Customer and PWT Engineers discuss about the test campaign objectives the device to test the test conditions and measurement requirements Then PWT Engineers verify the feasibility of the test campaign on the basis of the given test condition Model geometry shape and dimensions and measurements requirements Followin
8. 50 mbar e Thermocouples Function Tech Description e Pyrometers Function Tech Description to measure the distribution of the temperature on the model surfaces Set of thermocouples type B max 40 and K max 60 for a maximum of 100 real time acquisition points measurement range of 0 1750 C to measure the temperature on the model surfaces Spot measurement two single colour and two dual wave instruments real time acquisition ranges of 400 800 600 1000 700 1400 and 1000 3000 C e Thermograph systems Function Tech Description to quantitatively map the temperature distribution on the model surfaces Two infrared scanners no real time acquisition spectral range of 8 12 um Page 13 of 23 Ka Flow properties along the Test Leg instruments e Static pressure measurement system Function to measure the static pressure in various points of the test leg 1 Plenum Chamber 2 Conical nozzle exit 3 Test Chamber 4 Diffuser Tech Absolute pressure transducers Description real time acquisition 1 Two transducers range 0 5 5 and 0 22 bar 2 Two set of four transducers range 0 2 or 0 10 mbar 3 Two set of four transducers range 0 2 or 0 10 mbar 4 Sixteen transducers 8 of range 0 10 mbar and 8 of 0 100 mbar 10 TEST GENERAL ARRANGEMENT The Scirocco PWT facility have been designed for a 3runs day 10runs week 250runs year maximum test rate The currently
9. 72 CIRA entrance desk 39 0823 623001 15 REFERENCES 1 Caristia S De Filippis F Del Vecchio A Graps E Scirocco PWT Facility for high temperature material assembly testing Proceedings of the 54th International Astronautical Congress September 29 October 3 2003 Bremen Germany Page 16 of 23 CIRAN CIRA UM 04 008 CIRA PWT USER MANUAL 2 De Filippis F Caristia S Del Vecchio A Purpura C The Scirocco PWT facility calibration activities Proceedings of the a International Symposium on Atmospheric re entry vehicles and systems Arcachon F 24 27 March 2003 3 Caristia S De Filippis F Del Vecchio A Purpura C Scirocco final tests measured data comparison between theory and experiments Proceedings AN European Symposium on Aerothermodynamic for Space Applications 15 18 Oct 2001 capua Italy ESA SP 487 March 2002 4 Caristia S De Filippis F Del Vecchio A Scirocco facility qualification phase Proceedings of the 2 International Symposium on Atmospheric re entry vehicles and systems Arcachon F 26 29 March 2001 5 Caristia S De Filippis F Del Vecchio A Scirocco project start up phase 51 International Astronautical Congress Rio de Janeiro Brazil 2 6 Oct 2000 Page 17 of 23
10. Supply distributes dry air to the various segments of the arc heater column It is able to supply a flow range from 0 1 to 3 5 kg s with a total pressure range from 1 to 17 bar The Arc Page 2 of 23 Esa Heater column is cooled by circulation of demineralised water Fig 2 Facility schema The compressed air injected into the arc heater is heated up to 10000 K of temperature and flows through a convergent divergent Conical Nozzle increasing the velocity in the Mach range 6 12 The jet exiting from the nozzle is confined into a Test Chamber where interacts with the test article Then it is collected in a long Diffuser 50 m and cooled by an Heat Exchanger The test article is installed on the Model Support System MSS The last sub system of the Scirocco facility is the Vacuum System It generates the vacuum conditions required by each test The system consists of ejectors that make use of high pressure water steam as motor fluid 30 bar and 250 C Before ejection into the atmosphere the process fluid is scrubbed by chemicals in a subsystem called DeNOx System to eliminate the Nitrogen Oxides The Test Chamber is located into an area
11. an be executed e Simplified Dynamic Model SDM e Detailed Dynamic Model DDM e Real Time Simulator RTS The first 2 SW packages SDM and DDM can be used for the definition of the test parameters to be used in next test campaigns while the RTS is aimed to allow the functional validation of Automated Test Procedures before their actual execution on the SCAS SCAS Simulator SCAS SIM interfaced to the RTS for the execution of real time test simulations Peripherals and LAN items Data Acquisition System DAS The Data Acquisition System encompasses all the HW and SW equipment needed to acquire real time measurement data from the Test Instrumentation and field devices store them for further post processing and in case of LBDS transmit them in real time to HLAS to allow the control of the PWT at level 3 The HLAS can be further divided in Low Bandwidth Data Acquisition System High Bandwidth Data Acquisition System Low bandwidth data acquisition system The LBDS system shall be composed by two main items connected via TCP IP LAN Page 11 of 23 Kna 1 LBDS Workstation LBDS WS in charge to perform the following functions interface with the Operator for stand alone operations interface with the File Server for I O Configuration Tables loading and test data archiving interface with the Automation Computer for commands acquisition and events emission interface with the Au
