Liquid Propulsion Short Course
Development and Characteristics of the Russian / American RD-180 Rocket Engine
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Engine Development Course Overview • • • • • • •
Background Engine Characteristics Design Considerations Development Approach Development Summary RD-180 Flight Program EELV and Future Uses
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Overview
Russian Program Background RD-180 Engine Characteristics RD-180 Program Status • •
Development Flight
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 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. AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 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
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Engine Characteristics Characteristics demonstrate heritage to RD-170
Two chamber derivative of the RD-170 Identical chambers, scaled turbopumps Staged combustion cycle - LOX rich PB LOX/kerosene propellants o 2 thrust chambers (+/- 8 gimbal) LOX & fuel boost pumps Single 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 pump Hypergolic ignition AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Technical Data Chamber Pressure (psi) Flow Rate (lb/s) Total Sea Level Thrust (lb) Total Vacuum Thrust (lb) Sea Level Isp (sec) Vacuum Isp (sec) Mixture Ratio Nozzle Area Ratio Throat Area (in2) Engine Length (in) Circumscribed Exit Diameter (in) Single Nozzle Exit Diameter (in) Gimbal Angle Weight, Dry (lb) Weight, Wet (lb) Thrust/Wt (Sea Level, with TVC ) Thrust/Wt (Sea Level, No TVC )
Full Power (100%) 3,722 2,756 860,200 933,400 311.9 338.4 2.72 36.9 67.5 141 124 56.9 +/- 8 deg 12,225 13,260 70.4 74.5
Minimum Power (47%) 1,755 1,152 365,500 438,700 278.7 334.6
Powerful and Dependable AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Overall Interface Drawing Hot Gas Ducts
Gimbal Unit
Turbine
Frame Heat Exchanger LOX Boost Pump
Fuel Inlet Valve
Gimbal Actuator Combustion Chamber(2)
Preburner
Fuel Boost Pump
LOX Pump
Fuel Pump Nozzle
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Engine Schematic Fuel Inlet Valve Thrust Control Valve
Fuel Inlet
LOX Inlet Heat Exchanger LOX Boost Pump
Preburner Fuel Boost Pump
Main LOX Valve
Turbine
Hypergolic Start Ampoule
Hot Gas Bellows
Chamber Main Fuel Valve
LOX Pump Start Bottle
Fuel Pump
Mixture Ratio Valve
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Multiple Bell Nozzle Common 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
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Single Shaft Turbopump Evolutionary heritage of proven concept
Cycle implications: • •
• •
Inducer Impeller
Sub-critical rotor operation: •
robust, repeatable start characteristics both pumps spool up together - simple open loop control system for engine low parts count (1 turbine) low cost, high reliability
Shaft
no vibratory resonance
High Capacity • •
Turbine Blisk
750 lb/sec Fuel (6700 gal/min) 2000 lb/sec LOX (12,600 gal/min) LOX pump/turbine rotor assembly AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Enables LV Family Growth Atlas Family of Launch Vehicles by Lockheed Martin Astronautics 21st Century Growth
(k kg) (k lb) 13
30 5m PLF GSO Kit
26 GTO Capability
11 Single Engine Centaur
22 9
Common Centaur
18 7
3.8m Common Core Booster
Lox Tank Stretch
14
5 10 SRBs
3
6
1
2
First Flight
RD-180 Engine Atlas II Atlas IIA
12/91
Atlas IIAS
12/93
Liquid Strapons
SRBs Atlas III (SEC)
5/00
Atlas III (DEC)
Atlas V (400 Series) (0-3 SRBs)
Atlas V (500 Series) (0-5 SRBs)
Atlas V (HLV)
2/02
RD-180 AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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High Thrust Operation Engine characteristics have direct benefit to vehicle
High power capability allows vehicle growth and flexibility in trajectory
T h r u s t
Power Margin allows robust vehicle structure and simpler manufacturing techniques
Engine health check during start transient
Throttlability allows for control of “Max Q” and propellant depletion structural loads Time
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Mission variables drive test planning Atlas III vs. Atlas V Flight Thrust Profiles 100 90
Power PowerLevel Level - %
80 70 60 50 40 30 20
Atlas V MLV Atlas V HLV
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Atlas III
0 0
50
100
150
200
250
Seconds AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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350
400 14
Program Status
Atlas III Certification testing complete
Production engine deliveries completed (Atlas III only, 7 engines)
Delta Certification testing for MLV complete 1996 Q1
Milestones
1997 Q2
Q3
PDR
Q4
Q1
1998 Q2
Q3
Q4
Q1
1999 Q2
Q3
Q4
Q1
2000 Q2
Q3
Q4
Q1
Q2
Q3
Q4
CDR Atlas III Cert
Design & Analysis
