Issue No : 1 Copy No : Date of Issue :22/11/12

DOC. No: VSSC/INSTEF/TM-GSLV/45/2012 Security classification : Control Status :

TEST PLAN FOR

GSLV-F06 failure simulation pull test with GK CS Lower Shroud

Name Prepared by Reviewed by Approved by Rajeshkumar G Abhilash J O Sudhir S Nair SH, HPHTS/INSTEF Isac Daniel Division Head, INSTEF Signature Date

INTEGRATED STRUCTURAL TEST FACILITY STRUCTURAL DESIGN ENGINEERING GROUP STRUCTURAL ENGINEERING ENTITY VIKRAM SARABHAI SPACE CENTRE THIRUVANANTHAPURAM 695022

DISTRIBUTION LIST

Name Documentation Cell Head, INSTEF Deputy Director, STR Group Director, SDEG PD, GSLV Project APD (MS), GSLV Project Shri. Janardhanan, DPD, GSLV Project Group Head, CLSG/CMSE Head, CLSD/CMSE Head, QDC/QRPG/SR Head, QDMS/SR, VSSC. Head, CPSG/LPSC Senthil, CLSD/CMSE Manoj TK, CPSG, LPSC Pramod Rai, QDMS/SR Bhadrasheel, QDMS/SR

Copy No 1-3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Control Status Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled Controlled

CONTENTS

1. Introduction 2. Test Specimen 3. Test Objectives 4. Load Specification & Test sequence 5. Test set up LT Shroud structural Qualification
5.2 5.3 Connector demating simulation test with pull load. Failure simulation test with internal pressure& pull load.

Instrumentation

8. References

1. INTRODUCTION
GSLV-F06 Failure Analysis Committee identified the primary cause of the failure is the excessive static deformation of the shroud due to aerodynamic loads which resulted in untimely snapping of all separation plane connectors at theGS2/Cryogenic Stage Interface. FAC concluded that the failure has occurred due to a combination of factors such as:

a. Design inadequacy on the mounting scheme of the separation plane connectors lanyard on the shroud of the GK Cryogenic Stage. b. Not having an exact assessment of the local aerodynamic loads acting on the shroud in the presence of protrusions. c. Possible deficiencies in the slackness of the connectors and the P seal interface of the shroud.

The

review

on

GSLV-D5

vehicle

and

implementation

the

FAC

recommendations by Prof. UR Rao recommended to recreate the failure scenario of the GSLV-F06 and experimentally prove the failure theory evolved by the FAC. In line with the above recommendations the lower shroud test with separation connectors is planned to simulate the demating of the separation plane connectors by lower shroud deformation under aero loads.

2. TEST SPECIMEN
The hardware identified for the failure simulation test is the CS lower shroud hardware available with the fluid mockup stage (CSFM). Lower Shroud assembly comprises of the following major parts. 1. Lower shroud panels 2 numbers (180 deg each) 2. Cowling P+ 4

3. Cowling P6. E bracket P+ 7. E bracket P8. LT ring The separation plane lanyards are assembled to the E brackets and the separation plane connectors are also simulated in the test as in flight configuration.

3.

TEST OBJECTIVE
To simulate the deformation of the shroud and possibility of its structural failure. To simulate the separation of the connectors under GSLV-F06 flight loads and evaluate the pull load required for seperation.

4.

LOAD SPECIFICATION & REQUIREMENTS

Two tests are planned to for the GSLV-F06 failure simulation test

a. Connector demating simulation test with pull load.

The connector de-mating is to be recreated by applying point load on the cowling-E bracket interface locations without application internal pressure on the shroud. The fairings need not be assembled and the lanyard slackness of varying length shall be provided. This test is planned to estimate/ validate the following: a. Pull force required for de-mating the connectors in the lateral direction b. Validation of slackness requirements of the connectors to simulate the demating sequence of the connectors as in GSLV-F06 flight.

b. Failure simulation test with pressure/pull load. The shroud shall be pressurized to the GSLV-F06 flight conditions. As the internal pressure application at the cowlings are not feasible due to presence of separation connectors at the location, equivalent point load to be applied at the cowling-E bracket interface locations along with the fairings. This test would be a full simulation test of GSLV-F06 failure. Five regions of load applications are planned for the structural test of GKLower shroud.

Region 1 2 3 4 P- E bracket 5 P+ E bracket

Flight load -12.5 kPa -11.5 kPa -11 kPa Pressure equivalent point load (3600 N)

Pressure equivalent point load (2400 N)

1
1050

2 3

Fig.1: Development of the shroud indicating the pressure chambers

Lanyard slackness for separation plane connectors 1.8 mm to 5.86 mm slackness is to be provided on the separation connector lanyards as observed in the CS-7 stage. In order to study the sequence of demating of the connectors as in the GSLV-F06 flight the slackness of the connectors as in the table is proposed. The identification of the separation plane connectors are shown in above figure.

Fig.2: Identification of separation plane connectors.

5.

Test Setup
5.1 Connector demating simulation test with pull load.

