NASA Technical Reports Server (NTRS) 19940028594: Advanced transportation system study: Manned launch vehicle concepts for two way transportation system payloads to LEO

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ADVANCED TRANSPORTATION SYSTEM STUDY
Manned Launch Vehicle Concepts for Two Way
Transportation System Payloads to LEO
FINAL REPORT (DR-4)
Contract NAS8-39207
(NASA-CR-193951) ADVANCED N94-33100
TRANSPORTATION SYSTEM STUOY: MANNED
_ _i_ ¸
LAUNCH VEHICLE CONCEPTS FOR TWO WAY
TRANSPORTATION SYSTEM PAYLOADS TO Unclas
LEO Final Report, 15 Feb. 1992 - 15
Dec. 1993 (Rockwell International
Corp.) 589 p G3/16 0005512
-==
Submitted by:
Rockwell Intemational
__w_ Rockwell International
SpaceSystemsDivision
HuntsvilleOperations
SSD93M0025-t
ADVANCED TRANSPORTATION SYSTEM STUDY
I_anned Launch Vehicle Concepts for Two Way
Transportation System Payloads to LEO
FINAL REPORT (DR-4)
Contract NAS8-39207
Submitted by:
Rockwell International
___ Rockwell International
SpaceSystemsDivision
HuntsvilleOperations
This report is submitted in compliance with DR-4 of Contract NAS8-39207, Advanced
Transportation System Studies for the National Aeronautics and Space Administration, George
C. Marshall Space Flight Center. The report describes the results of Rockwell International's
work for the analysis of Manned Launch Vehicle Concepts for Two Way Transportation
System Payloads to LEO during the Basic Contract and the Option 1 Contract period of
performance (February 15, 1992 through December 15, 1993).
This report is organized in three volumes; an Executive Summary, a Final Report, and a Cost
Estimates Report.
The Executive Summary_ is a condensation of the study's major findings and a summary of
results for the several study activities. The findings and results are current with the study
progress as of December 10, 1993.
The Final R¢oort volume is an in-depth description of work performed during the study, with
accompanying illustrations of briefing charts and other documents which were generated
during the course of the study. This volume is organized by subject matter and includes an
appendix with research reports of detailed analyses on selected special topics. Sufficient data is
presented in this volume to reveal the depth of work performed and to provide data which
supports the findings presented in the Executive Summary.
The Cost Estimates Report is a compilation of the Work Breakdown Structure and cost
estimating techniques which were used to evaluate the several booster concepts during the
course of the study. A summary of data used and generated during the evaluation of each
booster type (or family of boosters) is provided. The data is organized by booster types which
represent unique cost estimating conditions, such as the reusable Space Shuttle, the proposed
low cost NLS family, existing expendable launch vehicles, and the Russian (C.I.S.) launch
vehicles.
2dI$.ZRA.C.
i
The purpose of the Advanced Transportation System Study (ATSS) Task Area 1 study effort is
to examine manned launch vehicle booster concepts and two-way cargo transfer and return
vehicle concepts to determine which of the many proposed concepts best meets NASA's needs
for two-way transportation to low Earth orbit. The study identified specific configurations of
the normally unmanned, expendable launch vehicles (such as the National Launch System
family) necessary to fly manned payloads. These launch vehicle configurations were then
analyzed to determine the integrated booster/spacecraft performance, operations, reliability, and
cost characteristics for the payload delivery and return mission. Design impacts to the
expendable launch vehicles which would be required to perform the manned payload delivery
mission were also identified. These impacts included the implications of applying NASA's
man-rating requirements, as well as any mission or payload unique impacts.
The booster concepts evaluated included the National Launch System (NLS) family of
expendable vehicles and several variations of the NLS reference configurations to deliver larger
manned payload concepts (such as the Crew Logistics Vehicle (CLV) proposed by NASA
JSC). Advanced, clean sheet concepts such as an F-1A engine derived liquid rocket booster
(LRB), the Single-Stage-to-Orbit rocket, and a NASP-derived aerospace plane were also
included in the study effort. Existing expendable launch vehicles such as the Titan IV, Ariane
V, Energia, and Proton were also examined.
Although several manned payload concepts were considered in the analyses, the reference i
manned payload was the NASA Langley Research Center's HL-20 version of the Personnel
Launch System. A scaled up version of the PLS for combined crew/cargo delivery capability, '
the HL-42 configuration, was also included in the analyses of CTRV booster concepts.
