The plume-induced environment created by the Ares 1 first stage, five-segment reusable solid rocket motor (RSRMV) will impose high heating rates and impact pressures on Launch Complex 39. The extremes of these environments pose a potential threat to weaken or even cause structural components to fail if insufficiently designed. Therefore the ability to accurately predict these environments is critical to assist in specifying structural design requirements to insure overall structural integrity and flight safety. This paper presents the predicted thermal and pressure environments induced by the launch of the Crew Launch Vehicle (CLV) from Launch Complex (LC) 39. Once the environments are predicted, a follow-on thermal analysis is required to determine the surface temperature response and the degradation rate of the materials. An example of structures responding to the plume-induced environment will be provided

Sulyma, Peter

Vu, Bruce T.

NASA Technical Reports Server

General Disclaimer 
One or more of the Following Statements may affect this Document 
 
 This document has been reproduced from the best copy furnished by the 
organizational source. It is being released in the interest of making available as 
much information as possible. 
 
 This document may contain data, which exceeds the sheet parameters. It was 
furnished in this condition by the organizational source and is the best copy 
available. 
 
 This document may contain tone-on-tone or color graphs, charts and/or pictures, 
which have been reproduced in black and white. 
 
 This document is paginated as submitted by the original source. 
 
 Portions of this document are not fully legible due to the historical nature of some 
of the material. However, it is the best reproduction available from the original 
submission. 
 
 
 
 
 
 
 
Produced by the NASA Center for Aerospace Information (CASI) 
https://ntrs.nasa.gov/search.jsp?R=20130010054 2019-08-31T00:04:06+00:00Z
CREW LAUNCH VEHICLE MOBILE LAUNCHER SOLID ROCKET

MOTOR PLUME INDUCED ENVIRONMENT 
Bruce T. Vu
Structures and Analysis 
NASA Kennedy Space Center 
Peter Sulyma
Aerosciences Branch
NASA - Marshall Space Flight Center 
ABSTRACT 
The plume-induced environment created by the Ares 1 first stage, five-segment reusable solid 
rocket motor (RSRMV) will impose high heating rates and impact pressures on Launch Complex 
39. The extremes of these environments pose a potential threat to weaken or even cause 
structural components to fail if insufficiently designed. Therefore the ability to accurately predict 
these environments is critical to assist in specifying structural design requirements to insure 
overall structural integrity and flight safety. 
INTRODUCTION 
This paper presents the predicted thermal and pressure environments induced by the launch of the 
Crew Launch Vehicle (CLV) from Launch Complex (LC) 39. Once the environments are 
predicted, a follow-on thermal analysis is required to determine the surface temperature response 
and the degradation rate of the materials. An example of structures responding to the plume-
induced environment will be provided. 
LAUNCH ENVIRONMENT 
The following factors are considered for the predictions of CLV ML plume induced 
environments: coordinate systems, lift-off trajectory, ML configuration, and SRM engine 
performance. The 5-segment reusable solid rocket motor (RSRMV) with propellant mixture 
provided by ATK is used in the simulation of nozzle condition. The nozzle and plume 
calculations for the RSRMV were generated with a chamber pressure of 905 psia. The 
computational codes used to produce the plume flow field solutions include Chemical 
Equilibrium Code (CECITRAN72), Reacting Multi-Phase Program (RAMP2), and Standard 
Plume Flow Field (SPF3). At the end of SPF calculations, the exhaust plume is calculated and 
consists of the following flow variables: Mach number, velocity, static temperature, static 
pressure, flow angle, particle mass flux, particle momentum flux, particle kinetic energy, particle
thermal energy flux, particle flow angle, and N2 mole fraction. As an example, the near-field 
plume Mach number is shown in Figure 1. 
-MACH NUMBER 
3 
	
