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Develop and test a rocket engine that operates on environmentally friendly propellants; Liquid Oxygen (LOX) and Liquid Methane (LCH4). Due to modifications the rocket engine designed last summer (KJ_REX) is not the same rocket thruster tested this summer, but very similar. The new modified rocket thruster was built for NASA by Orion Propulsion Inc. (OPI), Huntsville, AL.
Integrated Systems Health Management (ISHM) is a comprehensive capability. An ISHM system must detect anomalies, identify causes of such anomalies, predict future anomalies, help identify consequences of anomalies for example, suggested mitigation steps. The system should also provide users with appropriate navigation tools to facilitate the flow of information into and out of the ISHM system. Central to the ability of the ISHM to detect anomalies is a clearly defined catalog of anomalies. Further, this lexicon of anomalies must be organized in ways that make it accessible to a suite of tools used to manage the data, information and knowledge (DIaK) associated with a system. In particular, it is critical to ensure that there is optimal mapping between target anomalies and the algorithms associated with their detection. During the early development of our ISHM architecture and approach, it became clear that a lexicon of anomalies would be important to the development of critical anomaly detection algorithms. In our work in the rocket engine test environment at John C. Stennis Space Center, we have access to a repository of discrepancy reports (DRs) that are generated in response to squawks identified during post-test data analysis. The DR is the tool used to document anomalies and the methods used to resolve the issue. These DRs have been generated for many different tests and for all test stands. The result is that they represent a comprehensive summary of the anomalies associated with rocket engine testing. Fig. 1 illustrates some of the data that can be extracted from a DR. Such information includes affected transducer channels, narrative description of the observed anomaly, and the steps used to correct the problem. The primary goal of the anomaly lexicon development efforts we have undertaken is to create a lexicon that could be used in support of an associated health assessment database system (HADS) co-development effort. There are a number of significant byproducts of the anomaly lexicon compilation effort. For example, (1) Allows determination of the frequency distribution of anomalies to help identify those with the potential for high return on investment if included in automated detection as part of an ISHM system, (2) Availability of a regular lexicon could provide the base anomaly name choices to help maintain consistency in the DR collection process, and (3) Although developed for the rocket engine test environment, most of the anomalies are not specific to rocket testing, and thus can be reused in other applications.
The John C. Stennis Space Center (SSC) requested The Aerospace Corporation to examine the current testing capability of all existing large liquid engine test facilities located in the United States. That information along with projected liquid rocket engine development was used to examine future liquid rocket engine testing facilities needs in the coming decade. Current domestic liquid engine test facilities capabilities, when examined against engine concepts for the coming decade, indicate there are ample facilities offering altitude simulation during test. In addition, it was observed that many contractor facilities have limited ambient test capability of larger thrust engines under current consideration. Finally, it was concluded that diminished contractor participation engine development testing will drive this activity to the government sector. Only three facilities are seen as key contributors to engine testing in the coming decade, namely John C. Stennis Space Center (SSC), Marshall Space Flight Center (MSFC), and Air Force Research Laboratory (AFRL). Past rocket engine test experience was evaluated as a possible resource for projecting future engine test needs. A database comprised of various engine models and the level of testing performed to flight qualify those systems for their first flight was constructed. For comparison purposes in this study, development and qualification efforts were totaled and treated as one test program. Based on experience with past Air Force programs, the time on the test stand accounts for typically 50% or more of the total program time. Historical data show that the time to design and develop new engines has increased over the last 40 years, most likely due to scarcer resources in today's funding environment.
John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.
