development and characteristics of the russian / american...
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AIAA Technical ActivitiesJoint Propulsion Conference Indianapolis, IN July 2002
Liquid Propulsion Short Course
1
Development and Development and Characteristics of theCharacteristics of theRussian / American Russian / American
RDRD--180 Rocket Engine180 Rocket Engine
Liquid Propulsion Short CourseLiquid Propulsion Short Course
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RD-180 Engine Development
Course OverviewCourse Overview
• Background• Engine Characteristics• Design Considerations• Development Approach• Development Summary• RD-180 Flight Program• EELV and Future Uses
AIAA Technical ActivitiesJoint Propulsion Conference Indianapolis, IN July 2002
Liquid Propulsion Short Course
3
RDRD--180 Overview180 Overview
Russian Program BackgroundRD-180 Engine CharacteristicsRD-180 Program Status
• Development• Flight
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Liquid Propulsion Short Course
4
RDRD--180 Background180 Background
• RD-180 Originally Pursued by General Dynamics in early 90’s for Atlas upgrade
• After General Dynamics merged with Martin Marietta which later became Lockheed Martin, engine studies solidified.
• In 1995, Lockheed Martin selected the joint venture team of NPO Energomash and Pratt & Whitney, (RD AMROSS) to provide the RD-180 for the Atlas IIAR (now Atlas III) and for their EELV LV designs.
• A three-phased development and certification program has now been completed which certifies the RD-180 for use on the Atlas III, Atlas V MLV, Atlas V HLV Strap-on LRBs and the Atlas V HLV Core (Common Core Booster) launch vehicle models.
• The Russian-American cooperation in this endeavor is unprecedented.
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RDRD--180 Design Background180 Design Background
RD-180 derived from the NPO Energomash designed RD-170• man-rated, reusable - Energia / Buran• more than 900 tests and 100,000 seconds of testing time• RD-180 70% similar
RD-170(1.8M lb thrust)
RD-180(0.9M lb thrust)
1/2
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RDRD--180 Engine Characteristics180 Engine Characteristics
Characteristics demonstrate heritage to RD-170
Two chamber derivative of the RD-170Identical chambers, scaled turbopumpsStaged combustion cycle - LOX rich PBLOX/kerosene propellants2 thrust chambers (+/- 8o gimbal)LOX & fuel boost pumpsSingle shaft high pressure turbopump
– 2 stage fuel pump– single stage LOX pump– single stage turbine
Self contained hydraulic system (valves, TVC) powered with kerosene from fuel pumpHypergolic ignition
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RDRD--180 Technical Data180 Technical DataFull Power (100%) Minimum Power (47%)
Chamber Pressure (psi) 3,722 1,755Flow Rate (lb/s) 2,756 1,152Total Sea Level Thrust (lb) 860,200 365,500Total Vacuum Thrust (lb) 933,400 438,700Sea Level Isp (sec) 311.9 278.7Vacuum Isp (sec) 338.4 334.6Mixture Ratio 2.72Nozzle Area Ratio 36.9Throat Area (in2) 67.5Engine Length (in) 141Circumscribed Exit Diameter (in) 124Single Nozzle Exit Diameter (in) 56.9Gimbal Angle +/- 8 degWeight, Dry (lb) 12,225Weight, Wet (lb) 13,260Thrust/Wt (Sea Level, with TVC ) 70.4Thrust/Wt (Sea Level, No TVC ) 74.5
Powerful and Dependable
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Overall Interface DrawingOverall Interface Drawing
FrameTurbine
Hot Gas Ducts
LOX Boost Pump
Fuel Boost PumpLOX
Pump
Fuel Pump
Gimbal Actuator
Heat Exchanger
Preburner
Nozzle
Gimbal Unit
Combustion Chamber(2)
Fuel Inlet Valve
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RDRD--180 Engine Schematic180 Engine SchematicFuelInlet
HeatExchanger
LOX BoostPump
Fuel BoostPump
Fuel InletValve
FuelPump
LOXPump
Preburner
Turbine
ChamberMain Fuel
Valve
StartBottle
MixtureRatio Valve
ThrustControlValve
Main LOX Valve
HypergolicStart
Ampoule
Hot GasBellows
LOXInlet
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Multiple Bell NozzleMultiple Bell NozzleCommon use in Russian designs