Atlas V Cert
Component Testing Core Engine Testing
Atlas III
Atlas V
Development Testing Certification Testing 1st Atlas III Flight
3/5/21/3,781 (8 Engines/14 Builds/70 tests / 10,596 Sec) 4/5/25/4,618
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
1/1/5/1,024
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Program Status - cont’d
Atlas V HLV demonstration tests completed
Production engine deliveries continue, common for Atlas III or V
Delta Certification testing for HLV, completed 3-Q 2001 2000 Q1 Q2
2001 Q3
Q4
Q1
2002 Q2
Q3
Q4
Q1
Q2
Q3
Q4
Atlas V HLV
Demonstration Testing Certification Testing
12 Tests 5 Tests 1st Atlas V MLV
1st Flight
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Engine Systems Level Test Comprehensive Verification of Requirements Performance - Margins - Thrust & Isp - Mixture ratio range, margins - Helium HEX - Repeatability - Proven production acceptance test Control - Propellant inlet extremes - Chilldown, pre-start, shutdown - Control capability, accuracy - Transient response - Throttling
Structure/Design - Vibration - Durability/life, margins Integration - Thrust vector control, flightlike gimbal actuations - Interface loads - Tolerance to vehicle commanded start/launch abort
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Test Time Accumulation Consistent Progress Toward Program Goals 35000 Atlas III Cert
MLV Cert
HLV Cert
30000
Time (Seconds)
25000
29,385 seconds and 161 firings as of 1 April 2002
AC-204
20000
AC-201 15000
10000
5000 2T
3T 4T 5T
1A
0 01-Jan-96
2A
5A2 4A 1B 3A
31-Dec-96
6A
7A
8A 6B 7B 9A 9A 5B2 9A 1T 1T
31-Dec-97
6T 7T 8C
4A, MSFC 5A5 10A
31-Dec-98
1TC 8B
11A
5B5
31-Dec-99
2T
8T 9T 10T 10T
13A 8D 11B 13B 12A 12A 12B
30-Dec-00
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
10T 11T 11T 12T 12T 13T 11C 14A
30-Dec-01
30-Dec-02
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RD-180 Testing at MSFC
Development RD-180 shipped from Khimky, Russia to Marshall Space Flight Center in Huntsville, AL Engine mated to Atlas III thrust structure and tank simulator Four 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 incorporated into flight procedures • •
Double check all technical information - double check translation accuracy Consultation with Russian experts key to successful procedure development AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Production 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
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Flight Program Engine Delivery
Lockheed Martin Denver Operations
Receiving Inspections
Engine-to-Vehicle Integration
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Self Contained Propulsion Package Efficient installation and checkout at Lockheed Martin Denver Operations
All pneumatics/hydraulics, actuators and thrust frame contained in engine subassembly Minimum interfaces (11 fluid) Fully tested prior to delivery to customer Minimum test and checkout - no re-assembly required during vehicle connections LV integration activities reduced from 80 days to 12 compared to previous engine design
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Flight Program Cape Canaveral Air Force Station Operations Boost Stage Delivery
Booster Erection
System Level Checkouts (Wet Dress Rehearsal, etc)
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Flight Program – First Atlas IIIA
AC-201 SUCCESS !! • •
Wednesday May 24, 2000 7:10 PM
Eutelsat W4 spacecraft placed in above-nominal orbit Nominal RD-180 performance
Lessons Learned Minor In Nature 80% of Atlas V Risk Retired
Payload Fairing Jettison
87% Cruise Operation
Boost Stage Separation
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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RD-180 Flight Program - First Atlas IIIB
AC-204 SUCCESS • •
EchoStar 7 telecommunications satellite placed in above-nominal orbit Nominal RD-180 performance
No Engine Issues
AC-204 EchoStar 7 Thursday Feb. 21, 2002 7:43 AM AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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Delta Certification for EELV
Atlas V to be used as Lockheed Martin’s Evolved 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-2001 Atlas V HLV Core demonstration tests completed Atlas V HLV engine certification testing completed late-2001
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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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 6 Wednesday August 21, 2002 6:05 pm EDT 7 October 2001
1
RD-180 Future RD-180 ready for current and future applications
Atlas III Atlas V
? RFS
AIAA Technical Activities Joint Propulsion Conference Indianapolis, IN July 2002 Liquid Propulsion Short Course
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