Simulated altitude test facilities selection for Space Shuttle Orbiter Engine
The Data Acquisition and Control Systems (DACS) Laboratory is a facility at Stennis Space Center that provides an off test-stand capability to develop data-acquisition and control systems for rocket-engine test stands. It is also used to train new employees in state-of-the-art systems, and provides a controlled environment for troubleshooting existing systems, as well as the ability to evaluate the application of new technologies and process improvements. With the SSC propulsion testing schedules, without the DACS Laboratory, it would have been necessary to perform most of the development work on actual test systems, thereby subjecting both the rocket-engine testing and development programs to substantial interference in the form of delays, restrictions on modifications of equipment, and potentially compromising software configuration control. The DACS Laboratory contains a versatile assortment of computer hardware and software, digital and analog electronic control and data-acquisition equipment, and standard electronic bench test equipment and tools. Recently completed Control System development and software verification projects include support to the joint NASA/Air Force Integrated Powerhead Demonstration (IPD) LOX & LH2 PreBurner and Turbopump ground testing programs. In other recent activities, the DACS Laboratory equipment and expertise have supported the off-stand operation of high-pressure control valves to correct valve leak problems prior to installation on the test stand. Future plans include expanding the Laboratory's capabilities to provide cryogenic control valve characterization prior to installation, thereby reducing test stand activation time.
The SMART (Scalable Mobile Autonomous Rocket engine Test) testbed system initiative at SSC was conceived to attempt to address many of the principal cost drivers in developing and maintaining a rocket engine test facility. The system (optimized to test engines and components generating up to 10K lbf nominal thrust) is serving as a testbed for innovative technologies and processes to provide lower cost test services with a rapid test cadence and expedient turnaround times. The system can also potentially be used as a testbed to test other related technologies relevant to surface situations (e.g., moon, Mars associated with crogenic fluid management, engine/component testing, autonomous operations, etc.). This FY20 CIF project, being conducted as part of the SMART testbed system, is developing and testing a propellant delivery system via electrically driven centrifugal pumps (obviating dependence upon Multi-Layer Pressure Vessels) with configuration and operation by a minimal number of personnel. During FY20 the team identified the requirements and worked with P3 and Masten Space Systems to develop the long lead (9 months after receipt of order) items, the 400 VDC pumps, for delivery in mid FY21. Since control of the 400 VDC pump motor is not well developed the team has established heuristics to control flows in LN2 at off nominal shaft speeds to allow deep throttling of the pump in flow test scenarios. Various test scenarios including nominal i.e. high flow high pressure, high flow low pressure, low flow high pressure, low flow low pressure, minimum throttle step change, and low inlet pressure cavitation testing were developed ahead of the anticipated hardware delivery and test. FY20 COVID Stage 3 conditions restricted access to the center and hindered lab work, so efforts focused on the system design and testing plans along with the project procurement paperwork for the hardware... now with its anticipated delivery in spring FY21. Some limited access to the center is expected by spring/summer FY21 for the continuing second year (FY21) CIF project effort meant to be focused upon system integration and initial testing.
A new rocket engine concept that is presently being evaluated offers significant performance, cost, and configurational advantages. The Linear Rocket Engine System, (LRES) combines the unique performance and operational advantages of the aerospike nozzle with the configuration versatility of low cost modular combustors, which results in a high-performance rocket engine package designed specifically for use in advanced configuration vehicles. This paper describes the design, fabrication, and testing of the LRES concept to evaluate its potential for vehicle integration. The program was conducted under the sponsorship of NASA's Marshall Space Flight Center.
Noise spectra in nuclear rocket engine ground test
In-tank shutoff valve is installed with the valve poppet and actuator inside the tank to provide maximum blast protection during rocket engine test operation. This valve design is applicable wherever explosive fuels are used and is currently being used in lox and liquid hydrogen tanks at a rocket engine test site.
A test program was performed to evaluate hydrazine (N2H4) as a fuel for a 445 Newton (100 lbf) thrust bipropellant rocket engine. Results of testing with an identical thruster utilizing monomethylhydrazine (MMH) are included for comparison. Engine performance with hydrazine fuel was essentially identical to that experienced with monomethylhydrazine although higher combustor wall temperatures (approximately 400 F) were obtained with hydrazine. Results are presented which indicate that hydrazine as a fuel is compatible with Marquardt bipropellant rocket engines which use monomethylhydrazine as a baseline fuel.