Multiple chambers allow• faster gimbaling/smaller actuators• increased combustion stability
margin• manufacturing efficiency• full 3-axis flight control without an
auxiliary propulsion system for roll control
• shorter engine length
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Single Shaft TurbopumpSingle Shaft TurbopumpEvolutionary heritage of proven concept
Cycle implications:• robust, repeatable start
characteristics• both pumps spool up
together - simple open loopcontrol system for engine
• low parts count (1 turbine)• low cost, high reliability
Sub-critical rotor operation:• no vibratory resonance
High Capacity• 750 lb/sec Fuel (6700 gal/min)• 2000 lb/sec LOX (12,600 gal/min)
InducerImpeller
Shaft
TurbineBlisk
LOX pump/turbinerotor assembly
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RDRD--180 Enables LV Family Growth180 Enables LV Family Growth
Atlas Family of Launch Vehicles by Lockheed Martin Astronautics
Atlas V(HLV)
Atlas V(500 Series)(0-5 SRBs)
Atlas IIAS Atlas III(SEC)
Atlas III(DEC)
Atlas IIAtlas IIA
12/91 12/93 5/00First Flight
Atlas V(400 Series)(0-3 SRBs)
2
6
10
14
18
22
26
30(k kg) (k lb) 21st Century Growth
SingleEngineCentaur
LoxTankStretch
RD-180Engine
SRBs
CommonCentaur
3.8mCommonCoreBooster
5m PLFGSO Kit
SRBs LiquidStrapons
1
3
5
7
9
11
13
GTO
Cap
abili
ty
2/02
RD-180
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High Thrust OperationHigh Thrust OperationEngine characteristics have direct benefit to vehicle
High power capability allows vehicle growth and flexibility in trajectory
Power Margin allows robust vehiclestructure and simpler manufacturingtechniques
Thrust
Throttlability allows for control of “Max Q” and propellant depletion structural loads
Engine health check during start transient
Time
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Mission variables drive test planningMission variables drive test planning
Atlas III vs. Atlas V Flight Thrust Profiles
0
10
20
30
40
50
60
70
80
90
100
0 50 100 150 200 250 300 350 400
Seconds
Pow
er L
evel
Atlas V MLVAtlas V HLVAtlas III
Pow
er L
evel
-%
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Program StatusProgram Status
Atlas III Certification testing completeProduction engine deliveries completed (Atlas III only, 7 engines)Delta Certification testing for MLV complete
MilestonesDesign & AnalysisComponent TestingCore Engine TestingDevelopment TestingCertification Testing
PDRAtlas III
Cert
Atlas V
1996 1997 1998 1999 2000Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
CDRAtlas V
Cert
Atlas III
1st Atlas III Flight1/1/5/1,024
(8 Engines/14 Builds/70 tests / 10,596 Sec)3/5/21/3,781
4/5/25/4,618
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Program Status Program Status -- cont’dcont’d
Atlas V HLV demonstration tests completedProduction engine deliveries continue, common for Atlas III or VDelta Certification testing for HLV, completed 3-Q 2001
Demonstration Testing
Certification Testing
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q42001 20022000
Atlas V HLV
1st Flight1st Atlas V MLV
12 Tests5 Tests
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RDRD--180 Engine Systems Level Test180 Engine Systems Level TestComprehensive Verification of RequirementsComprehensive Verification of RequirementsPerformance- Margins- Thrust & Isp- Mixture ratio range, margins- Helium HEX- Repeatability- Proven production
acceptance testControl- Propellant inlet extremes- Chilldown, pre-start, shutdown- Control capability, accuracy- Transient response- Throttling
Structure/Design- Vibration- Durability/life, margins
Integration- Thrust vector control, flight-
like gimbal actuations- Interface loads- Tolerance to vehicle
commanded start/launchabort
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RDRD--180 Test Time Accumulation180 Test Time Accumulation
Consistent Progress Toward Program Goals
0
5000
10000
15000
20000
25000
30000
35000
01-Jan-96 31-Dec-96 31-Dec-97 31-Dec-98 31-Dec-99 30-Dec-00 30-Dec-01 30-Dec-02
Tim
e (S
econ
ds)
Atlas IIICert
MLVCert
HLVCert
