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


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


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


Team has Recent Rocket Engine Development Experience

Fastrack

RS-68SSME Block II

XRS-2200

IPD

RS-72 AR2-3

RS-83Team


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


RS-83BaselineEngineBalance

EID-04798

RS-83Engine

TransientAnalysis

EID-04905

RS-83CAIV

AllocationsCAIV-00005

RS-83SystemAnalysisBaseline

DocumentEID-04904

RS-83Maintainablity


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


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


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


SSME Block II Failure Probabilityby Component

HPFTP25%

HPOTP15%

LTMCC10%

Nozzle10%

Main Inj.4.75%

Propellant Valves6.54%


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


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


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


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


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


Designs Maturing Rapidly

CoDR completed on all major partsCoDR completed on all major parts


Advanced Mat’ls &Processes

Model Correlation Flow Characterization

Component Demo ComponentCharacterization

Technology Evaluation

Key Risk Mitigation Tests in Work


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

Documents

Main Engine Prototype Development for 2 nd Generation RLV RS-83