Springer Aerospace Technology

Transcription

1 Springer Aerospace Technology

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3 Wolfgang Kitsche Operation of a Cryogenic Rocket Engine An Outline with Down-to-Earth and Up-to-Space Remarks With 100 Figures and 19 Tables 123

4 Wolfgang Kitsche Deutsches Zentrum für Luft- und Raumfahrt e.v. (DLR) Langer Grund Hardthausen Germany ISBN e-isbn DOI / Springer Heidelberg Dordrecht London New York Springer Series in Aerospace Technology ISSN e-issn Library of Congress Control Number: c Springer-Verlag Berlin Heidelberg 2011 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover design:wmxdesigngmbh,heidelberg Printed on acid-free paper Springer is part of Springer Science+Business Media (

5 ...and one remark up to heaven All we do should increase the honour of God, as a beneficial lead for those who have lost their connection to their Creator and Father in heaven and to the joy of those who know their Lord and Saviour; only then is a service complete. Because we cannot complete any service without His help, prayer is the beginning of any deed and service. All human measures, planning and skill are no guarantee for the success of anything, but the help of God can lead from situations without hope to wonderful success; for Him nothing is impossible. Wolfgang Kitsche, June by my God have I leaped over a wall. King David, Psalm 18 Verse 29

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7 Preface A Test Facility, if you ve seen one of them, you ve seen all of them ; that was the comment of a colleague showing a picture in his presentation about the utilisation of hydrogen. This book will invite the reader to see not only the trivial pipeline on the test facility, but rather to discover that here all efforts are merging to operate a propulsion system of ultimate performance. The development and studies of many branches of science, constructions and prototypes of various high tech companies have to prove their quality here. A prototype of some gigawatts is handed over to the test engineer with a value of umpteen millions of Euros and the focus of the whole space program is on the result of his work. The test cell of the facility is the meeting point of specialists in the most exciting phase of the development of a rocket engine. Some authors having devoted a chapter of their books to the test facility, this book sets the focus on the operational aspects of the rocket engine in the test facility. This book will be useful to engineers and scientists who are concerned with the test facility, to aerospace students it will provide an insight to the job on the test facility and to interested readers it will provide an impression of this thrilling area of aerospace. The comments in this book reflect the experience of 2 decades of test periods on one of the two largest test facilities for cryogenic rocket engines in Europe. Hardthausen, Germany October 2010 Wolfgang Kitsche vii

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9 Acknowledgement Thanks go first of all to everybody in the test team only their elaborate work made so many successful tests possible. The author also wants to thank his colleagues from the engine manufacturer SNECMA for the amicable cooperation which amplified the ability and professionalism of the whole test team. Special thanks go to Oskar Haidn and Gerd Krühsel for their friendly support; they closely studied the draft of this book and addressed many hours to discussing and improving the content. Thanks are also due to the head of the DLR Space Propulsion Institute, Stefan Schlechtriem and the former Head of Institute, Wolfgang Koschel for their support in the course of producing this volume. Many thanks also go to the author s family who had to abstain from his presence for many hours but always had the higher priority. The greatest honour is due to God, who gave us all the ability and the opportunity to do this thrilling work without any serious incident. Hardthausen, Germany Wolfgang Kitsche ix

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11 Contents 1 Introduction Operational Aspects of the Rocket Engine and the Test Facility Propulsion Systems Test Facilities Test Periods Organisation and Clients of Test Programs Development Tests Acceptance Tests Technology Support Test Campaign on the Test Bench Handling of the Specimen Work Instructions and Computer Programs Test Execution Test Analysis Operation of the Test Bench Measurement, Control and Command System Pre- and Post-Test Inspections Functional Test Leak Measurement Visual Inspection Determination of Dimensions Pollution Control Engine Test Test Configuration Test Readiness Hot Run Preparation Chill Down of Cryogenic Rocket Engines Hot Run Start Up Transient xi

12 xii Contents Control and Regulation Monitoring of Engine Parameters Shut-Down Transient Engine Performance Map Test of Expander Cycle Engines Bench Systems Principles for the Erection of a Test Facility Back Up Systems Fuel and Oxidiser Supply Vacuum Insulation Feed System Measurement, Control and Command (MCC) Systems Historical Review Control Programs Engine Control Data Acquisition Measurement Validation Detection Systems Test Cell Systems Exhaust System Altitude Simulation Simulation of Flight Conditions Pump Inlet Pressure Profile Pogo Oscillation Acoustic Load Nozzle Load Weather Conditions Ambient Temperature Rain and Humidity Thunder and Lightning Sight and Fog Wind Atmospheric Sound Propagation Test Procedures Test Readiness Procedure Non-conformance Procedure Risk Management During Operation Configuration Management Safety... 83

13 Contents xiii 10 Documentation Facility Documents Test Documents Test Request Instruction Manual Chronology Inspection Results Test Report Plan of Activities on the Engine Checklists and Work Procedures Test Team Appendix A Chamber Valve Characteristic Appendix B Chamber Igniter Characteristic Appendix C Measurement and Correction of the Ovality of a Vulcain Nozzle Appendix D Compare of Flow Schemes Vulcain/Vulcain Appendix E Flow Scheme of the Ariane 5 Main Stage Appendix F Flow Scheme of Vulcain Appendix G Flow Scheme of Vinci Appendix H Mixtures of Oxygen and Nitrogen Close to Their Boiling Points Appendix I Jet Pump Appendix J Fluids of the Test Process Appendix K Pressure Transducer Appendix L Measurement Chain Appendix M Valve Control Circuit Appendix N Oxygen Detector...131

14 xiv Contents References Index About the Author...141

15 List of Abbreviations A/D Analog/Digital ARTA Ariane Research and Technology Accompaniment CNES Centre National d Études Spatiales CTA Commission de Traitement des Anomalies DLR Deutsches Zentrum für Luft- und Raumfahrt EADS European Aeronautic Defence and Space Company ECA Evolution Cryotechnique Type A EGAS European Guaranteed Access to Space ESA European Space Agency FMECA Failure Mode Effects and Criticality Analysis FORTRAN FORmula TRANslation, program language H0 Time of hot run start H2 Time of hot run stop He Helium L5 Launch number 5 LH2 Liquid hydrogen LO2 Liquid oxygen LOX Liquid oxygen LSD Load Simulation Device MCC Measurement, control, command MkII Mark II, initial name of the Vulcain 2 N 2 Nitrogen NASA National Aeronautics and Space Administration NCR Non-conformance report NE Nozzle extension NEA NetzErsatzAggregat Norsk Data Norwegian computer system NPSH Net pressure suction head O 2 Oxygen P1.2 Test facility on the Lampoldshausen test centre P4.1 Test facility on the Lampoldshausen test centre P5 Vulcain test facility at DLR, Lampoldshausen P8 Test facility on the Lampoldshausen test centre xv

16 xvi PF50 PLC RAMS SCA SEP SMO SNECMA SPF TNT USV VFW List of Abbreviations Vulcain test facility at SNECMA, Vernon Programable logic controller Reliability, availability, maintainability, safety Attitude control system Société Européenne de Propulsion Specification de mise en ouvre Société Nationale d Etudes et de Constructions de Moteurs d Aviation Single point failure Trinitrotoluol UnterbrechungsfreieStromVersorgung Vereinigte Flugtechnische Werke