Garcia, Sam

Homan, Jonathan L.

NASA Technical Reports Server

Refurbishment of NASA’s Johnson 
Space Center Liquid Nitrogen Bulk 
Storage Tanks in preparation for 
Thermal Vacuum Optical Testing of the 
James Webb Space Telescope (JWST)
Presented By
Sam Garcia
30th Space simulation Conference
November 5-8, 2018
Annapolis, Maryland
https://ntrs.nasa.gov/search.jsp?R=20180007818 2019-08-31T17:18:14+00:00Z
Space Environmental Simulations Laboratory
• The Space Environment Simulation Laboratory (SESL) was 
constructed in May 1962 under NASA Administrator James Webb 
Located  at Johnson Space Center in Houston, Texas. 
• SESL was developed to meet the need for Apollo testing to expedite 
US space capability during the height of the US/Soviet Space Race
• Specialized Support Systems include:
– Helium cryogenic system
– Low & High Vacuum systems
– Liquid Nitrogen System 10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
• Primary use of Liquid Nitrogen for this facility is for Environmental 
Cooling in Chamber B and a Thermal Shield in Chamber A. 
• The liquid nitrogen bulk storage(tank farm) is comprised of six tanks 
with the following capacities. 
• 162,500 Water volume 
• 146,250 Gallon Capacity adjusted for ullage
10/18/2018 30th Space Simulation Conference
Vessel 
Name
ASME Serial 
#
Size 
(Gal) Manufacturer
MAWP 
(PSIG)
Year 
Built Type
TK-LN2-101 C-3793 28,000 Horton Tank 165 1958 I
TK-LN2-102 C-3787 28,000 Horton Tank 165 1958 I
TK-LN2-103 C-3796 28,000 Horton Tank 165 1958 I
TK-LN2-104 C-3786 28,000 Horton Tank 165 1958 I
TK-LN2-201 T-201-19 26,500 LOX Equipment 100 1960 II
TK-LN2-202 59G0244-1 24,000 Strutners-Wells 165 1960 II
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
8/23/1612/1/15 PHASE 1 
FY16 THERMALPATHFINDER 
THERMAL 
VACUUM TEST
OGSE 2 PATHFINDER 
THERMAL
VACUUM TEST
8/25/1711/15/16 PHASE 2 
FY17
OTIS
FLIGHT
THERMAL
VACUUM TEST
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
• Challenges
– The bulk storage vessels(Tank Farm) also supplies Liquid Nitrogen to 
the entire JSC center so one vessel had to remain in service at all 
times. 
– One overall drawing with limited information exists for only TYPE I
vessels
– No vessel fabrication drawing existed for the TYPE II tanks. 
– Warming the tanks took 30 days.
– One tank had to remain in operation to support JWST concurrent test 
build up and provide Liquid Nitrogen to
– Weather considerations were monitored to coordinate field welds and 
installation prevent rain water intrusion into the annuls
– Work stretched between December to August. Snow, rain and the 
continuous humidity could have fouled the annulus and extended the 
project schedule.
– Concurrent James Webb Thermal Pathfinder and Flight unit integration 
support.  
– Testing Schedule limited how much work could be done to meet test 
schedule so a two year plan was developed to perform between tests.
10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
• All tanks have 304 S.S. inner vessel with carbon steel outer shell.
• All tanks are pearlite insulated with active full time vacuum pumping.
• Each vessel had the original annulus safety devices with associated 
piping, valves and method of measuring vacuum annulus pressure. 
All items attached to the annulus were carbon steel and we at the 
end of their life service. 
• In 2015 degradation of vacuum performance was identified on half 
of the vessel inventory. This was cause for concern for reliability and 
longevity for JWST testing.
• One tank was deemed unserviceable and was placed inactive due 
to a high vacuum pressure in the annulus. 
• Corrosion and weathering of components- major impacts
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
• Phase I
– Remove and Replace the Annulus Safety Devices on the -200 Type II Vessels. 2 
vessels only. 
– Remove and Replace the carbon steel vacuum piping with 304 S.S. piping
– Replace all vacuum isolation valves. 
– Install new thermocouple vacuum tubes with isolation valves. 
– Connect one thermocouple vacuum tube to facility data acquisition & monitoring 
system.
– Perform a helium leak check on all six vessels and rate of rise.
– Paint all new carbon to stainless steel transition welds. 
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
PHASE 1 –PREXISTING 
SAFETY DEVICE TK-201 SAFETY DEVICE TK-202
VACUUM GAUGE ISOLATION 
VALVES 
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