In addition to strictly manned payloads, two-way cargo transportation systems (Cargo Transfer
& Return Vehicles) were also examined. The study provided detailed design and analysis of
the performance, reliability, and operations of these concepts. The study analyzed these
concepts as unique systems and also analyzed several combined CTRV/booster configurations
as integrated launch systems (such as for launch abort analyses). Included in the set of CTRV
concepts analyzed were the Medium CTRV, the Integral CTRV (in both a pressurized and
unpressurized configuration), the Winged CTRV, and an attached cargo carrier for the PLS
system known as the PLS Caboose.
ii
TABLE OF CONTENTS
V
Volume I Executive Summary
. Introductign I-1
1.1 Si_ificant Achievements I-4
1.1.1 Manned Booster Studies 1-5
1.1.2 Cargo Transfer & Return Vehicle Studies I-7
1.1.3 Launch Abort Studies 1-9
1.1.4 SSTO MPS Operability Studies 1-11
1.2 Summary. of Resd_ 1-13
1.2.1 Manned Booster Studies 1-13
1.2.2 Cargo Transfer & Return Vehicle Studies 1-29
1.2.3 Launch Abort Studies 1-56
1.2.4 SSTO MPS Operability Studies 1-67
Volume II Final Report
2.1 Manned Booster Studie_ 11-1
2.1.1 Man-rating Requirements Analysis II-2
2.1.2 Performance Analysis 11-17
2.1.3 Cost Analysis II-31
2.1.4 Launch Processing Analysis 11-44
2.1.5 Reliability Analysis 11-52
2.2 Cargo Transfer & Return Vehicle Studies 11-67
2.2.1 PLS Caboose Concept 11-71
2.2.2 Medium CTRV Concept II-81
2.2.3 Integral CTRV Concept 11-110
2.2.4 Winged CTRV Concept 11-129
2.3 Launch Abort Studies I/-161
2.3.1 Abort Studies Approach II-161
2.3.2 Abort Coverage of Selected Boosters I1-165
2.3.3 Abort Studies Findings /1-183
2.4 SSTO MPS Operability Analyses n-185
2.4.1 Operations Simulation Analysis II-185
2.4.2 SSTO Engine Throttling Studies 11-206
2.4.3 SSTO MPS Design Layout 11-219
2.5 Aooendices I/-224
A. Structural Analysis of CLV on NLS-2
B. Structural Analysis of PLS with CRV on NLS-2
C.
Man-Rating Requirements Report (Rev. A)
D.
Learning Curve Analysis of Shuttle Processing
V
iii
Volume HI Program Cost Estimates
[h-o_m--amCost Estimates Document
1
1.0 Scope
2
2.0 Background Information
5
3.0 Manned Booster Cost Estimates
_p.22AJ.f192
WBS and Dictionary.
1
Work Breakdown Structure (WBS)
3
1.0 WBS Dictionary
4
1.1 Launch Vehicle Segment
9
1.2
Transportation Node Segment
9
1.3
Test Segment
10
1.4
Operations Segment
12
1.5 Software Segment
12
1.6 Ground Segment
14
1.7
Program Segment
V
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1.0 Introduction
j
L
The ATSS Task Area i team has conducted studies for the design,
performance, and evaluation ofa number of expendable booster concepts
currentlybeing considered forthe launch ofreusable (manned or two-way
cargo) spacecraft. These analyses were performed todetermine which of
the many proposed booster concepts best meets NASA's needs for two-
way transportationtolow Earth orbit.Detailed design and analysisof the
two-way cargo spacecraftwere alsoperformed under the study. Analysis
of the integrated configurationsof theseboosters and spacecraftrevealed
an improved understanding of the strengths and limitations of each
element. Integrated booster/spacecraft analysis were performed for
launch vehicleperformance and controllabilityr,eliabilityc,ost,launch rate
capabilityand facilityutilizationa,nd launch abort. Additional analyses of
the launch vehicle ground processing activitieswere also performed to
identifymeans of improving the operabilityof any launch vehicleconcept,
new or old. The product of thesestudiesisa betterunderstanding of the
roles which both the booster and the spacecraft play in achieving
improved access tospace.
Manned Booster Studies
The study identified specific configurations of the normally unmanned,
expendable launch vehicles (such as the National Launch System family)
necessary to fly manned payloads. These launch vehicle configurations
Were then analyzed to determine their performance, operations, reliability,
and cost characteristics for the manned payload delivery mission. Design
impacts to the expendable launch vehicles which would be required to
perform the manned payload delivery mission were also identified. These
impacts included the implications of applying NASA's man-rating
requirements, as well as any mission or payload unique impacts.
Booster concepts evaluated included the National Launch System (NLS)
family of expendable vehicles, several variations of the NLS reference
configurations, and the ESA Ariane V. Advanced, clean sheet concepts such
as an F-1A engine-derived Liquid Rocket Bosoter (LRB), the Single-Stage-
to-Orbit rocket, and a NASP-derived aerospace plane were also included in
comparisons of the several candidate booster configurations. Existing
expendable launch vehicles such as the Titan IV and the Russian Energia
and Proton launch vehicles were also compared to the proposed new
booster designs.
