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Sea Dragon Concept Volume 1: Summary

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Sea Dragon Concept Volume 1: Summary J _py No. Issue Date: 12 February 1963 3 LIQUIDROCKETPLAN ( ULclas 00/05 0157236 AEROJET GENERAL '1 Ii Report No. LRP 297, Volume III AEROJ ET-_,ENERAL CORPORATION TABLE OF CONTENTS PAR T 1 Int roduc tion PAGE NO. PAR T 2 Development I. OBJECTIVE Z-l II. DESCRIPTION OF SYSTEM Z-1 Ill. DEVELOPMENTAL PHILOSOPHY 2-i IV. DETAILED DEVELOPMENT PLAN Z-4 A, FIRST-STAGE PROPULSION Z-5 B. SECOND-STAGE PROPULSION AND THRUST VECTOR CONTROL 2-II C, VEHICLE INSULATION DEVELOPMENT Z-15 D. GUIDANCE SYSTEM DEVELOPMENT 2-16 E. COMBINED ENVIRONMENTAL TESTING 2-17 F. SMALL-MODEL TESTS OF OVERALL SEA DRAGON S YS TEM 2-18 \ Page ii Report No. LRP Z97, Volume III AEROJ ET-GE;NERAL CORPORATION TABLE OF CONTENTS (cont.) PART 2 (cont.) PAGE NO. G. FULL-SCALE SYSTEM SURFACE DYNAMIC TESTS 2-19 H. RECOVERY DEVELOPMENT (FOR RECOVERABLE FIRST STAGE) 2-21 I. WIND TUNNEL TESTS Z -2Z J. SELECTION OF MATERIALS Z-ZZ K. DEVELOPMENT OF MANUFACTURING SYSTEM 2 -23 L. TRANSPORTATION SYSTEM DEVELOPMENT 2-24 M. SEA OPERATIONS SYSTEM DEVELOPMENT Z -25 N. LAUNCH SUPPORT EQUIPMENT DEVELOPMENT 2-26 O. TRACKING AND RANGE SAFETY SYSTEM DEVELOPMENT 2 -27 P, FLIGHT TEST PROGRAM 2 -28 Q. OTHER SUBSYSTEMS 2-28 PART 3 Manufacturing and Fabrication Plan SUMMARY 3-I II. INTRODUCTION 3-3 A, GENE RAL 3-3 B. OBJECTIVES 3-4 C. MANUFACTURING CONSIDERATIONS 3-5 D. ALTERNATIVE PLANS'AND LIMITING FACTORS 3-6 Page iti Report No. LRP 297, Volume III AEROJET-eENERAL CORPORATION TABLE OF CONTENTS (cont.) PART 3 (cont. l PAGE NO. III. DISC USSION 3-7 A. SYSTEMS ANALYSIS 3-7 B. FABRICATION AND ASSEMBLY PLAN 3-8 C. FACILITIES PLAN 3 -28 D. QUALITY CONTROL PLAN 3 -30 E. MATERIAL CONSIDERATIONS AND PLAN 3 -33 F. VEHICLE PRODUCTION COSTS 3 -35 O. ALTERNATIVE APPROACHES 3 -37 IV. CONCLUSIONS 3 -39 APPENDIXES APPENDIX DETAILED OUTLINE OF THE SEA DRAGON MANUFACTURING AND FABRICATION PLAN REQUIREMENTS 3-1 SEA DRAGON MANUFACTURING PHASE HARDWARE AND EQUIPMENT "END ITEM" REQUIREMENTS 3-2 SEA DRAGON MANUFACTURING PHASE TENTATIVE BASIC PARTS LIST MASTER TOOLING SEA DRAGON MANUFACTURING PHAS-E DETAILED THRUST CHAMBER ASSEMBLY FABRICATION PLAN 3-5 Page iv Report No. LRP 297, Volume Ill AEROJET-GENERAL CORPORATION TABLE OF CONTENTS (cont.) PAR T 3 (c6nf. ) APPENDIX SECOND-STAGE FUEL TANK STUDIES SEA DRAGON SHIPYARD TANK FABRICATION PLANS SEA DRAGON THE WELDING OF THICKPLATE ALUMINUM ALLOY Z014 3-8 PAR T 4 Operational Plan I. SUMMARY - OPERATION PROCEDURES 4-I A. T RANS PO RT AT ION 4-I B. ASSEMBLY AND CHECKOUT 4-1 C. PROPELLANT SERVICING 4-2 D. LAUNCH SITE OPERATIONS 4-3 E. POST FIRE RECOVERY OPERATIONS 4-4 If. OPERATIONAL SUPPORT SYSTEM AND GENERAL SUPPORT SYSTEM PHILOSOPHY 4-4 III. OPERATION AND MAINTENANCE PLAN 4-6 A, TRANSPORTATI ON AND HANDLING 4-6 B. ASSEMBLY 4-10 C. TEST AND CHECK 4-12 D. PROPELLANT HANDLING 4-16 E. PRELAUNCH AND COUNTDOWN 4-19 Page v I li Report No. LRP 297, Volume III AEROJET-GENERAL CORPORATION TABLE OF CONTENTS (cont.) PART 4 (cont.) PAGE NO. F, MAINTENANCE AND LOGISTIC PHILOSOPHY 4 -22 G. RECOVERY OPERATIONS 4-23 