J CONTRACT NO. NAS8-37137 VOLUME II APPENDICES 6-8 FINAL REPORTS OF ROCKETDYNE, PRATT AND WHITNEY, AND TRW (\_ASA-L'_-lci_oD3) Lf .U[ _ ouCmrf c,OoRTrR NeO-IQi_ STU;Y. VuLU _'L z_, _<_._ _+, _P_L*,".JI_FS _-b: Rc!P!-!PTo _r _jC_k c [QYNc _ _KATT AN, r? WH[ [NLY, AN_3 TP. Fin]l R_i_orf (C, ener,._l r_yndmics Corn.) 55') _.; CSCI.. ?IH q J/Z0 LIQUID ROCKET BOOSTER STUDY FINAL REPORT GENERAL DYNAMICS Space Systems Division t_ APPENDIX 6 LRB FINAL REPORT FROM ROCKETDYNE _"_L_ Rockwell International Rocketdyne Dlvlslcm 6633 Canoga Avenue Canooa Park. California $11304 RZ/RDBB-180 LIQUIO ROCKET BOOSTER PHASE II STUDY REPORT 8 3une 198B PREPARED BY ROCKETDYNEOIVISION ADVANCED LAUNCH SYSTEMS CONTRACT NUMBER 08-01290 LIQUIDROCKETBOOSTERPHASEII STUDY REPORT FOREWORD This Phase II report, containing results of the Liquid Rocket Booster Study is submitted to General Dynamics Space Systems Division (GDSS) in accordance wlth General Dynamics contract 08-01290. This program was conducted under the direction of GDSS program manager Paul Bialla and Propulsion Project Manager Gopal Mehta. This document describes the results of a Liquid Rocket Booster engine study conducted in two parts; (1) Pressure fed engine design and analysis carried forward in more detail using the results of the Phase I studies, and (2) Pump-fed engine parametric and design point data. Technology program elements for the booster engines are also presented in this report. Specific costs are not included in this report due to their proprietary nature; however, they have been submitted to General Dynamics under separate cover. ABSTRACT Phase II of the Liquid Rocket Booster Study was conducted over a four month period by Rocketdyne. For the pressure-fed engines, detailed trade studies were conducted defining engine features such as thrust vector control method, thrust chamber construction, etc. This was followed by engine design layouts and booster propulsion configuration layouts. For the Pump-fed engines parametric performance and weight data was generated for both 02/H 2 and 02/RP-I engines. Subsequent studies by GDSS and NASA resulted in the selection of both LOX/RP-I and 02/H 2 propellants for the pump-fed engines. More detailed analysis of the selected LOX/RP-I and 02/H 2 engines was conducted during the final phase of the study. ii 15_q7 TABLE OF CONTENTS PAGE Foreword iii Table of Contents List of Figures List of Tables l.O INTRODUCTION l l.l Approach 2 1.2 Requirements 2 1.2.1 6round Rules and Baseline System 3 2.0 PRESSURE FED LOX/RP-I ENGINE 5 2.1 Recommended Configuration and Characteristics 5 2.1.1 Regenerative Cooling 5 2.1.2 Injector Selection 7 2.1.3 Main Combustion Chamber and Nozzle lO 2.1.4 Gimbal System Selection lO 2.2 PRELIMINARY DESIGN ANALYSIS 12 2.2.1 Engine Layout and Description 12 2.2.2 Schematic and Flight Instrumentation 16 2.2.3 Performance (Full Thrust and Throttled) 16 2.2.4 Weight Breakdown 21 2.2.5 Gimbal System Summary Use and Power 22 2.2.6 Engine Operation 24 2.2.7 Interface Requirements 