A novel technique has been developed for anomaly detection of rocket engine test stand (RETS) data. The objective was to develop a system that postprocesses a csv file containing the sensor readings and activities (time-series) from a rocket engine test, and detects any anomalies that might have occurred during the test. The output consists of the names of the sensors that show anomalous behavior, and the start and end time of each anomaly. In order to reduce the involvement of domain experts significantly, several data-driven approaches have been proposed where models are automatically acquired from the data, thus bypassing the cost and effort of building system models. Many supervised learning methods can efficiently learn operational and fault models, given large amounts of both nominal and fault data. However, for domains such as RETS data, the amount of anomalous data that is actually available is relatively small, making most supervised learning methods rather ineffective, and in general met with limited success in anomaly detection. The fundamental problem with existing approaches is that they assume that the data are iid, i.e., independent and identically distributed, which is violated in typical RETS data. None of these techniques naturally exploit the temporal information inherent in time series data from the sensor networks. There are correlations among the sensor readings, not only at the same time, but also across time. However, these approaches have not explicitly identified and exploited such correlations. Given these limitations of model-free methods, there has been renewed interest in model-based methods, specifically graphical methods that explicitly reason temporally. The Gaussian Mixture Model (GMM) in a Linear Dynamic System approach assumes that the multi-dimensional test data is a mixture of multi-variate Gaussians, and fits a given number of Gaussian clusters with the help of the wellknown Expectation Maximization (EM) algorithm. The parameters thus learned are used for calculating the joint distribution of the observations. However, this GMM assumption is essentially an approximation and signals the potential viability of non-parametric density estimators. This is the key idea underlying the new approach.
A gaseous H2/O2 rocket engine was constructed at the NASA-Lewis to provide a high heat flux source representative of the heat flux to the blades in the high pressure fuel turbopump (HPFTP) during startup of the space shuttle main engines. The high heat flux source was required to evaluate the durability of thermal barrier coatings being investigated for use on these blades. The heat transfer, and specifically, the heat flux to tubes located at the throat of the test rocket engine was evaluated and compared to the heat flux to the blades in the HPFTP during engine startup. Gas temperatures, pressures and heat transfer coefficients in the test rocket engine were measured. Near surface metal temperatures below thin thermal barrier coatings were also measured at various angular orientations around the throat tube to indicate the angular dependence of the heat transfer coefficients. A finite difference model for a throat tube was developed and a thermal analysis was performed using the measured gas temperatures and the derived heat transfer coefficients to predict metal temperatures in the tube. Near surface metal temperatures of an uncoated throat tube were measured at the stagnation point and showed good agreement with temperatures predicted by the thermal model. The maximum heat flux to the throat tube was calculated and compared to that predicted for the leading edge of an HPFTP blade. It is shown that the heat flux to an uncooled throat tube is slightly greater than the heat flux to an HPFTP blade during engine startup.
A preliminary uncertainty analysis has been performed for the High Area Ratio Rocket Nozzle test program which took place at the altitude test capsule of the Rocket Engine Test Facility at the NASA Lewis Research Center. Results from the study establish the uncertainty of measured and calculated parameters required for the calculation of rocket engine specific impulse. A generalized description of the uncertainty methodology used is provided. Specific equations and a detailed description of the analysis are presented. Verification of the uncertainty analysis model was performed by comparison with results from the experimental program's data reduction code. Final results include an uncertainty for specific impulse of 1.30 percent. The largest contributors to this uncertainty were calibration errors from the test capsule pressure and thrust measurement devices.
A preliminary uncertainty analysis was performed for the High Area Ratio Rocket Nozzle test program which took place at the altitude test capsule of the Rocket Engine Test Facility at the NASA Lewis Research Center. Results from the study establish the uncertainty of measured and calculated parameters required for the calculation of rocket engine specific impulse. A generalized description of the uncertainty methodology used is provided. Specific equations and a detailed description of the analysis is presented. Verification of the uncertainty analysis model was performed by comparison with results from the experimental program's data reduction code. Final results include an uncertainty for specific impulse of 1.30 percent. The largest contributors to this uncertainty were calibration errors from the test capsule pressure and thrust measurement devices.
