Liquid Rocket Engine Testing Overview PDF
Preview Liquid Rocket Engine Testing Overview
RR EE LL EE AA 41st Joint Propulsion Conference SS EE DD - - and Exhibit P P rr inin tt ee AIAA LRE Course dd d d Tuscon, Arizona oo cc uu mm ee nn July 13-14, 2005 tt ss m m aa yy b b ee o o bb ss oo lele tt ee ;; v v aa lidlid aa tt ee p p rr ioio rr t t Sub-Topic: oo u u ss ee Liquid Rocket Engine Testing .. AIAA Short Course on Liquid Rocket Engines Dr. Shamim Rahman NASA John C. Stennis Space Center, MS RR EE LL EE AA SS EE Section Outline DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu mm ee • Objectives and Motivation for Testing nn tt ss m m – Technology, RDT&E, Evolutionary aa yy b b ee o o • Representative LRE Test Campaigns bb ss oo lele tt – Apollo, Shuttle, ELV Propulsion ee ;; v v aa lidlid • Overview of Test Facilities for Liquid Rocket Engines aa tt ee p p riorio – Boost, Upper Stage (Sea-level and Altitude) rr t t oo u u ss • Statistics (historical) of Liquid Rocket Engine Testing ee .. – LOX/LH, LOX/RP, Other development • Test Project Enablers: Engineering Tools, Operations, Processes, Infrastructure Continued on Next Page … 2 RR EE LL EE AA SS EE Section Outline (cont.) DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu Continued from Previous Page … mm ee nn tt ss • Non-NASA Test Capability (CPIA) m m aa yy b b – National Rocket Propulsion Test Alliance ee o o bb ss – Commercial Test Sites oo lele tt ee – University Test Sites ;; v v aa lidlid aa • Summary tt ee p p rr ioio rr • BACKUP MATERIAL t t oo u u ss ee .. 3 RR EE LL EE AA SS EE DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu mm ee nn tt ss m m aa yy b b ee OOBBJJEECCTTIIVVEESS && MMOOTTIIVVAATTIIOONN o o bb ss oo lele FFOORR LLRREE TTEESSTTIINNGG tt ee ;; v v aa lidlid aa tt ee p p rr ioio rr t t oo u u ss ee .. 4 RR EE LL EE AA SS EE Key Terms DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu • Development testing is required to achieve design maturity, demonstrate capability, and to reduce risk to the mm ee qualification program. Development tests are conducted, as required, to: nn tsts – Validate new design concepts or the application of proven concepts and techniques to a new configuration, m m – Assist in the evolution of designs from the conceptual phase to the operational phase, aa yy b b – Validate design changes, ee o o – Reduce the risk involved in committing designs to the fabrication of qualification and flight hardware, bb ss – Develop and validate qualification and acceptance test procedures, oo lele – Investigate problems or concerns that arise after successful qualification, tt ee ;; An objective of development testing is to identify problems early in their design evolution so that any required corrective v v aa actions can be taken prior to starting formal qualification testing. lidlid aa tt ee p p • Qualification tests (also commonly known as certification tests) are conducted to: rr ioio – Demonstrate that the design, manufacturing process, and acceptance program produce hardware/software that meet rr t t specification requirements with adequate margin to accommodate multiple rework and test cycles, oo u u – In addition, the qualification tests should validate the plannedacceptance program, including test techniques, procedures, ss ee equipment, instrumentation, and software. .. Generally qualification follows completion of the development test program. • Acceptance tests are conducted to demonstrate the acceptability of each deliverable item to meet performance specification and demonstrate error-free workmanship in manufacturing. Acceptance testing is intended to: – Stress screen items to precipitate incipient failures due to latent defects in parts, processes, materials, and workmanship, – Component acceptance