150 -
	 28 
	
•	 26 
24 
-	 2.2 
2 
LL
	
•	 1.8 
	
100 -	 1.6 
o	 1.4 
	
50	 04 
	
I	 I 
	
0	 50	 100	 150	 200	 250 
AXIAL DISTANCE(FEET) 
Figure 1: Near Field Plume Mach Number 
The exhaust plume, coupled with the vehicle trajectory, is then used to predict the launch-
induced environments at specified locations on the ML and Ground Support Equipments (GSE) 
mounted on the ML. The plume-induced environments were predicted for the following 
modeled launch complex components: 
• RSRBV Exhaust Deflectors 
• RSRBV Hold-down Posts 
• RSRBV Aspirator Opening Blast Shields 
• GN2 Purge Line & Heater Unit 
• MLB Deck 
• Launch Tower Floors & Roof 
• Elevator Shaft 
• Elevator Shaft Blast Diverter 
• Sound Suppression Water Jets & Pipes 
A typical output showing the predicted environment on a cross beam is shown in Figure 2. The 
tabulated values will then be used as the input conditions to calculate the thermal responses of 
GSE components mounted on the ML.
2
:D
Isd) GJflS$aJd OPf$.Nd 
N
	
O
	
C)
	
N 
o
 0
 0
 0
 d
 o
 a
 a
 o
0
 
co
 
N. 
CD
U 
U
)?
 
C.) c,J 0 
0
	
0
	
0
	
0
	
0 
U)
	
0 
viS
a) 
n
Is
d
 189 
S S 
I
	
-
I-
-
-
-
-C---4
-
	() 
-
 
N 
'L 0
I
	
III
0
Co
.
'
 
0
0
0
0
0
C
)
c..i
N 
OH a)
CO
c
o
N 
E
Q
0
0 
U,000000 
0
0
0
0
 0 0 0 0 N 0
-
 
0
0 0 
0
0
0
0
0
0
0
F
CJ 
tz CO0
0
0
0
0
0
N
.
-
o 
C
Co
C'J 
(I) 
.
0
0
0
0
0
0
0
C
'4
N
0 
0
0
0
0
0
0
0
0
C)
0 
O
H
co 
a) (1)0
0
0
0
0
0
 
-
.
.o
•q
q
0
0
0
0
c
o
 
-
N
'
-
0
U) 
E
0
0
0
0
0
0
0
0
C\J
0
0 
I.-
dcdo
0
0
0
0
0
0
,:.0
co
- 
D
O
O
CO
 
c\jIt
) 
Cl)0
0
0
0
0
0) 
Cl) 
O
0
0
0
0
0
0
C
J
. 0) 
co 
•E
0
'JC
')tLt)C
O
N
cC
C
) 
Co
-J 
IL
PLUME-INDUCED THERMAL ENVIRONMENTS (THERM1D) 
The THERM1D code is a one dimensional heat conduction code designed specifically for launch 
and test stand design problems. It was developed from a thermal analyzer code developed by 
Pond (Reference 1) to support the Space Shuttle development program. Convective, radiative 
and particulate surface heating options are included in the model. The THERM113 code also 
accounts for melting or ablation of the material surface as well as the deposition of aluminum 
oxide or carbon based soot. Details of the theory used in THERM1D can be found in References 
1 and 2. The code features fully interactive input and output on a Windows 95/981NT/2000/XP 
environment. Materials and material properties for THERM1D structures are provided via a data 
file which can be edited and updated. Graphical outputs of deposition, melting and temperature 
at different depths in the structure are provided at the end of each THERM1D case run. 
EXAMPLES 
Shuttle Range Safety Cable 
There was a concern that the Shuttle Range Safety Cable might have survived the rocket exhaust 
plume and became debris. It was recommended that more accurate environments be used in the 
analysis to include the protective Al203 buildup on the cable. 
The cable is made of a combination of Teflon (outer jacket and core) and Copper (braid and 
conductor), as shown in Figure 5. Five inner locations have been identified along the radial 
direction of the cable. Figures 6 and 7 show the thermal response and material degradation, for 
body point 14, as a result of THERM1D calculation. Similar results for body point 14a are 
shown in Figures 8 and 9. It is noticed that for both body points 14 and 14A, the jacket melts at 
1.02 sec and cable burns through at 1.3 sec. Although there are some solid particle buildups, but 
they are not enough to keep the cable from melting.
4
to 
MOW-
A Q 
 14a 
( t	 7	 I	 ::. 
I iur& 3. Range Sit I'eh Cable on t w I kid I)os n Post 
H
Subsh*pe 6 
The top of the SRB support is 
14 represented by a seiM-sphere of 
radius 10. 375 in. The origin of this 
6	 subehape is located on its longi- 
y	 tudinal axis a	 a o en a ted s 7	 indicated. 
X7Subshape 7 - 
rehape
e side. of the SR3 
SUP are rcpre.ented 
 