1A 2A 5A2 4A 6A 7A 8A 6B 7B 9A 9A 5A5 10A 1TC 8B 5B5
4A, MSFC 8C 11A 13A 8D 11B 13B 11C 14A
2T 3T 4T 5T 6T 7T 2T 8T 9T 10T 10T 11T 12T 12T 13T
1B 3A 5B2 9A 1T 1T
12A 12A 12B
10T 11T
AC-201
AC-20429,385 seconds and 161 firingsas of 1 April 2002
0
5000
10000
15000
20000
25000
30000
35000
01-Jan-96 31-Dec-96 31-Dec-97 31-Dec-98 31-Dec-99 30-Dec-00 30-Dec-01 30-Dec-02
Tim
e (S
econ
ds)
Atlas IIICert
MLVCert
HLVCert
1A 2A 5A2 4A 6A 7A 8A 6B 7B 9A 9A 5A5 10A 1TC 8B 5B5
4A, MSFC 8C 11A 13A 8D 11B 13B 11C 14A
2T 3T 4T 5T 6T 7T 2T 8T 9T 10T 10T 11T 12T 12T 13T
1B 3A 5B2 9A 1T 1T
12A 12A 12B
10T 11T
AC-201
AC-20429,385 seconds and 161 firingsas of 1 April 2002
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RDRD--180 Testing at MSFC180 Testing at MSFC
Development RD-180 shippedfrom Khimky, Russia to MarshallSpace Flight Center in Huntsville, ALEngine mated to Atlas III thrust structure and tank simulatorFour engine tests conducted
• 130 seconds of test time• Verified vehicle/engine system interface• and operation• Validated engine start, abort, gimbal,
heat exchanger operation and shutdown.
Lessons learned incorporatedinto flight procedures
• Double check all technical information - double check translation accuracy• Consultation with Russian experts key to successful procedure development
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Production EnginesProduction Engines
Engine Currently in Serial Production• 15 flight engines delivered to Lockheed Martin to date• 2 engines flown (successful launches of AC-201 and AC-204)• Built in Russia, flown to Denver, launched from Cape Canaveral
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RDRD--180 Flight Program180 Flight Program
Lockheed Martin Denver OperationsEngine Delivery
Receiving Inspections
Engine-to-Vehicle Integration
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Self Contained Propulsion PackageSelf Contained Propulsion PackageEfficient installation and checkout at Lockheed Martin Denver Operations
All pneumatics/hydraulics, actuators and thrust frame contained in engine sub-assemblyMinimum interfaces (11 fluid)Fully tested prior to delivery to customerMinimum test and checkout - no re-assembly required during vehicle connectionsLV integration activities reduced from 80 days to 12 compared to previous engine design
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RDRD--180 Flight Program180 Flight ProgramCape Canaveral Air Force Station Operations
Boost Stage DeliveryBooster Erection
System Level Checkouts(Wet Dress
Rehearsal, etc)
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RDRD--180 Flight Program 180 Flight Program –– First Atlas IIIAFirst Atlas IIIAWednesday May 24, 2000 7:10 PM
AC-201 SUCCESS !!• Eutelsat W4 spacecraft placed in
above-nominal orbit• Nominal RD-180 performance
Lessons Learned Minor In Nature80% of Atlas V Risk Retired
Payload FairingJettison 87% Cruise Operation
Boost StageSeparation
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RDRD--180 Flight Program 180 Flight Program -- First Atlas IIIBFirst Atlas IIIB
AC-204 SUCCESS • EchoStar 7 telecommunications satellite
placed in above-nominal orbit• Nominal RD-180 performance
No Engine Issues
AC-204 EchoStar 7Thursday Feb. 21, 2002 7:43 AM
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Delta Certification for EELVDelta Certification for EELV
Atlas V to be used as Lockheed Martin’sEvolved Expendable Launch Vehicle Atlas V MLV engine testing completed
• Additional engine builds, tests, and test time
• Certify operation at high power levels and long durations
Atlas V MLV engine certification completed-2001Atlas V HLV Core demonstration tests completedAtlas V HLV engine certification testing completed late-2001
7 October 2001 1
RD-180 Flight Program – First Atlas V
• AV-001 SUCCESS– Launch at the beginning of the
launch window on the first day– Beat EELV competition Boeing
Delta IV to First Launch– Eutelsat Hotbird 6 spacecraft
placed in nominal orbit• No Engine Issues
AV-001 Hotbird 6Wednesday August 21, 2002 6:05 pm EDT