I-1
Although several manned payload concepts were considered in the
..j" analyses, the reference manned payload was the NASA Langley Research
Center's HL-20 version of the Personnel Launch System (PLS). Other
concepts such as the Crew Logistics Vehicle (CLV) proposed by NASA JSC
and a scaled-up version of the PIS for combined crew/cargo delivery
capability (the HL-42 configuration) were also included in the analyses.
These concepts could be used in either the manned mode or an unmanned
mode for delivery and return of cargo (such as for the Space Station cargo
resupply mission).
Cargo Transfer & Return Vehicle (CTRV) Studies
A wide range of concepts for the delivery and return of cargo payloads to
low Earth orbit (LEO) were designed and analyzed during the study. These
concepts are generally referred to as Cargo Transfer and Return Vehicles
(CTRV). These concepts include vehicles which deliver crew or cargo
separately as well as those vehicles which deliver combined crew and
cargo payloads. Combined crew/cargo delivery vehicles evaluated in the
study included LaRC's scaled-up version of the Personnel Launch System
(HL-42) and JSC's Crew Logistics Vehicle (CLV). Variations of all three
vehicle concepts were created during the study to provide varying payload
delivery and return capabilities. The CTRV, PLS, and CLV concepts,
combined with appropriate launch vehicle(s), formed the architectural
framework of NASA's Access to Space, Option 2 study. Identifying
competitive design configurations of the CTRV to support the Access to
Space study objectives was a principle activity of the study.
Launch Abort Studies
Trajectory analyses were performed to determine the ability of a variety
of expendable boosters to provide a mission abort capability for the HL-42
and CLV-P crew/cargo vehicles during the ascent mission phase. The
analysis was performed for several Access to Space study boosters
(Boosters 2A', 2C, and 2D for the HL-42, and Booster 2B for the CLV-P).
Specific design characteristics of the booster concepts were provided by
NASA MSFC. The HL-42 and CLV-P design data were provided by NASA
LaRC and JSC, respectively. The abort modes considered in the analysis
included; Return To Launch Site (RTLS), Trans-Atlantic Abort (TAL),
Engine Out (EO), Abort To Orbit (ATO), and Abort Once Around (AOA). A
North America Landing (NAL) abort mode was added for the Booster 2D
concept to compensate for this two-stage (series burn) booster design.
I-2
SSTO MPS Operabili W Studies
J
An investigation into means of achieving high operability in any new SSTO
concept was accomplished by evaluating an SSTO main propulsion system's
flight operations, ground operations, and design configuration
characteristics. All of these aspects of a system design interact to produce
a launch vehicle's net reliability and maintenance performance. Methods
used for improving aircraft operability were adapted for the ATSS study to
analyze the operability characteristics of SSTO concepts defined by NASA
in their recently completed Access to Space study, Option 3. The method
used simulation models to provide detailed assessment of the SSTO
propulsion system components and checkout activities and also provide a
system-level simulation of the SSTO launch rate capability, facility
requirements, and resource utilization needs. The simulations included
component level reliability and maintainability data as determined from
actual Space Shuttle MPS processing history. The MPS serves as a useful
benchmark for comparing the operability of the many competing SSTO
concepts.
The investigation included the evaluation of optimum SSTO main engine
operating techniques for maximizing both engine reliability and life, while
also providing adequate abort coverage. Variations in engine throttle
profiles and shutdown sequences were performed to find the minimum
engine operating times, the minimum engine operating time at 100%
throttle level, and the maximum engine out abort capability. Additionally,
a design study for an SSTO MPS aft fuselage was used to rigorously apply
the MPS design groundrules which were identified in the Operationally
Efficient Propulsion System Study (OEPSS) by NASA KSC and Rocketdyne.
k._j
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1.1 Significant Achievements
The ATSS Task Area 1 study has examined a wide range of launch sys terns
for two-way space transportation payloads. Launch vehicles for future
NASA spacecraft such as the PLS and CTRV concepts have been analyzed to
determine which boosters best meet NASA objectives. Impacts to these
boosters to perform manned payload missions have also been identified,
including the implications of NASA's man-rating requirements. Design and
analysis of several CTRV concepts which would compliment the PLS system
were also provided to support the NASA Access to Space (Option 2) study.
The ability to provide launch abort coverage for the return of reusable
systems was also examined, for both expendable launch vehicles and for
fully reusable SSTO concepts. The significant achievements and findings
reached during the conduct of these studies should be of value to NASA
and contractor engineers as plans for the next generation of manned
launch vehicle concepts are developed.
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