12. asurement System FEE Front End Equipment FS File Server CIRA UM 04 008 CIRA PWT USER MANUAL GWS Report Generation Workstation HBDS High Band Data System HLAS High Level Automation System II Maximum Enthalpy unin Minimum Enthalpy I Current ST Maximum Current LMSS Space Instruments and Facilities laboratory LBDS Low Band Data System LCU Local Control Unit MCC Motor Control Center Max Maximum Flowrate MSDS Model safety and Failure Mode Analysis MSS Model Support System OWS Operator Workstation Dain Minimum Pressure Prat Maximum Power PWT Plasma Wind Tunnel RWS Requester WorkStation RTS Real Time Simulator SCAS Supervisory Controls and Automation System SDM Simplified Dynamic model SDESIM Development System for Simulator SMSA Safety Management Sub Assembly TA Test Article TEWB Test Engineer s Work Bench TAL Test Automation Language TC Test Chamber UPS Uninterruptable Power Supply V Voltage 3 0 FACILITY DESCRIPTION The PWT facility lay out is shown in Fig 2 The heart of the facility is the segmented constricted Are Heater a column with a maximum length of 5 5 m and a bore diameter of 0 11 m At the ends of this column there are the electrodes cathode and anode which generates the electrical arc The Power Supply gives the voltage at the electrodes for the generation of the discharge it is able to support direct current up to 9000 A and a total power up to 70 MW A Compressed Air
13. data are used as experimental test results An independent supervisor system verifies that the all parameters of the facility operating conditions are within their safety ranges and each subsystem is properly operating HLAS OWS E Was ous HLAS RWS server ES Ewe SCAS SIM HLAS i AIS Mngm Link a HLAS Mi LA a S rocess Control Lini ESP rcu cus t Picus rend T Dag EI E ER EI LU e J el UU JUL A Gd gert gen Gs H d E ER ER a e A me Ha Ma e a REE PLASMA HEAT EX ZE SS TBE SET e Je E E posmo E A A Ea HODELSUFPORT gt TEST GRAMBER SS LE _TEST CHAMBER 3 Se SE eree ST CONVENTIONAL SST Se TEST INSTR VIRTUAL TEST INSTR PWT SUBSYSTEM Fig 15 Automation System scheme Page 10 of 23 Esa The building blocks of the PWT Automation and Instrumentation Systems are High level automation system The High Level Automation System encompasses all the computing and display resources needed to perform the control of t
14. de acquisition available ranges of 0 500 0 1000 and 0 3000 kW m Interchangeable absolute pressure transducer on stagnation point real time mode acquisition available ranges of 0 35 0 86 0 220 mbar Interchangeable differential pressure scanner transducer non real time mode acquisition ESP with seven ports available ranges of 0 25 0 70 and 0 350 mbar e Pressure probes Function Tech Description to measure the pressure at the test model stagnation point and the pressure profile in the transversal flow direction Interchangeable absolute pressure transducer real time mode acquisition available ranges of 0 8 6 0 35 0 86 0 140 and 0 220 mbar e Spectroscopic system Function Tech Description to characterise the chemical physical properties of the flow free stream and shock layer Fully computer controlled system non real time acquisition spectral range 190 1200 nm wave length scan rate 45 nm sec CCD detector 2000x800 pixels CIRA UM 04 008 CIRA PWT USER MANUAL Thermodynamic properties on the model surface instruments e Pressure Scanner Measurement System ESP Function Tech Description to measure the distribution of the pressure on the model surface Fully integrated system of interchangeable differential pressure scanner transducers ESP non real time mode acquisition up to 200 measurement points available ranges of 0 25 0 70 and 0 3
