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R=19770016544 2019-10-10T17:26:11+00:00Z

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NASA CR-13518(
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R76-115

m
FINAL REPORT
SMALL,HIGH-PRESSURELIQUID HYDROGEN TURBOPUMP

by
A . Csomor and R . Sutton

R o c k w e l lI n t e r n a t i o n a l
R o c k e t d y n eD i v i s i o n

p r e p a r e df o r
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

NASA-Lewis R e s e a r c hC e n t e r
C o n t r a c t NAS3-17794
R . E . C o n n e l l y ,P r o j e c t Manager
 e ,
NOTICE
This report was prepared an asaccount of Govern-
ment sponsored work. Neither the United States,
'nor theNational Aeronautics and Space Administra-
tion (NASA), nor any person acting on behalf of
NASA :
A.) Makes any warranty or representation,
expressed or implied, with respect to
the accuracy of the information contained
in this report, or that the use of any
information, apparatus, method, pro-
or
cess disclosed in this report may not
infringe privately-owned rights; or
B.) Assumes any liabilities with respect to
the use of, or for damages resulting from
the use of, any information, apparatus,
method or process disclosed in this report.
As used above, "person acting
on behalf of NASA"
includes any employee or contractor
of NASA, or
employee or such contractor,
to the extent that such
employee or contractor of NASA or employee of such
contractor prepares, disseminates, or provides access
to any information pursuant to his employment
or con-
tract with NASA,or his employment with such contractor.

Requests for copies of this report should be

referred to

National Aeronautics and Space Administration

Scientific and Technical Information Facility
P.O. Box 33
College Park, Md.20740

Attention: SAF/DL, ACQ Division

 TECH LIBRARY KAFB, NM

-
I . Report No. 2. Government Accession No. 3. Racipimt'r C a t a l o g No.
NASA CR-135186 I
1. Title and Subtitle 5. Report Date
18 May 1977
SMALL, HIGH-PRESSURE HYDROGEN
TURBOPUMP
6. Performing Orenization Coda

7. Author(sl' 8. Pwfwming Orgmnization Report No. '

A. Csomorand R. Sutton R76-115

10. Work Unit No.
8. krforming Orwnizstion Name and Address

R o c k e t d y n eD i v i s i o no fR o c k w e l lI n t e r n a t i o n a l 11. Contract or G n n t No.

6633CanogaAvenue
CanogP a a r kC, a l i f o r n i 9
a 1304 NAS3-17794
13. T y p of Report and h i d C o v e r d
2. Sponsoring AgencyName and Address F i n a lR e p o r t( A u g u s t1 9 7 3 -
A D r i l 1976) '
N a t i o n a lA e r o n a u t i c sa n dS p a c eA d m i n i s t r a t i o n 14. S w r o r i n g Agency code
W a s h i n g t o n , D.C. 20546

5. Supplementary Notes

P r o j e c tM a n a g e r ,R o b e r tC o n n e l l y , NASA-Lewis R e s e a r c hC e n t e r ,
ClevelandO , hio

6. Abstraa

A h i g h - p r e s s u r e ,l i q u i dh y d r o g e nt u r b o p u m pw a sd e s i g n e d ,f a b r i c a t e d ,a n dt e s t e dt o a maximum
s p e e do f 9739 r a d / s (93,000 rpm)and a maximum pump d i s c h a r g ep r e s s u r eo f2 8 6 1 N/cm2
( 4 1 5 0p s i a ) .T h ea p p r o a c h e su s e di nt h ed e t a i la n a l y s i sa n dd e s i g n of t h et u r b o p u m p are
d e s c r i b e d ,a n df a b r i c a t i o nm e t h o d s are d i s c u s s e d . Data o b t a i n e d from g a sg e n e r a t o r tests,
t u r b i n ep e r f o r m a n c ec a l i b r a t i o n ,a n dt u r b o p u m pt e s t i n ga r ep r e s e n t e d .