H. REFURBISHMENT REQUIREMENTS 4-24 IV. EQUIPMENT REQUIREMENTS 4-25 A. SPONSON UNIT (Figure 4-4) 4-Z5 B. HYDRAULIC MATING TOOL (Figure 4-8) 4-26 C. SERVICE VESSEL (Figure 4-I0) 4-Z7 D. VERTICAL SERVICE CAR (Figure 4- l i) 4-28 E. DRILLED IN ANCHOR (Figure 4-12) 4-Z8 F. EXPANDABLE NOZZLE HANDLING SLING (Figure 4-13) 4 -29 G. AUTOMATIC BRAZING UNIT (Figure 4-14) 4-29 H. LAUNCH CONTROL VESSEL, 4-30 V. FACILITIES REQUIREMENTS 4-31 A. ASSEMBLY LAGOON 4-31 B. FUEL SERVICE AREA 4-32 C. LOX SERVICE FACILITY 4-33 VI. CONCLUSION 4-34 Page vi Report No. LRP 297, Volume III AEROJET-OENERAL CORPORATION TABLE OF CONTENTS (cont.) PART 4 (cont.) APPENDIX SEA DRAGON SUPPORT SYSTEM FUNCTIONAL FLOW DIAGRAMS AND TECHNICAL REQUIREMENTS 4-1 EQUIPMENT AND MANPOWER LIST 4-Z THERMODYNAMIC CONSIDERATIONS IN PROPELLANT SERVICING 4-3 PART 5 Cost Analysis I. SUMMARY 5-1 II. INTRODUCTION 5-Z A. VEHICLE DATA 5-Z B. WEIGHT (LB) 5-2 III. COST EFFECTIVENESS EQUATION 5-3 IV. PAYLOAD CONSIDERATION 5-4 V. ELEMENTAL COST EQUATIONS 5-4 A. VEHICLE PRODUCTION COST 5-5 B. P, PROPELLANT COST 5-6 C. T, TRANSPORTATION COST 5-7 D. L, VEHICLE LAUNCH COST 5-8 E. M, VEHICLE MAINTENANCE AND REPAIR 5-8 Page vii I I', Report No. LRP 297, Volume III AEROJET-@ENERAL CORPORATION TABLE OF CONTENTS (cont.) PART 5 (cont.) PAGE NO. VI. COMBINED COST EFFECTIVENESS EQUATION 5-8 VII. DETERMINATION OF COSTING FACTORS 5-9 A. PRODUCTION COST PARAMETERS 5-II B. PROPELLANT COST PARAMETERS 5-14 C. TRANSPORTATION COST PARAMETERS 5-17 D. LAUNCH COST PARAMETERS 5-18 E. MAINTENANCE AND REPAIR COST PARAMETERS 5-18 F. RANGE AND GENERAL OV_HEAD COST PARAMETERS 5-19 G. SURFACE SUPPORT EQUIPMENT COST PARAMETERS 5-19 H. LAUNCH FACILITY COST PARAMETERS 5-19 I. DEVELOPMENT COST PARAMETERS 5-Z0 J. RELIABILITY PARAMETERS 5 -g2 VIII. SUMMARY AND CONCLUSIONS 5-23 IX. REFERENCES 5 -25 Page viii 1 l i Report No. LRP 297, Volume III AEROJET-GENERAL CORPORATION TABLE LIST TABLE NO. PART 2 Sea Dragon Flight Test Program (For Recoverable First Stage) Z-I PART 5 Launch Costs 5-1 Maintenance and Repair Costs 5-Z Surface Support Equipment Costs 5-3 Launch Facility Costs 5-4 Development Cost Breakdown 5-5 Summary of Cost Parameter Values (Case l) 5-6 Summary of Cost Parameter Values (Case 2) 5-7 Summary of Cost Parameter Values (Case 3) 5-8 Summary of Cost Parameter Values (Case 4) 5-9 Summary of Cost Parameter Values (Case 5) 5-10 Summary of Cost Parameter Values (Case 6) 5-i1 Summary of Cost Parameter Values (Case 7) 5-12 Summary of Cost Parameter Values (Case 8) 5-13 Effects of Varying Costs Parameters 5-14 Page ix 1 ! Report No. LRP 297, Volume III AEROJET-eENERAL CORPORATION FIGURE LIST FIGURE NO. PART 1 Sea Dragon Work Breakdown Structure Showing Resource Requirement Necessary to Implement Concept l-l PART 2 First-Stage Static Test at Sea 2-I Water Entry Model Being Fired Into Water Tank 2-2 Sea Dragon Development Schedule 2-3 PART 3 Manufacturing Assembly Flow Diagram 3-I Manufacturing Ope rations 3-2 Vertical Tank Assembly 3-3 Tankage Fabrication Schedule 3-4 Expandable Nozzle Fabrication Technique 3-5 Heavy Plate Welding 3-6 Stage I Engine ROM Cost 3-7 Stage II Engine ROM Cost 3-8 Stage I Vehicle ROM Cost 3-9 Stage II