24 2.3 POGO AND STABILITY ANALYSIS 2B 2.3.1 Introduction and Summary 2B 2.3.2 The POGO Phenomenon 31 2.3.3 Recommendations 43 2.4 RELIABILITY ANALYSIS 43 2.5 LRB PRESSURE FED ENGINE PROGRAMMATICS 50 2.5.I Engine Development Philosophy 50 2.5.2 Program Approach 52 2.5.3 Test Plan 52 2.5.4 New Technology Requirements 57 iii 1539z TABLEOF CONTENTS (CONTINUED) PAGE 2.6 LOX/RP-1 Pressure Fed Liquid Rocket Booster Preliminary 61 Contract End Item 61 2.6.1 Background 61 2.6.2 Selected Engine Description 61 2.6.3 LRB CEI Requirements 62 3.0 PUMP FED LOX/RP-I ENGINE 69 3.1 Engine/Subsystem Configuration Selection 69 3.1.1 Thrust Chamber Cooling Selection 69 3.1.2 NPSH Requirements with and without Boost Pumps 72 3.1.3 Injector Selection and Rationale 74 3.1.4 Mixture Ratio Control During Throttling "74 3.1.5 Gas Generator (GG) Exhaust "/5 3.1.6 Control "75 3.2. Engine Design, Analysis and Operation 75 3.2.1 Engine Description "7"7 3.2.2 Engine Instrumentation "77 3.2.3 Engine Performance and Throttling Characteristics 81 3.2.4 Engine Weight Summary B4 3.2.5 Start and Shut Down 84 3.2.6 Thrust Vector Control Actuation Torque and Power Rqmts. 8B 3.2.7 Boundary Layer at the Exit Plane Gas Condition Analysis BB 3.3. POGO Stability Analysis 90 3.3.1 POGO Suppressor Design Philosophy 90 3.3.2 Suppressor Configuration 92 3.4. Failure Mode Analysis and Reliability Estimate 94 3.4.1 Preliminary Failure Mode andEffects Analysis - Pump Feed LRB 95 3.4.2 Criticality Definition 95 3.5 Programmatics 102 3.5.1 Development Schedule 102 3.5.2 Development Plan 104 3.5.3 Program Approach 104 3.5.4 Component Test Program 105 iv 1539z TABLE OF CONTENTS (CONTINUED) PAGE 3.5.5 Engine Test Program 110 3.5.6 Technology Plan for LRB Pump Feed Engine I16 3.6 LOX/RP-1 Liquid Rocket Booster Preliminary Contract End Item (CEI) lib 3.6.1 Background lib 3.6.2 Selected Engine Description 119 3.6.3 LRB CEI Requirements ll9 4.0 LOX/HYDROGEN PUMP FEED ENGINE 126 4.1 Introduction 126 4.2 Main Propulsion System 126 4.2.1 Engine System 126 4.2.2 Engine Schematic and Operation 132 4.2.3 Engine Control and Condition Monitoring System 140 4.2.4 Engine Description 143 4.2.5 Engine Instrumentation 148 4.2.6 POGD and Stability Analysis 150 4.2.7 Failure Mode and Effects Analysis and Reliability Estimate 150 4.2.B Programmatics 152 4.3 LOX/H 2 Liquid Rocket Booster Preliminary Contract End Item (CEI) 152 4.3.1 Background 152 4.3.2 Selected Engine Description 152 4.3.3 LRB CEI Requirements 163 1539z LIST OF FIGURES PAGE 2-I Simplified Engine Schematic 6 2-2a Injector Cross Section B 2-2b Distribution of Ig Modules B 2-2c Cross Section of a Typical Module B 2-3 Thrust Chamber Assembly ll 2-4 LRB Pressure Fed Engine System 13 2-5 Conceptual Valve Design 16 2-6 Pressure Fed LRB Engine Schematic 17 2-7 Meaning of Computer Printout Terms 18 2-8 Baseline Design Point for Pressure Fed Engine 19 2-9 Baseline Design Point Throttled to 60% of Nominal Thrust 19 2-10 Engine Startup & Shutdown 26 2-11 Interface Drawing 29 2-12 Four