Space transportation propulsion systems; diagnostics testbed facility characteristics; engine plume diagnostics; and thermal infrared imaging technology development are outlined. This presentation is represented by viewgraphs

Chenevert, Don J.

English

NASA Technical Reports Server

N/LRA
Stennis Space Center
,_91-28259
PRESENTATION 4.3.8
SPACE TRANSPORTATION
PROPULSION SYSTEMS
SYMPOSIUM
D.J. Chenevert
NASA/SSC June 25-29,1990
N/LRA
Stennis Space Center
Presented to: "1990 Symposium on Space Transportation
Propulsion Systems Technology"
At: Conference Center of Pennsylvania State.
University in University Park, Pennsylvan=a
For: Operational Efficiency Panel, June 25-29, 1990
By: Don Chenevert
NASA
Stennis Space Center, Mississippi
(601) 688-3126/FTS 494-3126
1203
https://ntrs.nasa.gov/search.jsp?R=19910018945 2020-03-19T17:27:26+00:00Z
IJOHN C. STENNIS SPACE CENTER
ROLES AND MISSIONS
• Provide, manage, and operate facilities, laboratories, and related
capabilities essential to the development testing of propulsion
systems including the Space Shuttle Main Engine, the Advanced
Launch System, and the Advanced Solid Rocket Motor
• Conduct research and development in propulsion test tec..h,nologies
including cryogenics, high-pressure gas, metrology, eng,ne diagnostics,
and safe operations
• Conduct research and technology development to support.NASA goals
in earth and environmental system sciences and observataons,
commercialization of remote sensing, and applications development
• Provide technical and institutional support services to resident
agencies
1204
ORIGINAL PAGE IS
OF POOR QUALITY
MAJOR CONTRACTORS AT SSC
• Rockwell International
(MPTA)
• Rocketdyne
(SSME Testing)
• Martin-Marietta
(External tank Support)
• Ford Aerospace-BDM
Division (Support)
• Pan Am World Services, Inc.
(Facilities Services)
• Sverdrup Technology, Inc.
(Technical Services)
• Lockheed Engineeringand
Sciences ComL_any (Remote
Sensing, R&D Support)
• Ouad S Company
(Security Services)
• Mason Chamberlain, Inc.
(Mississippi Army Ammunition Plant)
• Computer Sciences Corporation (NOAA National Data Buoy
Center Support Services)
PROPULSION TEST TECHNOLOGY
DEVELOPMENT AT SSC
• Technology development complements test operations
• SSC has 25 years of large engine ground testing experience
• SSC has the capability for long duration static firings (2,000 seconds)
• Three active, greater than 500,000 pound thrust, test stands (one
sea level and two altitude test stands)
• SSC has signflcant experience in handling large quantities of liquid
hydrogen, oxygen and nitrogen
• Current SSME test program and future test programs offer windows of opportunity
for developing non-intrusive and diagnostic instrumentation and validating
computational codes
• SSC has a very active plume diagnostic test program to develop advanced
non-intrusive instrumentation systems
• Advanced ground test instrumentation/control systems and techniques can be
developed economically
• SSC has extensive experience and expertise in non-intrusive remote
sensing optical instrumentation sensors and systems
• Authorized by SSC charter
1205
STENNIS SPACE CENTER
SPACE SHUTTLE MAIN ENGINE (SSME) TESTING PROGRAM
Year No. of Seconds Cryogens/Gases Consumption
Tests of Lox LH2 LN2 GHe
Testing (Tons) (Tons) (Tons) (SCF)
1987
1988
1989
1990"