Vehicle ROM Cost 3-I0 Page x Report No. LRP 297, Volume III AEROJ ET-(3EN ERAL CORPORATION FIGURE LIST (Cont.) FIGURE NO. PART 4 Operational Flow 4-0 Sea Dragon Operation Area 4-i Assembly Lagoon 4-Z Vertical Access Equipment 4-3 Sponsor Unit 4-4 Stage Assembly 4-5 Ballast As sembly 4-6 Ballast in Place 4-7 Hydraulic Mating Tool 4-8 'LOX Loading 4-9 Service Vessel 4-10 Vertical Service Car 4-11 Drill Anchor 4-12 Expandable Nozzle Sling 4-13 Automatic Brazing Unit 4-14 Vertical Servicing 4-15 PART 5 Unit Straight Line Learning Curve Estimated Operational Reliability of Sea Dragon First and Second Stage Estimated Reliability of Sea Dragon Recovery O/W - Dollars/Lb of Payload in Orbit vs Operational Year (IZ0 Launches) Page xi Report No. LRP 297, Volume III AEROJET-GENERAL CORPORATION FIGURE LIST (Cont.) FIGURE NO. PART 5 (Cont.) E-Dollars/Lb of Payload in Orbit vs Operational Year 5-5 (120 Launches) O/W-Dollars/Lb of Payload in Orbit vs Operational Year 5-6 (Z40 Launches) E-Dollars/Lb of Payload in Orbit vs Operational Year 5-7 (240 Launches) Effects of Varying Cost Parameters 5-8 Page xii 1 ! Report No. LRP 297, Volume III, Part 1 AEROJET-GENERAL CORPORATION PART 1 INTRODUCTION 1 Ii Report No. LRP Z97, Volume III, Part 1 AEROJET-GENERAL CORPORATION In order that the functions, activities, and requirements necessary for the Sea Dragon System from inception to completion be determined, a pre- liminary program plan has been prepared. This plan covers all aspects of the system support requirements; for convenience of analysis and clarity of presentation the program has been divided into three general areas (Figure I-I): I. DEVELOPMENT PLAN (PART 2) All required major research and development activities from subscale feasibility testing through the tenth full-scale developmental flight will be included in this plan. The approach is concentrated on parallel development of operational facilities and support functions with the basic vehicle so that higher reliabilities and reduced costs can be achieved early in the program. II. MANUFACTURING AND FABRICATION PLAN (PART 3) All manufacturing and fabrication operations for the vehicle and its support equipment are encompassed by this plan. The general approach has been to describe the complete manufacturing process in preliminary form and then to develop more detailed analyses for specific hardware such as the RP-I tank or Stage I engine fabrication. The more severe problems can be studied in greater depth than would otherwise be possible. III. OPERATIONAL PLAN (PART 4) All operational activities from acceptance of the vehicle components at the manufacturing locations through launch are included in this plan. Transportation, vehicle assembly, propellant servicing, launch, and recovery operations are covered in detail. Page 1 - l % Report No. LRP Z97, Volume III, Part 1 AEROJ ET-(3ENERAL CORPORATION Ill, Operational Plan (Part 4) (cont.) The materials necessary to establish the feasibility of the concept and develop the resource requirements in facilities, equipment, material, and personnel necessary to implement the concept are presented in this plan.
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