PHASE 1 –PREXISTING 
VACUUM PIPING WITH VALVE AND
SAFETY DEVICE
VACUUM PIPING WITH VALVE
CAPPED
ANNULUS
SAFETY 
DEVICES
-LEAKING-
VACUUM
ISOLATION
VALVES
-LEAKING-
VACUUM
ISOLATION
SOLENOID
VALVES
-NOT WORKING-
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE 1 –PREXISTING 
SHOP FABRICATION OF VACUUM PIPE SPOOLS WITH ANNULUS SAFETY DEVICES
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
PHASE 1 – NEW  
INSTALLATION OF VACUUM ANNULUS SAFETY DEVICES 
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
PHASE 1 – NEW  
NEW INSTALLED VACUUM PIPING
THERMOCOUPLE VACUUM TUBE
Typical Process on all tanks 
Surface Preparations(Emphasis on the S.S. to Carbon Steel)
Remove paint (Step 1 )Rust Knockout (Step 2)Passivate (Step 3)
S.S Carbon 
Steel
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE 1 – NEW  
CORROSION CONTROL
Primer using Maxropoxy 646 (Step 4 )
Top Coat using Acrolon 218 HS (Step 5)
Top Coat Process -Typical on all Tanks Paint 4” beyond the S.S side weld seam
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE 1 – NEW  
NEW INSTALLED PIPING WITH COATING
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
TK-101
Before
TK-102
Before
TK-103
Before
TK-104
Before
TK-201
Before
TK-202
FY16 
Mod
FY16 Mod FY16 
Mod
FY16 
Mod
FY16 
Mod
FY16 
Mod
MODIFICATION
COMPLETE
√
√ √ √ √ √
Helium Leak 
Checked
FAILED FAILED FAILED FAILED √ √/PASS
NDE √ √ √ √ √ √/PASS
PSMO BUY OFF √ √ √ √ √ √
Rate of Rise √/166 
microns
√/Out of Range √/Out of 
Range
√/331 
microns
√/Out of 
Range
√/18 
microns
Blank off Vacuum
Pressure (Warm 
Tank)
(Microns)
150
Before/37 
After 
255 Before/123 
After
364  Before 
mod 1/
116  after  
mod 1
120 
Before/75 
After 
250  – 450
w/out heat, 
Out of Range 
with Heat
22 microns
Vessel Helium 
Leak heck
√/Fail √/Fail √/Fail √/Fail √/PASS √/PASS
Process Tank 
Purge (Dew 
point< -50 C)
√ √ √ √ √ √
PHASE 1 – SUMMARY OF WORK – August 2016  
(1) Placed tank out of service for JWST Thermal-Pathfinder suspect high water content in annulus
(2) Heated inner vessel and pumped annulus for +50 days thru cold trap to remove water/moisture from annulus.
1 2
3 3 3 3
(3) Placed back into service for test. Tanks that failed helium leak check were fixed after Thermal Pathfinder Test 
3
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
• Phase I Post modification Findings
– Helium leak check on vessels revealed annulus safety devices were all 
leaking on the -100 Type I tanks. 4 total tanks. 
– Tank -201 after replacement of both annulus safety devices could not 
be successfully pumped down.
• Two mechanical pumps were fouled in the process of vacuum 
pumping. 
• Culprit-Previous annulus safety device had allowed water to intrude 
through the corrosion. 
– Tank -202 successfully reached < 35 microns and success full three day 
rate of rise.
– Performed exploratory engineering evaluation on one Type I Tank 
flange to aid in the design to remove and replace the leaking safety 
devices. 
– Tank -201 coldtrap water vapor collection. Trap was
Changed every 4-6 hours for +50 days during JWST 
Thermal pathfinder test.
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
PHASE 1 –Exploratory Engineering– August 2016  
During helium leak checks all Type 1 
tank annulus safety devices failed helium
leak checks. An effort was made to identify
if the pearlite fill Flanges could be used to
accommodate new safety device.
Pearlite Fill Flange, Carbon Steel
O-ring groove on blank flange. 
Note: A gasket was used with an unknown 
sealant. 
Pearlite flange with carbon steel flange.
Major corrosion on studs
In place 32 RMS machining 32 RMS finis with 316 S.S Studs and  blank flange with
O-ring groove and Viton O-ring(AS568)
Refurbishment of Liquid Nitrogen Bulk Storage 
Tanks
10/18/2018 30th Space Simulation Conference
• Phase II
– Remove and Replace the Annulus Safety Devices on the -100 Type I tanks. 4 
vessels only.  This would eliminate vacuum leaks on these tanks
– Remove and Replace all ancillary process valves. 
– Replace the liquid level high and low process isolation valves and tubing to liquid 
level instrument. 
– Perform a helium leak check and rate of rise on all modified vessels. 
– Paint all new carbon to stainless steel transition welds. 
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
ANNULUS
SAFETY 
DEVICES
-LEAKING-
SIZED NEW REQUIRED
DISCHARGE AREA FOR 
EACH TANK PER
CGA 341-6.4.2