81 33,738 26,285 4,067 12,604 19,636,000
89 40,414 34,873 5,020 16,166 22,523,000
83 35,319 29,665 4,304 17,567 18,043,000
49 18,454 15,523 2,314 7,914 8,580,000
*Through May 1990
Space Transportation Propulsion Technology Symposium
[ Operational Efficiency
_mll_SS Assurance
Safety and Condition Monitoring/Plume Diagnostics
1206
Plume Diagnostics:
• Diagnostics testbed facility (DTF) characteristics
• Engine plume diagnostics instrumentation
• DTF test/experiment results
• Applications on SSC test stands
A-l, Sea Level/Ambient
- B-l, Aspirated/Diffuser
Safety and Condition Monitoring:
• Smart hydrogen sensor (SHS) and fugitive gas detection system
(FGDS)
• Thermal infrared imaging technology development
PLUME
SPECTRAL DIAGNO6TICS
SIGNATURE TESTBED
EMISSION FACILITIES
DATA BASES
SSME D'rF
DTF SPACES DTFIIATP SRM DTFSTME TESTST_OSOTHER !R c_=
TEST ENGINE
MONITORING _ MATERIALS
SYSTEMS DATA BASES
EDC SSME
SMART EDC ATP
CLOSED LOOP EDC STME
EXPERT SYSTEM EDC LIF, CARS OTHER
CT
OTHER
GAS & LEAK
DETECTION
1207
STENNIS SPACE CENTER
PROPULSION TEST TECHNOLOGY
RELATED TECHNOLOGY, DEVELOPMENT FACILITIES
Facility
*Diagnostics Testbed Facility
• 1200# Thruster
• LOX/GH2 and Alternate fuels capability
• Thrust chamber seeding capability
• Small, inexpensive, accessible, flexible,
quick-turnaround fadlty
"Electro-Optics Laboratory
.Lasers
• Spectrometers
• Optic_ tables
• Reference Calibration Sources
• Optical Systems
"Advanced Sensor
Development laboratory
• Airborne remote sensing systems
• Field remote sensing systems
• Leafier Model 23 aircraft
Accomolishments
EDC - Engine (Plume)
Diagnostics Console
SHS - Srna_ Hydrogen
Sensor
STI - Shuttle Thermal
Imager
IDS - Ice Detection System
OMA - Optical Mulichannel
Analyzer
TIMS - Thermal Infrared
Multispectral Scanner
CAMS - Calibrated Airborne
Multispectral Scanner
IRIS - Infrared Intelligent
Scanner
PRT5 - Precision Radiation
Thermometer
EIr.Bx_Un
• Deve_ ofengined_nostk=
sensors, Inmrumentatlon, and systems
: ..rut oontmlandclata
acquisition technology teslt)ed
• Leak detection testbed
• Propulsion toetJng sensor and
cryogenics teslbed
• Non-intake wsteme develocment,
prototyplng,msJntenance, end
calibration ares
• Remote sensing systems design,
development, maintenance, calibration,
and ,d_ ,y,tem, ¢.dy
1208
DIAGNOSTICS
TESTBED FACILITY
CHARACTERISTICS
DIAGNOSTICS TESTBED FACILITY
EXPERIMENT PROGRAM:
Use DTF and SSME test stands to develop non-intrusive
instrumentation to assist in optimizing operational testing
frequency and safety.
DTF'S FUNCTION:
Allow precise exhaust plume seeding with trace levels of
matenal specie to quantify spectral sensitivity and response
time of spectrometer and advanced sensor based plume
diagnostics instrumentation systems.
1209
DIAGNOSTICS TESTBED FACILITY
USAGE TO DATE
Acquisition, evaluation, and compilation of spectral
database for SSME related elements and materials
Development of engine diagnostics sensors, instrumentation and
systems
Training of test operations personnel
Control system proving ground
OMA/OPAD field verification
Hydrogen detection field experiments
Thermal image cryogenic leak detection experiments
Cryogenic liquid level sensor experiments
Mass flowmeter evaluation (LOX and GH2)
MSFC/LeRC Code R CSTI-ETO Projects
1210
ENGINE PLUME DIAGNOSTICS
INSTRUMENTATION
