Engineering topics

Szabo, Roland

Publications and source records attributed to Szabo, Roland.

3 records

NASA NTRS2013

Powerpack Testing of the J2-X Oxidizer Turbopump

The J-2X PPA-2 (Powerpack 2) test series was conducted from February through December 2012 on the A1 test stand at NASA Stennis Space Center in a joint effort between Pratt and Whitney Rocketdyne (PWR) and NASA Marshall Space Flight Center (MSFC). The series consisted of 13 tests for a total hotfire duration close to 6500 seconds. Among the chief test objectives was characterization of the capabilities of the new J-2X turbopumps. This paper concentrates on the test results pertaining specifically to the Oxidizer Turbopump (OTP) operation in liquid oxygen (LOX). The two bladed inducer configuration that was tested had a 0.81% blade height tip clearance and incorporated the B-groove modification to the inducer tunnel outboard of the inducer leading edge. Data was collected on inducer suction performance, pump radial loading, and the pump dynamic environment in LOX. Comparisons were made to prior data collected on two geometrically similar subscale inducers tested in water at NASA MSFC (70% scale) and Concepts NREC (52% scale). In overview, the results of the powerpack testing were consistent with the radial load assessment from the water tests. The inducer performed differently in the other two categories, however. The inducer suction performance capability in LOX was notably improved. This was expected and is probably attributable to thermal suppression head (TSH) effects. While the dynamic environment was similar in most aspects to water test observations, the higher order cavitation (HOC) during the powerpack testing was much more benign.

Jambusaria, Mitul↗

NASA NTRS2010

Solving Component Structural Dynamic Failures Due to Extremely High Frequency Structural Response on the Space Shuttle Program

For many years, the capabilities to determine the root-cause failure of component failures have been limited to the analytical tools and the state of the art data acquisition systems. With this limited capability, many anomalies have been resolved by adding material to the design to increase robustness without the ability to determine if the design solution was satisfactory until after a series of expensive test programs were complete. The risk of failure and multiple design, test, and redesign cycles were high. During the Space Shuttle Program, many crack investigations in high energy density turbomachines, like the SSME turbopumps and high energy flows in the main propulsion system, have led to the discovery of numerous root-cause failures and anomalies due to the coexistences of acoustic forcing functions, structural natural modes, and a high energy excitation, such as an edge tone or shedding flow, leading the technical community to understand many of the primary contributors to extremely high frequency high cycle fatique fluid-structure interaction anomalies. These contributors have been identified using advanced analysis tools and verified using component and system tests during component ground tests, systems tests, and flight. The structural dynamics and fluid dynamics communities have developed a special sensitivity to the fluid-structure interaction problems and have been able to adjust and solve these problems in a time effective manner to meet budget and schedule deadlines of operational vehicle programs, such as the Space Shuttle Program over the years.

Frady, Greg↗

NASA NTRS2007

The Effect of Acoustic Disturbances on the Operation of the Space Shuttle Main Engine Fuel Flowmeter

The Space Shuttle Main Engine (SSME) uses a turbine fuel flowmeter (FFM) in its Low Pressure Fuel Duct (LPFD) to measure liquid hydrogen flowrates during engine operation. The flowmeter is required to provide accurate and robust measurements of flow rates ranging from 10000 to 18000 GPM in an environment contaminated by duct vibration and duct internal acoustic disturbances. Errors exceeding 0.5% can have a significant impact on engine operation and mission completion. The accuracy of each sensor is monitored during hot-fire engine tests on the ground. Flow meters which do not meet requirements are not flown. Among other parameters, the device is screened for a specific behavior in which a small shift in the flow rate reading is registered during a period in which the actual fuel flow as measured by a facility meter does not change. Such behavior has been observed over the years for specific builds of the FFM and must be avoided or limited in magnitude in flight. Various analyses of the recorded data have been made prior to this report in an effort to understand the cause of the phenomenon; however, no conclusive cause for the shift in the instrument behavior has been found. The present report proposes an explanation of the phenomenon based on interactions between acoustic pressure disturbances in the duct and the wakes produced by the FFM flow straightener. Physical insight into the effects of acoustic plane wave disturbances was obtained using a simple analytical model. Based on that model, a series of three-dimensional unsteady viscous flow computational fluid dynamics (CFD) simulations were performed using the MSFC PHANTOM turbomachinery code. The code was customized to allow the FFM rotor speed to change at every time step according to the instantaneous fluid forces on the rotor, that, in turn, are affected by acoustic plane pressure waves propagating through the device. The results of the simulations show the variation in the rotation rate of the flowmeter due to the interaction of the flow straightener wakes and the upstream propagating acoustic waves. A detailed analysis of the acoustic disturbance effects is presented along with an assessment of the impact on measurement accuracy.

Marcu, Bogdan↗