56 in^2  WAS REQUIRED 
PER TANK
THE EXISTING PORT  
PLUS TWO PEARLITE 
FILL PORT FLANGE 
WOULD HAVE TO 
ACCOMMODATE THE 
NEW SAFETY DEVICES. 
PHASE II  
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
10/18/2018 30th Space Simulation Conference
• Design would weld one safety device and weld another to exiting safety device pipe stub
PHASE II  
10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE II  
SCAFFOLDING DAY
10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE II  
DEMO DAY
Tank 201 Before Tank 201 After
Flanges
Material Delivery for LN2 tank annulus safety components
Safeties
Tank 201 Modification
Shop Welding Freeport Welding
5% X-ray, 100% Dye Penetrant
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
Tank Preparation for safety devices retrofit 
Removal of old safeties and piping by JACOBS Techs and NASA Rigging
Vacuum Annulus Safety Devices Bench Checking
Helium Leak 
Checking by 
JACOBS Techs.
Abate PaintScaffolding Demolition End of Service Life
Safeties
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
Field Installation of Welded Safeties
Installation of Flanged Safeties
Removing Existing Flanges Existing Flange Condition Mobile Machining Flanges After Machining Final with New S.S. Studs New Safeties Installed
WeldingCutting flanges Completed Welded Assy
Primer Coat 
100 % Dye Penetrant
Primer Coat Primer Coat Top Coat Completed Retrofit
• Successful Mobile 
Machining
• Successful Field 
Welding
• Successful Helium 
Leak Checks
• Successful Vacuum 
Rate of Rise 
• Successful Pressure 
System Weld 
Inspection
• Zero Accidents
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
TK-101
Before
TK-101
After
TK-102
Before
TK-102
After
TK-103
Before
TK-103
After
TK-104
Before
TK-104
After
TK-201
Before
TK-201
After
TK-202
FY16 
Mod
FY17
Mod
FY16 
Mod
FY17
Mod
FY16 
Mod
FY17
Mod
FY16 
Mod
FY17
Mod
FY16 
Mod
FY17
Mod
FY16 
Mod
MODIFICATION
COMPLETE
√ √
√ √ √ √ √ √ √ √ √
Helium Leak 
Checked
FAILED √/PASS FAILED √/PASS FAILED √/PASS FAILED √/PASS √ √/PASS √/PASS
NDE √ √/PASS √ √/PASS √ √/PASS √ √/PASS √ √/PASS √/PASS
PSMO BUY 
OFF
√ √ √ √ √ √ √ √ √ √ √
Rate of Rise √/166 
microns
5.4 
microns
@ 3 Days
√/Out of 
Range
8.4 
microns
@ 3 Days
√/Out of 
Range
37.2 
microns
@ 3 Days
√/331 
microns
5
microns
@ 3 Days
√/Out of 
Range
10.7 
microns
@ 3 Days
√/18 
microns
Blank off 
Vacuum
Pressure 
(Warm Tank)
(Microns)
150
Before/37 
After 
15 255
Before/123 
After
27 364  Before 
mod 1/
116  after  
mod 1
44 120 
Before/75 
After 
27 250  – 450
w/out 
heat, Out 
of Range 
with Heat
46 microns 22 
microns
Vessel Helium 
Leak heck
√/Fail √/PASS √/Fail √/PASS √/Fail √/PASS √/Fail √/PASS √/PASS √/PASS √/PASS
Process Tank 
Purge (Dew 
point< -50 C)
√ √ √ √ √ √ √ √ √ √ √
Current Status 
to Return to 
Service
N/A Cold, Full, N/A Cold, Full, N/A Cold, Full, N/A Cold, Full, - Cold, Full, 5/16/16
Returned 
to Service 
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
PHASE II – SUMMARY OF WORK – August 2017  
10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
• SUMMARY
– After almost 60 years of service the LN2 tanks have served well 
with original equipment. 
• Certain key components had reached their end of life service.
• Continual exposure to the elements had taken their toll on key 
components.
– Key components were commercially available for us to do the 
design and the majority of the work in house. 
– Qualified local shop fabricators and field welding contractors was 
key.
– Cost for Phase I and II project was equivalent to the price of one 
new vessel with less capacity not including the cost of retrofitting.
– A corrosion control program is critical to identify and mitigate 
problem areas and components on the annulus shell.
– The tanks are projected to operate for the next three decades 
without major maintenance on the annulus shell.      
10/18/2018 30th Space Simulation Conference
Refurbishment of Liquid Nitrogen Bulk Storage Tanks
QUESTIONS
30th Space Simulation Conference10/18/2018


Refurbishment of NASA's Johnson Space Center Liquid Nitrogen Bulk Storage Tanks in Preparation for Thermal Vacuum Optical Testing of the James Webb Space Telescope (JWST)

Refurbishment of NASA's Johnson Space Center Liquid Nitrogen Bulk Storage Tanks in Preparation for Thermal Vacuum Optical Testing of the James Webb Space Telescope (JWST)

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