15. e Scirocco PWT facility has been realized to simulate pressure and temperature to which earth atmosphere re entering space vehicles are exposed The requirements for Scirocco have been specified by ESA in terms of pressure and temperature on the test model stagnation point Based on the requirements two nominal sample configurations are defined CONTROL ROOM D emp tamil we a HE TEST HALL AREA e Nose configuration hemisphere with radius Ta of 300 or 240 mm and overall dimensions size of 600x600x600 mm e Leading edge configuration two dimensional hemicylinder with variable radius and curvature radius at stagnation point of 100 mm Overall dimensions size of 600x600x600 mm CUSTOMER OFFICE Sl gt Fig 4 Control room floor A dedicated large area is also available for working on the Arc Heater components Maintenance Hall Three workshop room are located near the Maintenance Hall for Instrumentation and Model preparation Before a specific test the selected Conical Nozzle configuration is installed between the The required stagnation point pressure and temperature are relative to three possible re entry trajectories named nominal extreme and safety They respectively represent a normal a extreme and an emergency trajectory re entry In the following tables there is a synthesis of Are Heater and Test Chamber Then
16. ecifications approved by CIRA The design material and instrumentation definition shall be completed 6 months typ before beginning of the test activity Meeting between Customer and PWT Engineers are held to define the tests details At the end of this phase are fixed Test Plan Instrumentation requirements specification Test Article installation procedures on PWT model support system Data collection and data elaboration if required Facility main configuration CIRA UM 04 008 CIRA PWT USER MANUAL One month before the tests PWT Engineers define the details of the Facility configuration for the Test campaign including auxiliaries requests Detailed schedule is issued reporting meetings runs gallery activities inspections and so on The Test Article arrival on site is requested one week before the begin of the installation activities to accomplish the incoming inspection and formal trasportation to the PWT Customer Model Preparation Area At arrival the Customer Personnel is informed on the procedure to follow when staying at PWT plant 14 CONTACT POINT The CIRA mail address is CIRA scpa Via Maiorise s n c 81043 Capua CE ITALY The CIRA responsible for Space Ground Test Facilities is Ing Sebastiano Caristia Phone 39 0823 623921 Fax 39 0823 633947 E mail s caristia cira it Phone 39 0823 623400 Assistant CIRA telephone operator number is 39 0823 623111 Fax 39 0823 9692
17. er The system has been designed in agreement with the following process requirements TEST CHAMBER CHARACTERISTICS Shape Cylindrical Vertical Overall Size height 9217 mm inner diameter 5170 mm Material Steel Fe 510 The list of the most important equipment is hereinafter reported Page 6 of 23 Esa 1 Openings to allow access for personnel to enter the model and for maintenance 2 Windows to allow the plasma flow monitoring 3 Retractable floor two sections 4 System to inject process air bleed air system 5 Air flow system In the Test Chamber some systems are foreseen to allow the correct model positioning in the plasma flow MSS to measure the plasma characteristics Calibration Probes and to facilitate the maintenance operations on the Model Retractable Floor During the PWT operative phase the plasma flow after having impacted the model is driven toward the Diffuser pick up section In the case of particular test conditions it is foreseen the possibility to inject in the Test Chamber a small process air stream through the bleed air system in order to increase the static pressure in the test chamber and facilitate the flow driving in the pick up section of the Diffuser in order to have a less severe Vacuum System operations After each test before allowing personnel access re pressurization air washing operations and internal air characterisation are performed The system
18. g technical discussion Customer issues the agreed test matrix as well as the Test Article characteristics instrumentation and data analysis requirements Page 15 of 23 Ka Preliminary Facility availability for the test campaign and relevant preliminary schedule are fixed at least 6 months before the beginning of tests All the necessary information are sent to the Customer in order to properly interface the Test Article with PWT Model Support System mechanical instrumentation cooling electrical interfaces are reported in a dedicated document as well as Test Article requirements in terms of maximum dimensions and weights This is typically accomplished 6 months before the tests The Customer shall issue the Test Article MSDS and a Model Safety and Faiulure Mode Analysis documents the former required for the CIRA Personnel health and safety precautions the latter to assure that the Model will not damage the Facility nor injury the CIRA Personnel Furthermore the Model design documentation shall be submitted to CIRA for approval The above is normally completed 3 months before the tests As an option the Test Article realization including holder and instrumentation can be done by PWT team if required In this case the Customer shall supply all the necessary design documents and specifications The materials can be selected and provided by Customer or by CIRA the latter case on the basis of Customer detailed sp