17. Key Words (Suggcltd by Author($) I 18. Distribution Statement

HydrogenTurbopump
C e n t r i f u g a l Pump
A x i a l Flow T u r b i n e
B a l a n c eP i s t o n
\

9. Security Clauif. (of this report) 20. Security Clauif. (of this cage) 21.NO. of P- 22. Rice*
Unclassified Unclassified 290

' For sale by the National Technical Information Service. Springfield, Virginia 22151

NASA-C-lhR ( R e v . 6 - 7 1 )
Mark 48-F LH2 Turbopump
 FOREWORD

Thework h e r e i n w a s conductedfromAugust1973 to April 1976.by

personnelfromthe A d v a n c e da n dP r o p u l s i o nE n g i n e e r i n ga n dE n g i -
n e e r i n g Test u n i t s a t Rocketdyne, a d i v i s i o n o f R o c k w e l l I n t e r -
n a t i o n a l ,u n d e rC o n t r a c t NAS3-17794. Mr. RoberC t onnelly, Lewis
R e s e a r c hC e n t e r , w a s NASA p r o j e c tm a n a g e r . A t Rocketdyne M r .
H a r o l d D i e m , ProgramManager, Mr. A. T. Z a c h a r y ,P r o j e c tM a n a g e r ,
and M r . A . Csomor, P r o j e c tE n g i n e e r , were r e s p o n s i b l e f o r t h e
d i r e c t i o n of t h ep ro g ram .

I m p o r t a n tc o n t r i b u t i o n st ot h ec o n d u c t o f t h ep r o g r a ma n dt ot h e
preparationofthereport material were made by t h e f o l l o w i n g
Rocketd y n e p e rs o n n e l :

Combustion Devices M r . R. F. S u t t o n

Turbomachinery Mr. S. B. Macaluso

Turbomachinery D r . E. D. J a c k s o n

Consultant D r . K. Rothe

iv
 CONTENTS

Summary . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . 3
Discussion . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . .
A n a l yasDni esds i g n 5
. . . . . . . . . . . . . . . . . .
Material S e l e c t i o n 84
Fabrication . . . . . . . . . . . . . . . . . . . . 123
Testing . . . . . . . . . . . . . . . . . . . . . 159
Appendix A
Mark 48-F Design . . . . . .
Ground Rules . . . . . . . . 247
Appendix B
Mark 48-F Turbopump RS009601E .
Assembly
Drawing . . . . . . . . 251
Appendix C
Mark 48-F T eSeq . . . . . . . .
s t u e n ce . . . . . . . . 253
Appendix D
Mark 48-F T e s t Data . . . . . . . . . . . . . . . . . . 257
Appendix E
References . . . . . . . . . . . . . . . . . . . . . 269
Distribution List: . . . . . . . . . . . . . . . . . . 271

