Main Engine Prototype Development for 2 nd Generation RLV RS-83
description
Transcript of Main Engine Prototype Development for 2 nd Generation RLV RS-83
Rocketdyne02RS83-006
RD01-298 Sec. 1-Page 1March 19-21, 2002
Main Engine Prototype
Development for
2nd Generation RLV
RS-83
Mark FisherJohn Vilja
April 12, 2002
Rocketdyne Propulsion & Power
Program Objectives
• Retire risks for a 2nd Generation Reusable Engine• All technologies demonstrated in prototype
• Build to most challenging conditions
• Component operation (e.g. combustion stability)
• Manufacturing capability (e.g. forgings)
• Enable commercial engine viability
• Work to requirements flowed to engine from program• Loss of crew 1 in 10,000
• Loss of vehicle 1 in 1,000
• $1000/lb to LEO
Rocketdyne Propulsion & Power
CY2000 2001 2002 2003 2004 2005
STAS 3B
NRA 8-27
RS-83 Prototype• Design• Technology
Risk Red.
- Milestones
Technology Maturation• Materials• Components• IVHM
PDR CDR
IPDTechnologies:• Hydrostatic Bearings• H2 Compatible Materials• Turbine Damping
PrototypeTest
SRR
Basic Option 1
ATP
RFP• Prototype Fabrication• Prototype Test
SDR
Overview Schedule
Rocketdyne Propulsion & Power
NASA COTRMark Fisher
NASA RPP REP
Jeff BlandProgram Manager
John Vilja
DPMWalt
Janowski
DPMRoger
Campbell
Funded by subcontracts with primes
Boeing: Raj Varma
LMA: Steve Fusselman
NG/OSC: Dan Levack
BusinessManager
Gale Augur
Chief ProgramEngineerVernon
Gregoire
EngineIntegration IPTJon Volkmann
NASA IPTMike Mims
TurbopumpIPT
Brian Shinguchi
NASA IPTMichael Haynes
ThrustChamber IPTMike Krene
NASA IPTDave Sparks
InjectorsIPT
Ken Hunt
NASA IPTDave Sparks
Engine Development
IPTEric Stangeland
NASA IPTMike Mims
Charlie Nola
SE&ISteveHobart
NASA SystemsEngineerMike Ise
RPPMSFCLocation
RS-83 Management Team
Rocketdyne Propulsion & Power
Team has Recent Rocket Engine Development Experience
Fastrack
RS-68SSME Block II
XRS-2200
IPD
RS-72 AR2-3
RS-83Team
Rocketdyne Propulsion & Power
Integrated Systems Engineering Processes
Risk Mgmt
U Calcs
Selection Criteria
Utility Analysis
Balance Rev. 1.7d
TPM Unit of Measure Spec Value Current StatusMargin / Variance*
Trend Chart
Vacuum Specific Impulse sec 0xx yyy x0 GreenEngine Weight lbm zzzz aaaa xxx2 Green
Mean Time Between Catastrophic Failures flights zzzz yyyy zzz9 GreenMean Time Between Benign Failures flights xxx0 ? #VALUE! #VALUE!