As rocket engine components experience wear or failure, anomalous materials may be entrained in the plume. Historically, visible plume anomalies have preceded many rocket engine failures, some of which have been catastrophic. Development of a small, rugged, high-speed, high resolution Fabry-Perot interferometer (FPI) based spectrometer capable of detecting the spectral signatures of eroding engine components during rocket engine test and/or flight operations is described. An operational plume spectrometer fabricated with miniaturized optics has been successfully tested. An extensive test series was conducted to define the limits of the spectrometer with respect to time-response and resolution. The data collected during testing were correlated with measurements obtained using sensitive ground equipment in order to benchmark the spectrometer's performance against a known device. The FPI demonstrated the reliability required for a flight instrument by functioning satisfactorily at or near the rocket engine test stand environment. Several of the optical components are interchangeable, allowing collection of a greater variety of plume signals. Also, the FPI's high resolution capabilities suggest it is suitable for application to both absorption and emission spectroscopy.
A recently completed experimental test program obtained performance data on an optimally contoured nozzle with an exit-to-throat area ratio of 1025:1 and on a truncated version of this nozzle with an area ratio of 440:1. The nozzles were tested with gaseous hydrogen and liquid oxygen propellants at combustion chamber pressures of 12.4 to 16.5 mPa (1800 to 2400 psia). Testing was conducted in the altitude test capsule at the NASA Lewis Research Center's Rocket Engine Test Facility (RETF), and results were compared with analytical performance predictions. This testing builds on previous work with this nozzle at Lewis, where testing was completed at nominal chamber pressure of 350 psia. High-area-ratio nozzles have long been sought as a means to increase the performance of spacebased rocket engines. However, as the area ratio increases, the physical size and weight of the nozzle also increase. As a result, engine and vehicle designers must make tradeoffs between nozzle size and performance enhancement. Until this test program, very little experimental data existed on the performance of the high-area-ratio nozzles used in rocket engine designs. The computer codes being used by rocket engine designers rely on data extrapolated from tests of low-area-ratio nozzles, and these extrapolations do not always provide the accuracy needed for a reliable design assessment. Therefore, we conducted this high-area-ratio nozzle testing program to provide performance data for use in rocket engine design and analysis computer codes. The nozzle had a nominal 2.54-cm- (1-in.-) diameter throat, an exit diameter of 81.3-cm (32.0-in.) at an exit-to-throat area ratio of 1025, and a length of 128.6 cm (50.6 in.). Testing was conducted in an altitude test capsule to simulate the static pressure at altitude by vacuum pumping. Data such as propellant mass flow, oxidizer-to-fuel mixture, and thrust were measured. These measurements were then used to calculate performance factors such as the thrust coefficient, the characteristic exhaust velocity efficiency, and the vacuum specific impulse. In addition, the nozzle temperature was measured to calculate the amount of heat transferred from the combustion gases to the nozzle.
There are a number of architecture models for implementing Integrated Systems Health Management (ISHM) capabilities. For example, approaches based on the OSA-CBM and OSA-EAI models, or specific architectures developed in response to local needs. NASA s John C. Stennis Space Center (SSC) has developed one such version of an extensible architecture in support of rocket engine testing that integrates a palette of functions in order to achieve an ISHM capability. Among the functional capabilities that are supported by the framework are: prognostic models, anomaly detection, a data base of supporting health information, root cause analysis, intelligent elements, and integrated awareness. This paper focuses on the role that intelligent elements can play in ISHM architectures. We define an intelligent element as a smart element with sufficient computing capacity to support anomaly detection or other algorithms in support of ISHM functions. A smart element has the capabilities of supporting networked implementations of IEEE 1451.x smart sensor and actuator protocols. The ISHM group at SSC has been actively developing intelligent elements in conjunction with several partners at other Centers, universities, and companies as part of our ISHM approach for better supporting rocket engine testing. We have developed several implementations. Among the key features for these intelligent sensors is support for IEEE 1451.1 and incorporation of a suite of algorithms for determination of sensor health. Regardless of the potential advantages that can be achieved using intelligent sensors, existing large-scale systems are still based on conventional sensors and data acquisition systems. In order to bring the benefits of intelligent sensors to these environments, we have also developed virtual implementations of intelligent sensors.