.
 ILLUSTRATIONS

.
1 ASE S y s t eSch m e m at i c . . . . . . . . . . . . . . . . 6
.
2 Mark 48-F Turbopump . . . . . .
Assembly . . . . . . . 9
3. Pump I n l e t Vane . . . . . . . . . . . . . . . . . . 14
4. . . .
Mark 48-F Pump I n l e t Vane C o n f i g u r a t i o n . . . . . . . 15
5. Mark 48-F Pump I n l e t Vane Angle Variation . . . . . . . . . 16
6 . Mark 48-F Pump .
I n l e t Variation a t Guide Vanes . . . . . . . 17
7 . Mark 48-F !lead-Flow C h a r a c t e r i s t i c s With0.523and0.654
Radian (30 a n d 37.5 d e g r e eI)m p e l l eD r i s c h a r gA e ngles . . . . . 19
8 . R a d i aDl i f f u s earnCd r o s s o v e r . . . . . . . . . . . . . 20
9 .Mark 48-F F u e lI m p e l l e r Vane T h i c k n e s sD i s t r i b u t i o n . . . . . . 21
10 . F u e Il m p e l l e r .
R e l a t i v e V e l o c i t i e s I. n n e rS t r e a m t u b e . . . . . 22
.
11 F u eIl m p e l l e r R e l a t i v e V e l o c i t i e sO .
. u t eS r treamtube . . . . . 23
12 . F u eIlm p e l l ePr r e s s u r L e oading . . . . . . . . . . . . . 24
13 . I m p e l l e rC r o s s - S e c t i o nL a y o u tW i t hF u l lB l a d e .
Wrap A n g l e s . . . 25
1 4 . I m p e l l e rC r o s s - S e c t i o nL a y o u tW i t hP a r t i a lB l a d e Wrap A n g l e s . . . 26
15 . Mark 48-F Pump D i f f u s e r Vane . . .
Angle . . . . . . . . 28
16 . Mark 48-F Pump .
D i f f u s e r Area . . . . . . .. . . . . 29
17 . Mark 48-FPump D i f f u s ePr r e s s u rD .
e iagram . . .. . . . . 30
18 . Mark 48-F Pump D i f f .
u s e r
D e s i g n. . . . . . .. . . . . 31
19 . Mark 48-F Pump . .
V o l u t e Area D i s t r i b u t i o n . . .. . . . . 32
20 . M o l l i e
D ri a g r a m . . . . . . . . . . . . .. . . . . 33
21 . LiquidHy d ro g en Pump M o l l i e D . .
r iagram . . . .. . . . . 34
22 . Mark 48-F Pump . .
Perfo rm an c e . . . . . . .. . . . . 36
23 . Mark 48 F u e l Turbopump S t a t i cP r e s s u r e s . . . . .. . . . . 38
24 . Mark 48-F Turbopump F l u i d S t a t iT c emperature . . .. . . . . 40
25 . Mark 48-F Turbopump Flows . . . . . . . . . . . . . . 42
26 . Mark 48 Fu e l Turbopump F l u i d Densities . . . . . . . . . . 44
27 . Mark 48-F T u r b i nVe e l o c i tD . . .
yi a g r a m . . . . . . . . 48
28 . Mark 48-F T u r b i n P e r e s s u r ae n d T e m p e r a t u rD e istribution . . . . 51
29 . Mark 48-F T u r b i nEef f i c i e n c y . . . . . . . . . . . . . 53
30 . Nark 48-F T u r b i n eF i r s t - S t a g eN o z z l e Vane Shape. . . . . . . 57
31 . Mark 48-F T u r b i n F e i r s t - S t a gR e o t oB r l a dSe hape . . . . . . . 57
32 . Mark 48-F TurbineSecond-StageNozzleVaneShape . . . . . . . 57
33 . Mark 48-F T u rb i n eSec o n d -St a g eR o t o B r l a d eS h a p e . . . . . . . 57
34 . Mark 48-F T u r b i n eF i r s t - S t a g eN o z z l e . . . . . . . . . . . 58
35 . Mark 48-F T u r b i nFe i r s t - S t a gR e otor . . . . . . . . . . . 59
36 . Mark 48-F T u rb i n
Sec
e o n d -St a gNoz
e zle . . . . . . . . . . 60
37 . Mark 48-F T u rb i n Sec
e o n d -St a g R
e otor . . . . . . . . . . . 61
38 . Mark 48-F B a l a n c P
e i s t o F
n l u i F
d l o wPath . . . . . . . . . 63
39 . Mark 48-F Turbopump .Axial F o rces . . . . . . . . . . . 64
40 . Mark 48 F u e l Pump B a. l a n c P
e i s t o n . . . . . . . . . . . 66
41 . B e a r i n g D e s i g n . . . . . . . . . . . . . . . . . . 67
42 . Mark 48-F B e a r i n g B1 L i f e . . . . . . . . . . . . . . 70
43 . Mark 48-F B e a r i n gL i f e v s A x i a l Load . . . . . . . . . . . 71
44 . Mark 48-F B e a r i n gS t i f f n e s sV e r s u sA x i a l . .
Load . . . . . . 72
45 . Mark 48-F B e a r i n gA x i a l
D e f l e c t i o n v s Axial . . .
Load . . . . 74
46 . Mark 48-F Turbopump R o c k e t d y n eB e a r i n gI n s t a l l a . .
tion . . . . 75
47 . Mark 48-F Turbopump MTI B a l l B e a r i n g Installation . . . . . . 75
48 . Mark 48-F T u r b o p u m H p ybriB d e a r i n Ign s t a l l a t i o n . . . . . . . 75