19. he PWT at level 3 i e test conduction control of the overall facility exploiting data acquired by Test Instrumentation via DAS to fix operating parameters of the Control System LCU The HLAS includes the computers workstations equipments following Supervisory Control and Automation System SCAS on which are executed the Automated Test Procedures File Server FS which acts as a general repository of all the HLAS data including e data prepared by the Test Engineers using the TEWB e data acquired by the LBDS Test Engineer s WorkBench TEWB a SW development environment to allow the preparation of the Automated Test Procedures written in Test Automation Language TAL and of the I O Tables for a specific test session HLAS Operator Workstation OWS which is the main MMI of the system and allows both to examine in real time a selected subset of the acquired data and to issue automation control commands for the test conduction HLAS Requester Workstation RWS allowing to examine in real time a selected subset of the acquired data but without the possibility to issue automation control commands customer W S HLAS Report Generation Workstation GWS dedicated to the post processing of the data acquired in real time during a test execution session CIRA UM 04 008 CIRA PWT USER MANUAL SW Development System for Simulator SDESIM on which the following main SW packages c
20. he Conical Nozzle System is to expand the plasma flow coming from Arc Heater for increasing its speed and simulate into PWT facility the requested thermo fluidodynamic conditions Four conical nozzles are available all of them have the same throat and seven different Page 8 of 23 Ena expansion sections are connected in such a way to return the required nozzle This system has been designed in agreement with the process requirements at the component battery limits PROCESS min max REQUIREMENTS Air mass flow kg sec 0 1 35 Enthalpy air content inlet 2 5 45 0 MJ kg Air pressure bar inlet 1 0 16 7 Air pressure mbar outlet 0 01 29 Air speed m s inlet 120 350 outlet 2000 7000 The combination of the operative conditions as above reported permits to obtain on the test model surface the required conditions in terms of Heat Flux from 125 to 1035 KW m and Stagnation Pressure from 5 to 175 mbar On the device instruments for monitoring are installed Measurement of plasma pressure corresponding to nozzle exit has been foreseen Fig 12 Conical nozzle mounted into Test Chamber 1150 mm exit diameter configuration CIRA UM 04 008 CIRA PWT USER MANUAL 7 0 TEST EQUIPMENTS 7 1 MODEL MSS SUPPORT SYSTEM The model to test is interfaced to an automated cooled arm fig 13 the Model Support System MSS aS Fig Model Support System The model mechanical interface with MSS ge
21. irect current Ampere 1000 0 9000 0 and allows the personnel access in the system Voltage Volt 1000 0 30000 0 Page 7 of 23 Fig 8 Arc Heater components Heater Fig 10 Typical segment pack It is necessary to point out that the ignition of the arc heater is with the injection of argon only Moreover the combination of argon air gas injection and magnetic rotational force generated by the current flow into the magnetic CIRA UM 04 008 CIRA PWT USER MANUAL coils helps to position the arc on the electrode surface rapidly and thanks to an electromagnetic mechanism the interaction point between the electrode surface and the arc foot moves continuously minimising copper erosion and extending electrode lifetime 3 Plenum section The plenum chamber fig 11 constitutes the connection piece between the arc heater and the conical nozzle The plenum function is to reduce the process air total enthalpy through cold air injection Fig 11 Plenum chamber and nozzle throat The following instrumentation is foreseen for monitoring and controlling the arc heater operation e Current measurement on each power cable connected to the arc electrode rings e Measurement of the voltage fluctuations generated between the anode and the cathode main power supply cables e Voltage measurement among some arc heater column rings e Plenum chamber pressure measurement Aim of t