ENGINE PLUME DIAGNOSTICS
• Engine Plume Diagnostics System Development at SSC
- OMA (Optical Multichannel Analyzer) on SSC test stands
- EDC (Engine Diagnostics Console)
- OMA & Video on Aspirated/diffuser Test Stand, B-1
- OPAD (Optical Plume Anomaly Detector) Participant
• Bottom line - developed limited capability to look at SSME's
exhaust plume to:
Call for engine shutdown to avoid major damage in many
cases
Determine if a turbopump may be tested again before
teardown
Post test anomaly resolution assistance
1211
SYSTEM CONFIGURATION
Collection
Lens
0
C_t¢
Cable
Spectrometer
Analog
Data
OMA IEEE 188 Bul
1212
DTF TEST/EXPERIMENT RESULTS
PLUME SEEDING TEST PLAN
Elements prioritized by:
A - Critical SSME component
B - Alloy or compound frequency of occurrence
C - Element frequency of occurrence
Group I Elements
(High Priority)
Initial Survey
Test Completed Detection
Nickel (Ni) X YES
Iron (Fe) X YES
Chromium (Cr) X YES
CobaR (Co) X YES
Calcium (Ca) X YES
Tungsten (W) X TBD
Manganese (Mn) X YES
Molybdenum (Mo) X TBD
Copper (Cu) X YES
Strontium (Sr) X YES
1213
PLUME SEEDING TEST PLAN
Group 2 Elements
(Intermediate Priority)
Initial Survey
Test Completed
Detection
Aluminum(AI) X YES
Titanium (Ti) X YES
Silver (Ag) X YES
Tin (Sn) X TBD
Hafnium (Hf) X NO
Vanadium (V) X TBD
Yttrium (Y) X YES
Gold(Au) X TBD
Magnesium (Mg) X YES
Silicon (Si) X TBD
Tantalum (Ta) X TBD
Niobium(Nb) X NO
Zirconium (Zr) X TBO
Beryllium (Be) Not to be Tested TBD
Group 3 Element
(Low Priority)
Fluorine (F) TBD
Chlorine (CI) X NO
Carbon (C) TBD
Zinc (Zn) X TBD
Lithium(Li) X YES
Rhodium(RI) Not to be Tested TBO
Palladium (Pd) X TBD
PLUME SEEDING TEST PLAN
Group I Materials
Inconel 718
Haynes 188
MAR-M 246+Hf
Waspaloy X
AISI 440C
NARIoy-Z
MoS2
NiCrAIY
ZrO2 8O/oY203
PTFE
Armalon 1214
Initial Survey
Test Completed
X
X
X
X
X
X
X
X
X
DTF DATA AT MACH DIAMOND LOCATION
14-
12-
='_o-
N
i '-6-
4-
2"
50 ppm Inconel 718
or
3O0
i Oxidesof
Cr, Fe, Ni II
I I I I I I I I I I
350 400 450 500 550 600 650 700 750 800
Wavelength (nanometers)
1215
ENGINE PLUME DIAGNOSTICS
APPLICATIONS ON SSC TEST STAND
OMA Status:
Planned:
Breakout:
Current Status:
Under Development
or Experimental
Operational
Intensified array (IA)
Video
Open- Closed
Ambient Aspiratec//Diffuser
Test Stand Test Stand
C O00
30MAs 10MA 20MAs 10MA
20PS 10PS 10PS 1 EXP.
1 EXP. 1 EXP.
20MAs Probe in 10MA 10MA
Fabrication
10MA - 10MA -
1 1 1 1
2 On-Order On-Order 1
--7
--4
-3
(2+1)
1216
ENGINE PLUME DIAGNOSTICS
AMBIENT TEST STAND A-1
TEST CONTROL CENTER
CAMERA/OMA
POSITIONING CONTROL
I
I
I
I
SPECTRAL
DATA
DISPLAY
VIDEO
DISPLAY
488 BUS _.EXTENDER
[_ HARD STORAGE
I
I
I
I
I
I
I
e
TEST STAND
AT ENGINE LEVEL
PAN AND
11LT
OMA OPTICS
VIDEO
CAMEP_
SPECTROMETER
488 BUS [EXTENDER
I
FIBER OPTIC/
DATA CONTROL
UNK
TEST STAND
HARD CORE
1217
OMA CONFIGURATION
_h O_n_nd VkDw
II I Olsk_ InJr- - _, t
TToOMA,_Z::_'-. .............. . I tcDi_mt
- ............. .................... IjF'idVIm.
if -
I NozzleExA_ " I
I
I
I o_ C_k_m
_._ _ ....
....._..°...°...Bo. ...e
ToOMA :::::;:::: ...................
EXPANDED VIEW SHOWING MINOR FLASHES AND
PRECURSORS TO MAJOR EVENTS
A1 Stand SSMETest: 901-619 Engine: 0200 1/31/110
Cull PeakHeight(428 rim) Nozzle F.Jdt
: iI"
i
1218
WATERFALL PLOT FROM 68 TO 72.5 SECONDS
A1 Stand SSMETnt: 901.619 Englne: 0209 1/31/90
Nozzle Exlt Ylew t = 68-72.8 _¢.