vi
 49 . Mark 48-F Turbopump Shaft Seal Configuration . . . . . . .. . 76
50 . Mark 48-F Shaft Seal . . . . . . . . . . . . . . . . 77
51 . .
Pressure Forceson a Floating-Ring Seal . . . . . . . . . 79
52 . Typical Static Flange Seal Configuration
. . . . .. .. .. .. .. .. .. .. . 80
53 . Mark 48-F Impeller Wear Ring . 80
54 . Mark 48-F Turbopump Rotor Critical Speeds . . . . . . . . . 81
55 . .
Mark 48-F Turbopump Rotor Mode Shapes . . . . . . . .. . 83
56 . . . . .
Mark 48-F Materials Selection . . . . . . . . . 85
57 . Titanium (5.0 A1-2.5 Sn) Strength Ratio vs Temperature . . . . . 88
58 . Mark 48-F LH2 Turbopump Impeller Average Temperature
. . . . . . .
or Time
. . .
.
. . . 89
59 . ASE Turbine Manifold Transient . . 90
60 . Steady-State Isotherm for Mark 48-F First Turbine Disk . . . . . 92
61 . . . . . . . . .
ASE Turb.ine Blade Transient . . . . . . 93
62 . . .
Mark 48-F Pump Housing Finite-Element Model . . . . . . 94
63. . . .
Mark 48-F Pump Housing Constant-Strain Map . . . . . . 95
64. . . .
Mark 48-F Pump Housing Constant-Strain Map . . . . . . 96
65. Mark 48-F First- and Second-Stage Impellers Finite-Element 1Mode . 98
66. Mark 48-F First- and Second-Stage Impellers Constant-Stress Map . . 99
67. . . . . . .
8

Mark 48-F Third-Stage Impeller Finite-Element Model 100

68. . . . .
Mark 48-F Third-Stage Impeller Constant-Stress Map . . 101
69. Mark 48-F First- and Second-Stage Turbine Disk Finite-
. . . . . . . . . . . . . . . . .
Element.Mode1 . . 103
70. Mark 48-F Turbine First-Stage Disk, Constant-Strain Map . . . . 104
71 . Mark 48-F Turbine Manifold Finite-Element Model . . . . . . . 107
72 . . . . . .
Mark 48-F Turbine Manifold Constant-Strain Map . . 108
73 . Mark 48-F Split Impeller. . . . . . . . . . . . . . . 110
74 . Mark 48-F Third-Stage Impeller Underformed Structure . . . . . 111
75 . Mark 48-F First-Stage Impeller . . . . . . . . . . . . . 112
76 . . . . . . . . . . . . . . .
Enlarged End of Preimpeller 113
77 . . . . . .
Mark 48-F Split Impeller Preimpeller Effective Stress 114
78 . Deflected Shape of Split Impeller . . . . . . . . . . . . 116
79 . Titanium (5.0 A1-2.5 Sn) Predicted Minimum Tensile Strength . . . 117
80. . .
LH2 Turbopump Gas Generator . . . . . . . .. . . . 118
81. .
Gas Generator Coaxial Element . . . . . . . .. . . . 120
82. Gas Generator Priem Analysis . . . . . . . . . . . . . 121
83 . InjectorElement . . . . . . . . . . . . . . . . . . 122 .
84. . . . . .
Gas Generator Film Coolant Temperature . . . . . 124
85 . AbsorberExperience . . . . . . . . . . . . . . . . 125
86. Turbopump to Gas Generator Transition Joint. . . .. . . . 125
87 . Pump Inlet Housing. . . . . . . . . . . . . . . . . 127
88. .
Mark 48-F Inlet Housing Guide Vane Pantographing . . . . . . 128
89 . Partially Completed Mark 48-F Inlet Housing. . . . . . . . 129
90 . . . .
Mark 48-F Inlet Housings . . . . . . . . . . . . 130
91. Mark 48-F Turbine Axial Entry Pump Inlet . . . . . . . . . 131
92. Crossover Fabrication. . . . . . . . . . . . . . . . 131
93. .
Mark 48-F Diffuser EDM Setup . . . . . . . . . . . . 132
94 . LH2 Pump Crossover Details Before Welding. . . . . . . . . 133
95. Impeller EDM-ing Set-Up. . . . . . . . . . . . . . . 134
96. Second Stage Impeller. . . . . . . . . . . . . . . . 135
97 . LH2 Turbopump Rotor . . . . . . . . . . . . . . . . 135
98 . . .
Turbine Wheel Machining Set-Up and Electrode . . . . . . 137
99 . Turbine Wheels and Center Tie Bolt . . . . . . . . . . . 138