For this test a test set up is designed for fixing the LOX tank simulator bracket in a rigid frame and the E-bracket hole pitches are simulated in a light weight honey comb deck plate with sliding rollers for ensuring the low friction movement. The lanyards are attached between the LOX tank simulator and the honey comb deck plate in the same way as in flight. The slackness also will be provided as in flight. The honey comb deck plate is attached to a low

friction hydraulic jack and load cell assembly. The hydraulic jack will be activated with DT feed back control and load cell will measure pull load on the lanyards and the connector demating loads will be noted.

LOX Tank Bracket Displacement Transducer Lanyard

Load cell Hydraulic Jack

Honey comb deck plate as E- bracket simulator with roller support

Fig.3: Schematic of connector demating test assembly (section view).

Fig.4: Test fixture for connector demating test. (overall view)

5.2 Failure simulation test with internal pressure & pull load by vacuum. The failure simulation test planned to carry out in the configuration similar to the structural qualification tests of the re-designed lower shroud for internal pressure.

Fig.5: MS Fixrture for internal pressure application.

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Fig.6: MS Fixrture with air bags.

Fig.7: Indigenous Shroud test set up.

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MS Adaptor

JACK EYE VACUUM CHAMBER VACUUM BAG

COWLING GK Shroud

Fig.8: Test set up for vacuum application In addition to this the separation plane connectors are also simulated in the test as in the cryo fluid filled flight configuration. The P-seal and split ring assembly will be simulated in the test similar to flight condition. 16 Nos. of split ring support brackets fixed in internal pressure chamber will be holding the split ring and ensuring compression in the P-seal. The separation plane brackets of the LOX tank are mounted on two support brackets on the existing internal pressure fixture. The distance between the E bracket on the lower shroud and the separation plane bracket on the LOX tank is 150 mm. Lanyard attaching point is radially shifted inward by 7 mm wrt connector centre to compensate the inward movement of LOX tank during contraction.

Vacuum bagging will be done outside the cowling flight loads.

which is more closer to 12

The assembly details of the lanyard on the lower shroud with separation plane connectors is shown in fig 3. The configuration of the separation plane bracket on LOX tank for test is shown in fig. 4 and the support bracket for mounting on the internal fixture is given as annexure 2.

Fig.9: Layard and E-bracket arrangement inside shroud.

Fig.10: Layard and Ebracket arrangement inside shroud.

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Fig.10: Layard and E-bracket arrangement in the test set up (Schematic).

6. Instrumentation Details
The total instrumentation required for the test is given below. Displacement transducers 16 Nos Strain measurement 48 Nos (24 locations) Connector mating status monitoring 12 Nos Data acquisition shall be carried out at every 1 ms to precisely monitor the shroud deformation pattern and to capture the demating sequence of the connectors. Motion sensor also will be placed in the set up to capture the pattern of shroud movement in various planes.

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1138.5

1138.5

759.5

569.25

569.25

569.25

569.25 49

GB C/O4 DT9 DT8 DT10 C/O2 PH4 PH3 PH2 DT11 DT12

GB C/O3 GB C/O2

GB C/O1

DT7

DT13

DT14 PH1

So7 Si7

5 25 So11 Si11 SAo4 SAi4 VH1 C/O1

VH2

1050
So8 Si8 So9 Si9

So10 Si10 So12 Si12 28

P+
4554

Fig 8. Instrumentation locations at P+ panel

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1391.5

1138.5

885.5

1138.5

569.25

569.25

569.25

569.25 49

GB C/O8

GB C/O7

GB C/O6

GB C/O5

DT15 PH8 PH7 PH6

DT16 DT2 DT3 DT4

DT1

DT5 PH5

DT6

5 25

C/O4

So5 Si5

SAo1 SAi1 VH4 So1 Si1 So3 Si3 SAo2 SAi2 VH3

1 0 50
So2 Si2 SAo3 SAi3

C/O3 So4 Si4 So6 Si6 30

P
4554

Fig 9. Instrumentation locations at P- panel

Y+

16

225 30 3

148

SAo5 SAi5 So13 Si13

50 258

8 x 50 = 400

So14 Si14

R47

R1 5
R20

450

Fig 10. Instrumentation locations at P+ cowling

315 29 3

155.6 25

SAo7 SAi7 So15 Si15

50

479

So16 Si16

7 R4

R20

565

Fig 11. Instrumentation locations at P- cowling

30

479

SAo8 SAi8

258

30

479

SAo6 SAi6

17

Y
DT13 DT14 DT15 DT12 DT11

22.5

22.5

DT16

35

35

DT10

22.5

22.5

PDT1

DT9

P+

35

35

DT2
22.5 22.5

22.5

22.5

DT8

DT3 DT4 DT5 DT6

DT7

Y+
Fig 12.Displacement measurement locations

SAixx Inside axial direction strain gauge, xx stands for strain gauge no. SAoxx Outside axial direction strain gauge, xx stands for strain gauge no. Sixx Inside hoop direction strain gauge, xx stands for strain gauge no. Soxx Inside hoop direction strain gauge, xx stands for strain gauge no. DTxx stands for LVDT for displacement measurement, xx stands for LVDT no.

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7.

References
Test requirement document for the failure simulation pull test wth GK CS Lower shroud (Document No. GSLV-VSSC-PC-241209-2012)

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