22. kage around the model is foreseen The following table summarizes the allowable configurations nozzle model Nozzle exit Area Configur Model diameter ratio radius KEE mm mm 900 144 Nose 240 1150 196 Nose 240 1150 196 Nose 300 1150 196 Lead edge 100 1350 256 Nose 240 1350 256 Nose 300 1350 256 Lead edge 100 1950 400 Nose 240 1950 400 Nose 300 1950 400 Lead edge 100 Fig 6 represents the design maps of Stagnation point Pressure vs Heat Flux of Scirocco PWT facility CIRA UM 04 008 CIRA PWT USER MANUAL m EXPLORED REGION PREDICTED PERFORMANCES Stagnation Heat Flux kW m gt 3 1 10 100 1000 Stagnation Pressure mbar Fig 6 Performance map of Scirocco in terms of Pressure and Heat Flux at Stagnation Point on the model The facility calibration is in progress Actual results indicate coherence between experiments and predictions 5 0 TEST CHAMBER DETAILS The Test Chamber fig 7 is a cylindrical vessel where the model to be tested is placed together with the relevant moving system Model Support System In the Test Chamber the model is impacted by the plasma flow coming from the Conical Nozzle reaching the temperature and pressure conditions able to simulate the thermo fluidynamic conditions acting on the protection shield of space vehicles during the atmosphere re entry The exit of the Test Chamber is connected through a mating flange to the Pick Up of the Diffus
23. nd facility reservation Furthermore the CIRA location and nearest lodging options have been presented KEYWORDS Plasma Wind Tunnel Arc jet Hypersonic Experimental Instrumentation According to the italian law n 15 of January 4 1968 and successively revised on July 6 1997 the undersigning certifies the present copy to be true to the original which remains at your disposal for inspection Place Capua CE ITALY Company stamp CIRA S c p A Date Signature First name Last name Position II CIRAN CIRA UM 04 008 CIRA PWT USER MANUAL REVISION LIST LISTA DELLE REVISIONI DESCRIPTION DATE EDITOR M CIRAN CIRA UM 04 008 CIRA PWT USER MANUAL SUMMARY TO INTRODUCTION consi nnna 2 2 0 LIST OF ACRONYM Sion 2 3 0 FACILITY DESCRIPTION niciaininicalsacanca lali 2 4 0 TUNNEL OPERATION aran c 4 4 1 SCIROCCO PLASMAWIND TUNNEL AERO THERMOFLUIDODYNAMIC PERFORMANCES 4 5 0 TEST CHAMBER DETAILS 0 ccoccccccnnncconanoconanocananonananonanancnanarcnanar conan rronanrrananenan 6 6 0 ARC HEATER AND NOZZLE SYSTEMS ccsccccssscccnssecenssscenssseensesensesennseses 7 7 0 TEST EQUIP MEIN ES osito 9 7 1 MODEL SUPPORT SYSTEM Ms 9 7 2 CALIBRATION PROBE ARMS CPA occoccccccconononononononononononononononononononononononononononononos 10 8 AUTOMATION SYSTEM naci 10 SIS TRUMENTA TION scr a 12 10 TEST GENERAL ARRANGEMENT cccsseccssseecnsseeccsseeesseeeseeeessseensesenees 14 11 PERSONNEL SAFETY
24. nerally realized by the customer is through a plane flange d 304 mm with eight M12 plane holes at d 240 mm the corresponding flange on MSS side fig 14 is provided of two reference pin holes for clocking purpose Fig 14 MSS Interface flange Maximum overall model weight including instrumentations and cables is 1650 N center of gravity lying on MSS flange center line Page 9 of 23 Ka Maximum overall model length in plasma direction i e between the stagnation point and the MSS interface plane is 1010 mm Before the test the model is located under the Test Chamber floor level The MSS flange center line is 1650 mm far from plasma center line During the test the model is injected vertically in the plasma flow once achieved the plasma center line the model can be moved horizontally up to 750 mm downstream respect to the plasma flow and pitched 20 around a center of curvature 1010 mm upstream MSS interface plane During the motion the model is subject to the following maximum kinematic conditions Speed Acceleration Horizontal 02 ms 19 ma During the test the expected aerodynamic loads on the model must not exceed the following values 0N Lif 800 N ift Lateral 533N A maximum of 160 pressure channels and 100 temperature channels for the model are available at MSS interface A cooling system for the model is available at MSS interface providing a maximum demi water flo