a conic section who.. 
radius Increases ttn.arly 
oa 10.375 to 15.0 in. 
e origin of this sub- 
 is located on its
tigitudinal axis and i. 
iented an indicated. 
IF	 I
Figure 4. Shuttle Environment Prediction
5
--e, 
—.-0" 
0.0163" 
—*— 0.0325" 
o 0.0488" 
• 0.0650"i 
---0.0813" 
2000 Ch
1500 
1000 
ss. 
-cket 
Cxiter/ Inner Braid 
.Di electric Core 
Inner ' N 	 I 
;t0ni \\ 
Figure 5. Cable Cross Section
Body Point 14
500 
0H----•-Ht----F ±--h---i 
0	 0.2	 0.4	 0.6	 0.8	 1	 1.2	 1.4
Time, sec. 
Figure 6. Thermal Response
Body Point 14 
	
o	
"•'4111L,1 
	
-0.02	 ---
.-0.04 L 
-0.06  
I-
	
-0.08	 -- ---- - 
-0.1 
-0.12
0	 0.2	 0.4	 0.6	 0.8	 1	 1.2	 1.4
Time, sec. 
Figure 7. Material Loss 
2000 
V 
w
1500 
FL
1000 
I,
Body Point 14a
-.- Sur-face 
-4-0" 
—)— 0.0163' 
—*— 0.0325' 
o 0.0488" 
• 0.O65O' 
L0.0975 j 
Jj 
0	 1	 I 	 I	 I	 I	 I	 I 
0	 0.2	 0.4	 0.6	 0.8	 1	 1.2	 1.4
Time, sec. 
Figure 8. Thermal Response
7
Body Point 14a 
0.0000 ,.s.i.....is...s. .I.s.s.s.s.s.Isesess •uI.Ii 
	
.0200	 - -	 -- -.	 --
	
-0.0400	 -- -	 - 
	
-0.0600	 --	 --- --	 ____ 
	
-0.0800	 -	 -	 - 
	
-0.1000	 ----- --_____ - - 
-0.1200  
0	 0.2	 0.4	 0.6	 0.8	 1	 1.2	 1.4
Time, sec. 
Figure 9. Material Loss 
CLV Aft Skirt Umbilical 
The aft skirt umbilical (ASU), previously know as the GN2 purge line is subject to the direct 
impingement of the Crew Launch Vehicle (CLV) solid rocket exhaust plume (Figure 10). 
THERM11) has been used to calculate the thermal responses of the ASU during Ares-I launch. 
The launch-induced environments predicted at a body point 09XDA14 on the ASU are shown in 
Figure 11. The line is assumed to be made of 1.5-inch stainless steel. 
The thermal responses and material degradation of the ASU structure as predicted by THERM1D 
are shown in Figures 12 and 13, respectively. It is apparent that the top surface will reach steel 
melting temperature and will melt away at 4.2 seconds. The layers at 0.25" and deeper will never 
reach the melting temperature and will survive the rocket exhaust plume. In addition, there is an 
Aluminum Oxide particle buildup on the top surface. This particle layer can be considered as a 
protective coating and it helps slow down the melting and material degrading process. Figure 12 
shows the thermal response of the particle layer.
) E N
J 0 N
- N
- N
- (N N- N-
 L
U
L
U
L
U
W
N
.N
- (DLU 
I-
-
 
.
	