4.0
i '_3°-!_IV'v_'_- 1"._'_ ,_._.P
o.s ,ase ne_,me _ I ff_',v_._J
0.0 _ i J I I "t I I m l i
300 350 400 450 500 550 600 650 700 750 800
W_elength (_,m_Tm_)
IDENTIFICATION OF MAJOR EMISSION PEAKS DURING
STREAKING EVENTS AT 70.5 SECONDS
AI Stand SSME Test: 901-619 Engine: 0209 1/31/90
Nozzle Exlt Ylew t ,, 70.S se¢.
9-
8-
3
2-
I-
0
3OO
I !
,3
n
/ I : f/ Mr_ofCr.Cu. Fe
!
I I I I l I ! I
450 500 550 600 150 700 750 800
1219
MACH DIAMOND VIEW, SPECTRAL PLOT OF
HARDWARE ENHANCED PLUME AT 71.0 SEC.
AFTER IGNITION
A1 Stand SSME Test: 901-619 Engine: 0209 1/31/90
Nozzle Exit View t = 71.0 =ec.
1.0 --
N
_0.6 -
|
0.4-
0.2
0.0
30O
-rO
a
Z
z=. j
"-" I
•i_._ = _ . _r
• I I I I I I
350 400 450 500 550 600
Wavelength (nanometera)
Oxiclebandl
forCr and Fe
v!
I I I l
650 700 750 800
1220
ENGINE PLUME DIAGNOSTICS
ASPIRATED TEST STAND B-1
EDC OPTICAL PROBE SCHEMATIC FOR
ASPIRATED TEST STAND
HardstandWd
Optical Multichannel Analyser
(OMA) System
Control
Unit
Camer8
/
SSME
Nozzle
1221
SMART HYDROGEN SENSOR AND
FUGITIVE GAS DETECTION SYSTEM
SMART HYDROGEN SENSOR
DESIGN GOALS
Project Goal: "Develop a reliable GH2 sensor for
Inert and Air Environments"
• Main Characteristics:
Background Gases
• Air
• Nitrogen
• Helium
Range
• 0-4 percent GH2 by Volume
1222
SMART HYDROGEN SENSOR
Power
,--------..............................,
Sensors
Hydrogen
Microprocessor/Controller
4 - 20mA Serial
Output RS - 422 Alarm Status
8_
SENSOR RESPONSE TO 1.0% GH2 BY VOLUME
Direct Analog vs. Microprocessor Aided Output In Nitrogen
m
4_
q
OL
Microprocessor Aided Output (8.25 seconds to 95% of scale)
! /'_""_ DirectOutput (120seconds _1_I ./ to 95% of scale)
..... "if"* .... m
I I I I I I
200 400 600
Response Time (Seconds)
1223
SMART HYDROGEN SENSOR
Specifications
Temperature
0 to 50 C*
Pressure
0.5 - 1.5 atm
Humidity Selectivity
0- 100% RH Hydrogen
Only
Response Time < 10 Seconds
Hydrogen
0 - 8% Vol
0 - 200% LeL
0 - 5,300 ppm (m)
0 80,000 ppm (vol)
LE_i_todV=_u_,_ TBO_ Accuracy: 0.5 - 2.0% of scale
Calibration: Built in menu driven software
90 day calibration interval
Maintenance and Reliability: Rugged Construction/Built-in self-diagnostics
Outputs: 4 - 20 Milliamps/serial RS-422
Power: 24 - 28 VDC/800 Milliamps
"Current test results indicate that this specification could be widened signiKcan#y in
the final production units
SMART HYDROGEN SENSOR
PROGRAM STATUS AND PLANS
• Prototype- testbed
• Field testing first pre-production prototype
- One year in engine test environment with exposure to
high acoustic loads, overpressure, temperatures,
cryo-soak to LN 2 temperature and deluge spray--still
Tunctlonmg
• Patent Application submitted to Patent Office
• Fugitive Gas Detection System Spin-Off
• Qualification Testing by KSC - FY90-91
• Technology Utilization Office Commercialization Initiated
1224
FUTURE PLANS
SSC
KSC
RTOP
- LH2 Barges
High Pressure Gas Facility
All Engine/Component Test Stands
- Launch OPS
Flight
Orbiter AFT Fuselage
ET Intertank