25. oted separately 11 PERSONNEL SAFETY ISSUES Hazards Safety is first and foremost in the operation of PWT facility The plasma arc heater is especially sensitive to proper and prudent safety procedures The main risks are lethal voltage high pressure gas high pressure water high temperature noise mechanical hazards Detailed indications are positioned in each critical area nevertheless PWT users are not allowed to operate any plant components During pre run briefing the potential hazard is shown and discussed PWT users are also informed about safety procedures before the test program start This facility may pose serious hazards if strict adherence to all operating instructions and safety guidelines are not maintained Failure to comply may result in serious injury or death The facility must never be operated in presence of personnel in the test hall Protective Equipments Hardhat eyes and ears protection are available in the PWT Maintenance Hall Other personal equipment needed for model workshop activities are not provided by CIRA The PWT user has his own personal protection devices such as working gloves shoes to be used for model mounting and assembly in the model preparation area Emergency Procedures The CIRA emergency procedure is illustrated to the PWT users If required all people present in the PWT area follow the instructions given by the CIRA Team Safety Responsible CIRA UM
26. rt up 3 hour typ experiment conduction can be repeated several times facility shut down to safe condition 2 hour typ Customer on site Engineer is allowed to stay in the Control Room during the experiment conduction phase only i e when the TA is injected into the plasma After each test data are collected and stored on the Data Acquisition System File Server Then the most important facility and model rough data are printed for first evaluations Official test report is issued within 30 working days after the test campaign conclusion The format is both on paper and electronic format CDROM Three types of meeting are foreseen between LMSS and Customer s Team during the on site activities a a preparation meeting b one or more intermediate meeting c a test campaign conclusion meeting Typically LMSS supplies the Customer all the necessary information to interface the Test Article to the facility both mechanical and instrumental interface On request the LMSS Team can size and supply the Model Holder and mount it on the Test Article The time required depends on the test condition TA structure and instrumentation Typical time is 3 months Page 14 of 23 Kna The PWT is charged on the occupancy time plus number of tests basis regardless the test condition s to be achieved Model installation activities are considered within the occupancy time All the engineering and or service activities are qu
27. st Chamber e the thermodynamic properties on the model surface e the flow properties along the Test Leg in terms of temperature pressure heat flux and chemical composition CIRA test engineers are available for support and data interpretation Nevertheless customers are free to operate within their individual agreement with CIRA their own instrumentation To perform these measurements real time i e directly managed by the Data Acquisition System and non real time i e fully independent measurement system instruments are foreseen There are also some instruments able to follow the dynamic re entry trajectory simulations that Scirocco PWT would be able to realize All the instruments positioned outside the Test Chamber near the optical accesses are mounted on remote controlled positioners able to follow the model displacements along the flow axis and to focus the measurement region on the model surface Two video cameras are available They monitor the phenomena into Test Chamber during all the test phases In the following a detailed functional and technical description of the various instruments is given Page 12 of 23 Ena Flow properties in Test Chamber instruments e Calorimetric probes Function Tech Description to measure the heat flux and pressure distribution of the of the plasma jet on the surface of an hemisphere 100 mm diameter Gardon gauge calorimeters real time mo
28. talytic material with thermal conductivity of 7 W m K surface emissivity of 0 85 and model radius of 300 mm nose and of 100 mm leading edge The transformed requirements are reported in the following table REQUIREMENTS IN TERMS OF HEAT FLUX Nominal Extreme Safety trajectory trajectory trajectory NOSE Heat flux 428 846 846 1035 612 1035 kW m kW m kW m LEADING EDGE 125 260 230 380 300 600 Heat Flux kW m kW m kW m The facility has been designed to satisfy the ESA requirements the present design returns a greater capability as shown in the following The Arc Heater has the capability to provide to the Conical Nozzle air with a total pressure and a total enthalpy contained into the map reported in Fig 5 that represents the Performance Map CIRA UM 04 008 CIRA PWT USER MANUAL The curves in this figure have been obtained considering the operating and technological limits of the facility 1 Minimum air pressure of 1 bar for arc stability 2 Maximum allowable total gas enthalpy of 45 MJ kg 3 Maximum flow rate from Process Air System of 3 5 kg s 4 Minimum allowable total gas enthalpy of 2 5 MJ kg Between the column Arc Heater and the Nozzle a Plenum Chamber is located where it is possible to inject compressed air at ambient temperature in order to reduce the total gas enthalpy By this way it is possible to reduce the minimum gas total enthalpy up to 2 5 MJ kg in fact the minim