—
O
.—
O
)O
) 
C
	
D
N
- N
- N
-(N
-
 
 
-(N

©
 )- D O
 Q
' O
 0) 0) 0) 0) 
U
	
' 
x CD 
CL E 
U .	
D
W
N
.
-
0
) 
LU LU C
D
 N
- m
 w
 C) C) 
m
m
m
m
m
m
m
m
 
LULULULULULULULU 
—
j
C
D
 C
D
 CD C
) D
 LU
 lqr
 
C) 
a, E (V U-
C
D
W
W
 c
o
 L
D
 LU
 LU
 LU
 
I
	
I
	
I 
IC
 -
 
D
 N
-(N
 
r4
x
 LX)'
	
.C
D
N
N
LU
 
W
a) 
0
 0
0
 0
 0
 co
 ca
 
 
C CL
	
-
7
3
 
J
J
J
j
j
 
•
	
Q
) a
, 
a
) a
 a
)
	
Q) 
a
 
U
N
 (N (N (N (N (N (N (N 
Z
z
z
z
z
z
z
z
 
0
O
O
O
O
O
 
.E
 N
-N
C
'D
'1LU
C
D
N
-C
D
 
>1
m
m
m
m
m
m
m
m
 
0
 D
D
D
D
D
D
D
C
)
ON 
C C C E C ale
—
I 
O
IS
d)
	
0
P
d
 
c
o
 0
 
0
 0
 0
 
.t
	
c'J
	
o
	
q
	
q
	
0
	
0 
	
-4
	
cJ
	
0 
I
	
I
	
I
	
I 
0 
IL 
-J 
0) 
O
D
 
N
-
U
 
cP2
-
	
C.) 
LD 
0 m
m
 
c
	
c'J 
Lul 0 SI
0 
0
 
0
 
0
 
0
 
0
 
0
 
0
 0 
V
IS
d) Q
oiSsoid eflO
Q
SU
0
 
I
	
I 
I
	
I 
I
	
I
0
—
.
Cl)
c
o
0)
Co
U)
N- 
d
c
c'j 
c
..J._
c'J 
£
Q
0
o
jN
..C
L
n
,_
0
0
0
 
.
—
.
—
LI)
LI)
C'J
.
—
.
—
—
.
-
Cl)
o
o
Q
c
'ja
N
-c
')
C
O
C
J
0)u,
N 
C
N
C)
N-
a
N
. 
c
o
 
Cl) 
C OH
to
C
D
q
 
U)
0
0
0
C
O
0
('
.4
C')
U
)
C5)
C5)
)
 
-tz
0
0
0
N
.C
).-0
5
)L
O
C
\J.-0
 
E
d
ä
0
C
'J
O
d
O
O
 
.0
U?
U? 
'
0
0
00
-
.-
CO
ICT
 
U
)J
0
0)
00
CO 
Lf)C\iCU 
.
—
('.4 
C
')i00C
')C
5)C
\JN
-
Cl)
c
o
q t
c
o
C
D
CO 
c
o
 
C
l)
qt
1
1
 
C\i 
co
 
(1)
0
.
—
C'.J
C')
q
U)(0
N.
0
U 
a
 U
C) 
E
 
1C) 
E
D
 
o
t.oc.000 
9X0A14 G1Q
TnPnSTVRZ ,flnwz rn., I, 
0.000	 I	 I	 I	 I	 I	 I	
I	
I	 I	 I	 I	
I	
I 
o.	 0.	 * .000	 3.000	 4000	 S 000	 0	 7.	 3.000	 3.000	 t0. 
TIME (5eC) 
	
U 3*flfl3	 O.	 0.)	 0)500 Isa)	 0 S0 
Figure 12. Thermal Responses
11
9X0A14 GN2 
0_an -  .. 
0.001 - _	 .	 ..$ . 44 . 
I!.. . 
0000	 1000	 2.000	 3000	 4.000	 0.000	 1.000	 .000	 3 000	 9 000	 10 000
TIME (sec) 
Figure 13. Material Degradation 
ACKNOWLEDGEMENTS 
The author would like to acknowledge Mr. Larry Schultz, the CLV ML manager, for his 
continual support in the Launch Induced Environment tasks. 
REFERENCES 
1. Pond, J.E., "A Small Thermal Analyzer Package With Simplified Input," Lockheed Missiles 
& Space Company, Huntsville, AL, LMSCIHREC D162533, February 1971. 
2. Smith, S., "Unified Test Stand Design and Environmental Impact Model," PT-FR-03-01, 
Plumetech, Huntsville, AL, Contract No. NAS13-01006, July 16, 2003.
12


Crew Launch Vehicle Mobile Launcher Solid Rocket Motor Plume Induced Environment

Abstract

Similar works

Full text

Available Versions

NASA Technical Reports Server