FR-19691-4 VOLUME II 1 DECEMBER 1989 SPACE TRANSPORTATION BOOSTER ENGINE CONFIGURATION STUDY FINAL REPORT (DR4) INCLUDES DESIGN DEFINITION DOCUMENT (DR8) AND ENVIRONMENTAL ANALYSIS (DR10) 31 MARCH 1989 CONTRACT NAS8-36857 MODIFICATION NO.10 Pratt & Whitney Government Engine Business P.O. Box 109800 West Palm Beach, Florida 33410-9600 Prepared for Procurement Office George C. Marshall Space Flight Center National Aeronautics and Space Administration Marshall Space Flight Center, AL 35812 UNITED TECHNOLOGIES PRATT&WHITNEY RI_IQiI/30 Prlnled rn the United Slates of Ame(_ca Pratt & Whitney FR-19691-4 Volume II LiST OF ILLUSTRATIONS (Continued) Figure Page 4.1.1.4-8 STBE Derivative Gas Generator Assembly .................................. 38 4.1.1.5-1 STBE Derivative Gas Generator Regeneratively Cooled Nozzle ........ 40 4.1.1.5-2 STBE Derivative Gas Generator Nozzle Cooling Configuration ........ 41 4.1.1.5-3 STBE Derivative Gas Generator Nozzle Heat Transfer Performance Summary .............................................................................. 42 4.1.i.6-i STBE Derivative Gas Generator Engine Control and Health Monitor System Functional Concept Meets All Requirements With Low-Cost Approach .............................................................................. 44 4.1.1.6-2 Valve Sequence and Thrust Buildup for Engine Start ................... 48 4.1.1.6-3 Valve Schedule and Thrust Transient for Engine Shutdown ........... 49 4.1.1.6-4 Schedule Requirements Feasible With Ganged Valves .................... 50 4.1.1.6-5 Valve Sequencing Accomplished With Timed Logic ....................... 53 4.1.1.7-1 STBE Derivative Gas Generator Engine Assembly -- Side View ..... 55 4.1.1.7-2 STBE Derivative Gas Generator Engine Assembly -- Top View ...... 56 4.1.1.7-3 Internal Ball Strut Ducting Gimbai ........................................... 57 4.1.1.7-4 Externally Pinned Ducting Gimbal ............................................ 58 4.1.1.7-5 External Ball Race Ducting Gimbal ........................................... 58 4.1.1.7-6 STBE Derivative Gas Generator GO 2 HEX Geometry and Performance Data .................................................................. 60 Preliminary FMEA -- Major Engine Sections .............................. 61 STBE Derivative Gas Generator Engine Operating Characteristics at DPL .................................................................................... 85 4.1.2.1-1 STBE Unique Gas Generator Cycle Engine -- 625K Sea Level Thrust ................................................................................. 125 4.1.2.1-2 STBE Unique Gas Generator Cycle Engine -- 750K Sea Level Thrust -- Growth Capability ....................................................127 STBE Unique Gas Generator Characteristicsat Design Power Level 128 Simplified Flow Schematic for STBE Unique Gas Generator Cycle Engine .................................................................................129 Pratt & Whitney FR-19691-4 Volume II LIST OF ILLUSTRATIONS (Continued) F_ure Page 4.1.2.3-1 STBE Unique Gas Generator LO 2 Turbopump ............................. 132 4.1.2.3-2 STBE Unique Gas Generator Fuel Turbopump ............................ 133 4.1.2.3-3 STBE Unique Gas Generator Three-Stage Fuel Pump and a Single Discharge Volute .................................................................... 134 4.1.2.3-4 STBE Unique Gas Generator Two-Stage Fuel Pump and a Single Discharge Volute .................................................................... 134 4.1.2.3-5 STBE Unique Gas Generator Single-Stage Fuel Pump With Boost Pump (Conventional) and a Single Discharge Volute ..................... 135 4.1.2.3-6 STBE Unique Gas Generator Single-Stage Fuel Pump With Boost Pump (Conventional) and a Double Discharge Volute .................... 135 4.1.2.3-7 STBE Unique Gas Generator Two-Stage Fuel Pump With Jet Boost Pump and a Single Discharge Volute .........................................136 4.1.2.3-8 STBE Unique Gas Generator Single-Stage Fuel Pump With Jet Boost Pump and a Single Discharge Volute ................................136 4.1.2.3-9 STBE Unique Gas Generator High-Speed Boost Pump and a Single Discharge Volute ....................................................................137 4.1.2.3-10 STBE Unique Gas Generator High-Speed Boost Pump and a Single Discharge Volute ....................................................................137 4.1.2.4-1 STBE Unique Gas Generator Main Injector ................................139 4.1.2.4-2 STBE Unique Gas Generator Main Injector Element .................... 140 4.1.2.4-3 STBE Unique Gas Generator Main InjectorPattern ..................... 141 4.1.2.4-4 STBE Unique Gas Generator Combustion Chamber ...................... 