Turnaround Time shifts xx zz x GreenProbability of Unscheduled R&R nondimensional 0.x 0..0yyy 0.www GreenMinimum Throttle %RPL rr uu tt GreenUnit Cost $M uu pppp qqqq GreenOperations Cost $M 1 cccc 0yyy GreenDevelopment Cost $M 1xx hhhh jjjj.8 GreenTime to IOC months iii jjj lll GreenBoeing Utility nondimensional 0 0.1271 0.1271 GreenLockheed Utility nondimensional 0 0.5298 0.5298 GreenNASA Utility nondimensional 0 0.mmm 0.nnn Green
Chris Garrett, SLI SE&I
TPM Quicklook ReportRS-83
x6-1576 [email protected]
*Variance is shown by a negative number
1/15/01
Report Owner:
TPMs
TPM reports
Trade Studies
TSR
CP01-9439-01
RS-83OperabilityAllocationsEID-04908
RS-83Reliability
AllocationsEID-04902
RS-83EngineWeight
AllocationsEID-04903
RS-83BaselineEngineBalance
EID-04798
RS-83Engine
TransientAnalysis
EID-04905
RS-83CAIV
AllocationsCAIV-00005
RS-83SystemAnalysisBaseline
DocumentEID-04904
RS-83Maintainablity
AllocationsEID-04909
RS-83StructuralAnalysisCriteria
ER-00553
RS-83Engine
IntegrationCIDS
CP300R0001RD01-309
RS-83Engine
DevelopmentCIDS
CP406R0024RD01-308
RS-83Injectors
CIDSCP251R0002
RD01-306
RS-83Thrust
ChamberCIDS
CP251R001RD01-305
RS-83Turbopump
CIDSCP281R0001
RD01-304
RS-83Prime Item
DevelopmentSpecification
(PIDS)CP320R0058
RD01-284
InterfaceControl
Document(ICD)
RD01-202
RS-83FunctionalFlow BlockDiagram(FFBD)
EID-04906
RS-83Mission
ReferenceDocument
(MRD)EID-04907
2nd GenerationRLV Propulsion
SystemRequirements
Document(PSRD)
2GRLV-RQMT-016
Implementation Level
PERFORMTASK
PREPAREVERIFICATION
REPORTS
DOCUMENTCLOSURE
Define and P lan Verification Tasks
IDENTIFYALLALL
REQUIREMENTS
STEP 1 STEP 2
Perform Tasks and Close Requirements
STEP 3STEP 4STEP 5
DEFINETASKS & SUCCESS
CRITERIA
IDENTIFYTASK
INTERDEPENDENCY
PREPAREVERIFICATIONSCHEDULES
DEFINE CLOSURE STRATEGY
Schedules- Component- System- Integrated
VerificationCompliance
Reports
VerificationCompliance
Matrix
VerificationLogic
Networks(VLN’s)
DetailedVerification
Records(DVR’s)
Requirement Decomposition& Flowdown
Matrices
RequirementTraceability
Report
- Tests- Analyses- Demo- Inspection
Requirements
To FunctionalConfiguration
Report
V&V
Specs
Requirements
Safety/HazardsReliability
MaintainabilityOperability
AffordabilitySchedule
PerformanceTransients
WeightAllocation Reports
ICDs
Functional analysis
Rocketdyne Propulsion & Power
Utility Analysis
SRR/PIDS
Proposed Engine
NRA 8-27(Vehicle Reqts)
Additional Vehicle Reqts
PSRD
Trade Studies
Conceptual DevelopmentReqts Allocations
ComponentLimits
DerivedReqts
EngineBalance
Reqts Synthesis for Risk Reduction Prototype
Requirement Analysis and Development
Rocketdyne Propulsion & Power
Si n
gle
En
gin
e C
atas
tro
ph
i c F
ail u
r e M
TB
F
3
5
7
Resource/Time line/Risk Management Milestones
SSME Block II point of departure
Component Design
Allocation goal: 60% risk reduction(2.5 times MTBF improvement)
Engine Derating + Health Management
System + Component Design
Allocation goal: 40% risk reduction(1.67 times MTBF improvement)
Health Management System + Component
Design
Allocation goal: 50% risk reduction(2 times MTBF improvement)
Reference
10 Allocation Goal with reserve
9
PIDSReq’t
Catastrophic Loss of EngineAllocation to Subsystems and Component Teams
Rocketdyne Propulsion & Power
SSME Block II Failure Probabilityby Component
HPFTP25%
HPOTP15%
LTMCC10%
Nozzle10%
Main Inj.4.75%
Propellant Valves6.54%
Rocketdyne Propulsion & Power
Reliability Crit 1
Crit 1R or 2
Crit 3
Loss of Vehicle, Loss of Crew
Cat. Failures
Loss of MissionBenign