vii

I
 100 . H o u s i nF gabrication . . . . . . . . . . . . . . . . 139
101 . . .
Mark 48-F H o u s i n gF a b r i c a t i o nP r o c e s s . . . . . . . . 141
1 0 2. Mark 48-F B a l a n c i n gS e t u p . . . . . . . . . . . . . . 142
103. Mark 48-F Balance AssemblyRadialRunouts . . . . . . . . . 143
1 04 . Mark 48-F S/N 01-0 A s s e m b l y I n s t r u m e n t a t i o n a n d F r o n t
BeariC n gl e a r a n c e s . . . . . . . . . . . . . . . . 145
1 05 . Mark 48-F S/N 01-0 A s s e m b l yI m p e l l e rL a b y r i n t hC l e a r a n c e s . . . 146
1 06 . Mark 48-F T u r b i n e S/N 01-0 Axial C l e a r a n c e s . . . . . . . . 147
107 . Mark 48-F T u r b i n e S/N 01-0 Axial C l e a r a n c e s . . . . . . . . 148
108 . Mark 48-F T r u b i n e S/N 01-0 R a d i a l C l e a r a n c e s . . . . . . . . 149
1 0 9. Mark 48-F F r o n tB e a r i n gP r e l o a d . . . . . . . . . . . . 151
110 . Mark 48-F Rear B e a r i n g Preload . . . . . . . . . . . . 152
111 . Mark 48-F Turbopump B e a r i n g s L o a d s v s P i s t o n P o s i t i o n . . . . . 153
112 . Mark 48-F TurbopumpAssembly .
P u s h / P u l lS e t u p . . . . . . . 15 5
113 . Mark 48-F B ea ri n gPrel o a d Am . b ie n tT e m p e r a t u r e . . . . . . . 15 6
1 14 . Mark 48-F B e a r i n gP r e l o a d . .
LN2 T e m p e r a t u r e . . . . . . . 157
115 . Gas G e n e r a t o r I n s t a l l a t i o n . . . . . . . . . . . . . . 16 0
116 . Gas G e n e r a t o r I n s t a l l a t i o n . . . . . . . . . . . . . . 161
1 17 . Combustor I n t e r n a lE r o s i o n . . . . . . . . . . . . . . 164
118 . Combustor I n t e r n a l Heat Marks . . . . . . . . . . . . . 165
1 19 . Combu s t o rHea tPen e t ra t i o n . . . . . . . . . . . . . . 166
1 20 . ThermocoupleRake I n s t a l l a t i o n a n dT y p i c a lT e m p e r a t u r e
Measurements . . . . . . . . . . . . . . . . . . 167
1 2 1. C o m b u s t i o nT e m p e r a t u r ev sT h e r m o c o u p l eI n s e r t i o nD e p t h . . . . 167
1 22 . I n j e c t o r Water Flow Test . . . .
. . . . . . . . . . 169
1 2 3. .
U n i t No 3 LH2 Turbopump I n j e c t o r F a c e D i m e n s i o n a l
Inspectio .
Rne s u l t s . . . . .
. . . . . . . . . . 172
1 2 4. C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e r I n j e c t o r . U n i t 3.
Elementl-5 . . . . . . . . .
. . . . . . . . . . 175
125 . C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e rI n j e c t o r .U n i t3 .