LRB Engines 30 2-13 Engine Gimbal Block Accelerometer Outputs 32 2-14 Couch Vibration and AS-503 Crew Acceleration Tolerance 33 2-I 5 POGO Block Diagram 34 2-16 Comparison of Several Engines Involved with POGO 35 2-I 7 Oxidizer Injection Pressure Gain Response 39 2-18 Oxidizer Injection Pressure Phase Response 39 2-19 Inlet Pressure Gain Response to Tank Bottom Acceleration 41 2-20 Inlet Pressure Phase Response to Tank Bottom Acceleration 41 2-2l LRB Pressure Fed Engine Development Program 51 2-22 LRB Pressure Fed Engine System Test Plan 53 2-23 LRB Controls Component Development Plan 55 2-24 Engine Development Plan 56 2-25 Engine Development Program 56 2-26 LRB Pressure Fed Test Matrix Characterization Phase 58 2-27 LRB Pressure Fed Engine Development Program System Test/Hardware Requirements 5B 3-1a LOX/RP-I LRB Pump-Fed Engine 70 vi 1539z LIST OF FIGURES (continued) PAGE 3-1b Top View of LOX/RP-1 Engine 70 3-2 Simplified LRB LOX/RP-1 Pump-Fed Engine Flow Schematic 71 3-3 LOX Pump Inlet Pressure Effects "/3 3-4 LRB Flow Schematlc 76 3-5 LRB Pump-Fed Engine Characteristics 78 3-6 Bi-Propellant Engine Flow Schematic 79 3-7 Envelope Equations of Two Accelerometers 91 3-8 POGO Block Diagram 92 3-9 POGO Suppression System 93 3-10 LRB Pump-Fed Engine Development Program (LOX/RP-I or 103 LOX/H 2 Propellants) 3-I 1 LRB Pump-Fed Engine Component Development Program 106 (LOX-RP-I and LOX-H 2) 3-12 Engine Development Programs 111 3-13 Engine Life Development Program 113 3-14 LRB Pump-Fed Engine System Development Program I15 (LDX/RP-I and LOX/H 2) 4-I LRB LOX/Hydrogen Engine 127 4-2 Inlet Pressure Impact on Pump Size 129 4-3 Concept A, Turbine Exhaust Through Nozzle Wall Sonic Flow 129 4-4 Concept B, Turbine Exhaust Through Nozzle Wall - Supersonic Flow 130 4-5 Concept C, Turbine Exhaust at Exit Plane - Single Round Nozzle 130 4-6 STME Tank Head Start 131 4-7 Chamber Pressure During Start 131 4-8a Engine Schematic 13"/ 4-8b Engine Schematic Showing Flow Rates, Pressures, and Temperatures at EPL 137 4-9 Engine Start Valve Position Ramp Rates 139 4-10 Chamber Pressure as a Percent of Nominal 139 4-11 LOX/H2 LRB Engine Mixture Ratio During Start Transient 140 4-12 STME Closed Loop Control Diagram Modified for Use with the LRB 142 4-13 LOX/H2 LRB Injector Assembly and Co-axial Element Conceptual Design 145 vii 1539z LIST OF TABLES PAGE 1-] SRB Characteristics 2 2-1 Pressure-Fed Booster Engine 6 2-2 Injector Characteristics 9 2-3 Weight Comparison for Pressure Fed Engine 12 2-4 Modulation of Throttle Setting Changes In a Pressure-Fed Liquid Propellant Booster 20 2-5 LRB Pressure-Fed Baseline Engine Weight 22 2-6 LRB TVC Torque Breakdown for Head End Gimbal 23 2-7 Utility Requirements 27 2-8 Preliminary Failure Mode - Effects Analysis 44 3-1 LOX/RP-I Pump-Fed Engine Design Features 17 3-2 Engine Acceptance Testing Condition Monitoring Sensors BO 3-3 Preliminary Performance and Redline Flight Instrumentation List for the STBE BO 3-4 Engine Balance Printout 82 3-5 Engine Performance vs.