Engine Shutdown
Failure ModesVehicle Figure
of Merit
AvailabilityCost/Eng/Flt
Unplanned R&R/
Maintainability
MaintainabilitySupportabilityLogistics Support Plan
PlannedMaintenance
UnplannedMaintenance
Engine Figure of Merit
Reliability, Maintainability & Supportability
Rocketdyne Propulsion & Power
Key Operation Drivers being Derived from FFBDto Support Requirements
Operations Effects Modeled forAll Design Trade Studies
1 2 3 4 5 6 7 8 9 10 11
Land, Safe and Provide
AccessPropellant Loading
3.2.5.5 Chilldown
Time
3.2.5.1 Maintenance Time
3.2.5.9 Call up Time
Prep for Launch
3.2.5.2 Engine Change Out
3.2.5.7 Routine Pre-Launch Maintenance Time
3.2.5.6 Turnaround Time
External Insp & Drying
Vehicle to Launch PadMaintenance (planned & unplanned)
Land Launch
EXPORT CONTROLLED
Rocketdyne Propulsion & Power
ReferenceConfiguration
Viable Option1
Viable Option2
Viable Option3
Traded Options Option Assessment withrespect to Decision Attributes
• Isp• Weight• Cost• Reliability• Safety• Operability• Risk
Translate Assessmentinto Figures of Merit
Determine OverallRankings
Utilities
Sensitivities
On Select trades
Isp - vac
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
430 435 440 445 450 455 460
U(x
)
Utility-Based Trade MethodologySystem-Level Trades
ATTRIBUTE VALUEPerformance / Weight Vacuum Isp @ RPL (sec) 447.5 Vacuum Isp @ nominal PL (sec) 447 Single Engine Vacuum Thrust @ RPL (lbf) 751,717 Single Engine Sea Level Thrust @ RPL (lbf)650,000 Single Engine Weight (lbm) 10,513Reliability Single Engine Catastrophic Failure Prob. 5.187E-05 Single Engine Unscheduled R&R Prob. 0.0831788Operability 4 Engine Cluster Turnaround Time (shifts) 7Cost Development Cost ($M) Boeing Unit Cost ($M) Lockheed Unit Cost ($M)Schedule
Months from PDR to 1st flight set delivery 66Throttle Minimum Throttle (%RPL) 50%Envelope Nozzle Exit O.D. (inches) 96
Vehicle Independent Attribute Inputs
BA
SE
LIN
E
Rocketdyne Propulsion & Power
RS-83 Designs in High Reliability and Cost Reduction
• Series turbines• Eliminate potential for “Run Away”• Higher efficiency reduces turbine temp
• Reduced hot gas temperature• Improve turbine life• Eliminate hot-gas duct cooling
• Liquid/Liquid Preburners• Eliminates turbine temp spikes
• Turbopumps• Hydrostatic bearings provide long life
• Hydrogen compatible materials• Eliminate reliability, cost, and
maintenance issues with plating• Powder metal enables large parts
Rocketdyne Propulsion & Power
RS-83 Prototype Engine
• Thrust • Sea Level 664 klb
• Vacuum 750 klb
• Specific Impulse• Sea Level 395 sec.
• Vacuum 446 sec.
• Weight 12,700 lbm
• Life 100 Missions
• Dimensions• Length 171 in.
• Diameter 115 in.
• Demonstrates all candidate technologies for FSD engine
Rocketdyne Propulsion & Power
Designs Maturing Rapidly
CoDR completed on all major partsCoDR completed on all major parts
Rocketdyne Propulsion & Power
Advanced Mat’ls &Processes
Model Correlation Flow Characterization
Component Demo ComponentCharacterization
Technology Evaluation
Key Risk Mitigation Tests in Work
Rocketdyne Propulsion & Power
Summary
• RS-83 engine meets all SLI requirements with margin
• Project is on budget & schedule
• High performance NASA/contractor team in-place
• Trades based on rigorous systems engineering processes
• CoDRs conducted for Turbopumps and Combustion Devices
• Early retirement of key risks taking place
• Communication within team enhanced by web-based
information technology
• All elements in-place to assure success