- Fugitive Gas Detection System
FUGITIVE GAS DETECTION SYSTEM
SHS
/ \
• Central Control
• Hydrogen sensor Network
• Bulk Storage with Replay
• User Definable Sensor Subgroups
• Simultaneous Display of all Sensors
• Audible Alarm at Trigger H 2Level• Graphical Aids, Bar Graphs, Surfac Mapping
• "Predict" Algorithm Shortens Sensor Response
1225
Large monitor clisplayslocation
SmaJldi,_olayaJlows_multaneous graphics(real time video orsti,
monitoring of sever_ sites, picture) and ovedays sensor
graphics.--_ =
_agmm l_g_nd. _
INTERACTIVE
VISUALIZATION
DATA ASSIMILATION
MODELING
SIMULATION
SensorLocalJom
DATA ACQUISITION
SLIDING BAR SENSOR GRID VISUALIZATION
Sliding Concentration Bar
Video or Graphics Background
II •
Sensor Locations
Setup
Display Mode
File Options
System Options
1226
!
THERMAL INFRARED IMAGING
TECHNOLOGY DEVELOPMENT
THERMAL INFRARED IMAGING 1
• TECHNOLOGY /
DEVELOPMENT BY |
I iCE i
I DETECTION II I APPLICATIONS i I APPLICATION i
I SYSTEM i _
. /
• CETA l
• EMU l
1227
SHUTrLEICEDETECTIONSYSTEM(SIDS)
Shuttle Thermal Imaoer (STI)
Provide real-time capability to remotely monitor/measure
the launch stack temperatures.
7 units operational at KSC
-" Upgrades and additional units ongoing
Ice Detection System (IDSl
Differentiate between Dry TPS Surfaces, Water/
Condensate, and Ice/Frost Formations/Accumulations.
- Plan to test/evaluate prototype
THERMAL INFRARED IMAGING TECHNOLOGY
SAFETY APPLICATION
• LOX LEAKS • FIRE
I • REPORT IN I / DETECTION •
I REVIEW II l" VARIOUS •
I •NOT A I
I PROMISING I
I METHOD TO I
l DETECT •
• RESEARCH
EMPHASIS
TBD FROM
PHASE II
1228
UNFUNDED
APPLICATIONS/DEMONSTRATIONS CONDUCTED |
BY SSC CIVIL SERVANTS USING II
THERMAL IMAGING TECHNOLOGY |
II
I •
AT KSC:
• Magellan
Power
Supply
• Delta/Titan
AT SSC: I
• CRYO Barge
• DTF
• SSME
_...TJd].O.KO_
• 3 RSRM Test
Firings
LATMsFc i I.shu., i
__i_;_s_o_,I
OPERATIONAL APPLICATIONS OF
STENNIS SPACE CENTER
THERMAL INFRARED IMAGING TECHNOLOGY
Real-time precision temperature measurement and monitoring
Fire detection/monitoring
SRB case temperature mapping
GOX vent hood seal
- Cryogenic leak detection
Thermal modeling of launch stack
ET/SRB attach strut thermal isolation
Operations verification
Post-launch MLP damage assessment
Landing operations support
• Tire & brake temperatures
• Nose cone temperature
Leading edges temperatures
APU operation & shutdown
Missing/damaged tile/FRSI assessmentFire detection
• Night vision
1229
I DEVELOPING APPLICATIONS/DEMONSTRATION ACTIVITIES /
IN WHICH FUTURE SSC DEVELOPMENT II
JSC CREW AND THERMAL SYSTEMS DIVISION
SHUTTLE SUPPORT BRANCH (CODE EC6)
• Crew equipment translational aid (CETA) potential for other
hardware testing in the 24 foot chamber (e.g. PDAS)
• Extravehicular Mobility Unit (EMU) suit component testing,
11 foot chamber
• Shuttle Avionics Integration Lab (SAIL) Cold Plate verification
on OV105
1230


John C. Stennis Space Center roles and missions

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