29. tomation Computer for parameters sending and acquisition interface with the FEE for set up and data acquisition data calibration and transmission to Automation Computer support to calibration tables preparation 2 LBDS Front End Equipment LBDS FEE also called Measurement Front End in charge to perform the following functions interface with the Test Instrumentation for analog signals acquisition filtering and A D conversion handling of spare I O channels interface with the WS for set up and data transmission support to sensors and channel calibration operations Moreover the LBDS supply includes a IEEE 488 controlled instrument to support sensors and channels calibration operations High bandwidth data acquisition system The HBDS system is consisting of a Pentium based Personal Computer and a measurement front end dedicated to acquire the input signals from the Facility devices The HBDS computer is connected via a TCP IP LAN to the File Server for I O Configuration Tables loading and for HBDS data archiving and to the Automation CIRA UM 04 008 CIRA PWT USER MANUAL Computer for Commands Events acquisition sending The HBDS computer is located in the Computer Room and the HBDS front end is located in the Electronic Room 9 ISTRUMENTATION The Scirocco PWT facility is provided by an extended Test instrumentation supply in order to fully characterise e the flow properties in Te
30. um enthalpy level that the Arc Heater is able to produce is 10 MJ kg m EXPLORED REGION PREDICTED PERFORMANCES 40 4 Total Enthalpy kW m 8 L 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Total Pressure bar Fig 5 Theoretical Performance Map Total Pressure and Total enthalpy at the inlet of the convergent nozzle From the Performance Map an equivalent diagram of facility capabilities has been obtained in terms of pressure and heat flux at stagnation point as function of the model size and the nozzle configuration The facility can work with four different Conical Nozzle configurations providing exit nozzle diameters respectively of 900 mm 1150 mm 1350 mm and 1950 mm However the nozzle throat is always the same with a diameter of 75 mm For each configuration an effective exit nozzle diameter has been calculated taking into account the boundary layer thickness Page 5 of 23 Ens PROCESS REQUIREMENTS min max Air mass flow kg sec 0 10 3 5 Air enthalpy content MJ kg 2 50 45 Air operative pressure mbar 0 01 2 9 Exit Effective exit Area ratio diameter diameter A A mm mm 900 900 144 1150 1050 196 1350 1200 256 1950 1500 400 The requirement for the hemispheric model of Nose configuration must have two different sizes with radius of 300 mm and 240 mm The 900 mm exit diameter configuration cannot operate in conjunction with the model radius of 300 because the flow bloc
31. w rate of 18 m h at a maximum pressure inlet of 38 bar and at a minimum pressure outlet of 8 bar the minimum pressure outlet can be increased up to 15 bar An electrical system for the model is available at MSS interface consisting in a 500 W 220 VAC cable with 3 conductors phase neutral ground and a ground cable S 16 mm CIRA UM 04 008 CIRA PWT USER MANUAL 7 2 CALIBRATION PROBE ARMS CPA In the Test Chamber there are two calibration arm Calibration Probes Arms Also these arms are cooled using pressurised demineralized water Their function is to support and locate measurement instruments into the plasma in order to measure its characteristics in several positions The arms of the Calibration Probes can rotate around an axis parallel to the plasma flow axis and can be located in such a way that the center line of the installed instrumentation can coincide with the plasma flow axis The motion is actuated by electrical motors 8 AUTOMATION SYSTEM The PWT Control and Automation System is realised in different levels and the Data Acquisition System is integrated in it assuring the experimental data sampling and storage fig 15 The facility instruments are divided into two categories the control instruments and the process instruments The control instruments are those installed in the facility used to verify the proper operation of each subsystem The process instruments are those whose acquired
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