testing at the bench level serves to reduce risk for engine acceptance testing, but it may not simulate the engine environments adequately. Many components require engine hot fire to adequately reduce flight risk. (An engine LRU is a component that may be removed and replaced by a new unit, without requiring reacceptance test firing of the engine with the new unit. If the unit being replaced was included in an engine acceptance test firing as part of its acceptance test, then the replacement unit either should be subjected to such a test on an engine, or should undergo equivalent unit-level acceptance testing). 5 RR EE LL EE AA SS EE Objectives of Liquid Propulsion Testing DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu mm • Component Development ee nn tt s ms m – Combustion devices (turbomachinery, chambers, ignitors), e.g. RS-84 aa yy – Advanced technology demonstrators b b ee o o bb • Prototype Engine Development ss oo lele tete – J-2 S, XRS-2200, RL-60, MB-60 ;; v v aa lidlid • Flight Engine Qualification, Certification aa tt ee p p – J-2, F-1, SSME, RS-68, RL-10, etc. rr ioio rr to to • Flight Engine Acceptance u u ss ee .. – RS-68, SSME • Major Engine Upgrades – SSME Block Upgrades • Re-development and Re-Use Potential – LR-89 thrust chamber Some examples of each are listed 6 RR EE LL EE AA SS EE Typical Sequence of Testing DD - - P P rr inin tt ee AIAA LRE Course dd d d oo Subscale cc uu mm Component Test ee nn (pumps, preburners, tt ss m m thrust chambers) DATA aa yy b b Full Scale ee o o Component Test bb ss oo (pumps, preburners, lele thrust chambers, DATA tt ee ;; Powerheads, nozzles) v v aa “Battleship” lidlid aa Engine Test tt ee p p rr ioio DATA rr t t oo u u Flight Engine ss ee .. Dev. Test DATA Flight Engine Acceptance Test Flight Engine Qual./Cert. Test Flight Stage DATA Acceptance Test Flight Stage Qual. Test • An On-going process of risk reduction (components, engines, stages) 7 RR EE LL EE AA SS EE Testing Cost / Total Cost for Propulsion DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc uu mm ee nn tt ss m m Historical Full Scale Development Cost Distribution aa yy b b ee o o bb ss oo lele tt ee ;; v v aa lidlid aa tt ee p p rr ioio rr t t oo u u ss ee .. George, D.; “Chemical Propulsion: How To Make It Low Cost,” presented at Highly Reusable Space Transportation Meeting, 25-27 July 1995. 8 RR EE LL EE AA Survey of LOX/RP and LOX/LH Engine SS EE DD - - P P Development Programs rr inin tt ee AIAA LRE Course dd d d oo cc uu 14 mm ee nn Kerosene Booster Engines tt ss m m Kerosene Upper Stage Engines aa 12 yy n H2 Booster Engines b b o e oe o ati H2 Upper Stage Engines bb c ss i oleole alif 10 tete u ; v; v Q alidalid nd 8 aa a tete t p p n rr e ioio m rr to to op 6 u u l ss e ee v .. e D r 4 o f s r a e Y 2 0 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 Completion Year • Emdee, J., “A Survey of Development Test Programs for Hydrogen Oxygen Rocket Engines,” AIAA Paper No. 2001-0749. • Emdee, J., “A Survey of Development Test Programs for LOX/Kerosene Liquid Rocket Engines,” AIAA Paper No. 2001-3985. 9 RR EE LL EE AA SS EE Effect on Engine Flight Success Rate DD - - P P rr inin tt ee AIAA LRE Course dd d d oo cc 100% uu mm ee nn tt 98% ss m m aa yy b b 96% ee o o bb ss oo 94% lele tt ee ;; e va va at 92% lidlid R aa tete s p p s 90% riorio e rr c to to c 88% u u u ss S ee .. 86% 84% Kerosene Booster Engines H2 Booster Engines 82% H2 Upper Stage Engines 80% 0 500 1,000 1,500 2,000 2,500 3,000 Test Firings • Emdee, J., “A Survey of Development Test Programs for Hydrogen Oxygen Rocket Engines,” AIAA Paper No. 2001-0749. • Emdee, J., “A Survey of Development Test Programs for LOX/Kerosene Liquid Rocket Engines,” AIAA Paper No. 2001-3985. 10
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