142 4.1.2.4-5 STBE Unique Gas Generator Chamber Cooling Design Configuration 143 4.1.2.4-6 STBE Unique Gas Generator Chamber Heat Transfer Performance Summary .............................................................................. 144 4.1.2.4-7 STBE Unique Gas Generator Assembly ...................................... 146 4.1.2.4-8 STBE Unique Gas Generator Assembly ...................................... 147 4.1.2.4-9 STBE Unique Gas Generator Assembly Injector Element ............... 148 4.1.2.4-10 STBE Unique Gas Generator Assembly Injector Pattern ................ 149 vi Rlg_II/61 Pratt & Whitney FR-19691-4 Volume II LIST OF ILLUSTRATIONS (Continued) Figure Page 4.1.3.7-3 STBE Common Gas Generator Cycle Engine Operating Characteristics at Normal Power Level ....................................... 203 4.1.3.7-4 STBE Common Gas Generator Cycle Engine Operating Characteristics at Design Power Level ........................................ 204 4.1.4.1-1 STBE LO2/RP-1 Gas Generator Engine Performance Characteristics at Design Power Level ............................................................ 210 4.1.4.2-1 STBE LO2/RP-1 Gas Generator Engine Simplified Flow Schematic 211 4.1.4.3-1 STBE LO2/RP-1 Gas Generator Chamber Design Configuration ...... 214 4.1.4.3-2 STBE LO2/RP-1 Gas Generator Chamber Heat Transfer Performance Summary ............................................................ 215 STBE LO2/RP-1 Gas Generator Nozzle Design Configuration ......... 216 STBE LO2/RP-1 Gas Generator Nozzle Heat Transfer Performance Summary .............................................................................. 217 4.1.4.4-3 STBE LO2/RP-1 Gas Generator Film and Radiation Cooled Nozzle Thermal Summary ................................................................. 219 4.1.4.5-1 STBE LO 2/RP-1 Gas Generator GO 2 HEX Geometry and Performance Data .................................................................. 220 4.1.4.5-2 STBE LO2/RP-1 Gas Generator Engine Flow Schematic at Design Power Level (120%) ............................................................... 222 4.1.4.5-3 STBE LO2/RP-1 Gas Generator Engine Flow Schematic at Normal Power Level {100%) ............................................................... 223 STBE Derivative Split Expander Engines at Design Conditions ...... 229 Simplified Flow Schematic for STBE Derivative Split Expander Cycle Engine ......................................................................... 231 4.2.1.3-1 STBE Derivative Split Expander Oxidizer Turbopump ................... 233 4.2.1.3-2 STBE Derivative Split Expander Fuel Turbopump ........................ 235 4.2.1.3-3 STBE Derivative Split Expander LO 2 Turbopump Critical Speeds Analysis Showing the Pump Pitch Mode of the Rotor at 115% Design Speed (RPM ,, 7615) .................................................... 237 4.2.I.3-4 STBE Derivative Split Expander LO 2 Turbopump Critical Speeds Analysis Showing the Turbine Bounce Mode of the Rotor at 563% Design Speed (RPM - 37196) .................................................. 238 ix Rl_b'gl._l Pratt & Whitney FR- 19691-4 Volume II LIST OF ILLUSTRATIONS (Continued) Figure Page 4.2.1.3-5 STBE Derivative Split Expander Fuel Turbopump CriticalSpeeds Analysis Showing the Pump Pitch Mode of the Rotor at 96% Design Speed (RPM = 10815) ..................................................239 4.2.1.3-6 STBE Derivative Split Expander Fuel Turbopump CriticalSpeeds Analysis Showing the Turbine Bounce Mode of the Rotor at 267% Design Speed (RPM - 30122) ..................................................240 4.2.1.4-1 STBE Derivative Split Expander Main Injector ........................... 243 4.2.1.4-2 STBE Derivative Split Expander Main Injector Element ................ 244 4.2.1.4-3 STBE Derivative Split Expander Main Injector Pattern ................ 245 4.2.1.4-4 STBE Derivative Split Expander Combustion Chamber ................. 246 4.2.1.4-5 STBE Derivative Split Expander Thrust Chamber Cooling Design Configuration ........................................................................ 247 4.2.1.4-6 STBE Derivative Split Expander Thrust Chamber Heat Transfer Performance Summary ............................................................ 248 4.2.1.4-7 STBE Derivative Split Expander Nozzle Cooling Design Configuration ........................................................................249 4.2.1.4-8 STBE Derivative Split Expander Nozzle Heat Transfer Performance Summary .............................................................................. 250 4.2.1.5-1 Engine Control and Health Monitor System Functional Concept Meets All Requirements With Low-Cost Approach ........................ 252 4.2.1.5-2 STBE Derivative Split Expander Start/Shutdown Valve Sequences .. 256 4.2.1.5-3 STBE