Elementl-8 . . . . . . . . .
. . . . . . . . . . 177
1 2 6. C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e rI n j e c t o r .U n i t3 .
Element2-3 . . . . . . . . .
. . . . . . . . . . 179
127 . SmallH . igh-pressure Gas G e n e r a t o rC o m b u s t o rM o d i f i c a t i o n s . . . 182
1 28 . LH2 Turbopump Gas G e n e r a t o rI n s t a l l a t i o n . . . . . . . . . 183
129 . LH2 Turbopump Gas G e n e r a t o rE x i tP l a n eT e m p e r a t u r eP r o f i l e . . . 184
1 30 . ASE
LH2 Turbopump Gas G e n e r a t o Ir n j e c t o E . r lement . . . . . 185
131 . LH2 Turbopump Gas GeneratorCombustion Zone T e m p e r a t u r e
Profile . . . . . . . . . . . . . . . . . . . 186
1 32 . I n j e c t o rU n i t 3M F o l l o w i n g Test. . . . . . . . . . . . 187
133 . I n j e c t oPre r f o r m a n c e Map . . . . . . . . . . . . . . 188
134 . Mark 48-F T u r b i n eC a l i b r a t i o n . . . . . . . . .
Test S e t u p 19 0
1 35 . Mark 48-F T u r b i n e C a l i b r a t i o n S e t u p . . . . . . . . . . . 191
1 3 6. . .
S m a l l .H i g h - p r e s s u r eT u r b i n eC a l i b r a t i o nI n s t a l l a t i o n (View A) 193
137 . . .
S m a l l .H i g h - p r e s s u r eT u r b i n eC a l i b r a t i o nI n s t a l l a t i o n (View B) 194
138 . Mark48-F .
T u r b i n eP e r f o r m a n c e . . . . . . . . . . . . 197
1 3 9. Gaseous Hydrogen Turbine Drive . . . . . . . . . . . . 199
3.40. Gas G e n e r a t oTr u r b i nD .
e rive . . . . . . . . . . . . 200
1 4 1. Mark 48-F LH2 Turbopump T e s t Countdown Summary . . . . . . . 202
142 . LH2Turbopump . . . . . . . . . . . . . . . . . . 204
143 . O r i g i n a l Mark 48-F SpeedPickupSystem . . . . . . . . . . 214

viii
 144 . High-speed FM Tape Analysis. Mark 48-F LH2 Turbopump rpm
Test016-006 . . . . . . . . . . . . . . . . . . 215
145. High-speed FM Tape Analysis. Mark 48-F Turbopump rpm
. . . . . .
Spectral Analysis. Test 016-006 . . . . . . 217
146. . . . .
Original Mark 48 Speed Pickup Systems .. . . . . 218
147. .
Mark48-0 LO2 Turbopump Speed Monitor Checkout . . . . . . 219
148. . . . . . . . .
Mark 48-F Pump Performance . . . . . . 222
149. . . . . . . . .
Mark 48-F Pump Efficiency . . . . . . 224
. . .
'

150. Mark 48-F Pump Test Data: Run6 . Slice 10; N = 6125 rad/s 225
151. Mark 48-F Pump Test Data; Run . .
9. Slice 7; N = 9423 rad/s . . 226
152. Front Bearing Coolant Flow Path . . . . . . . . . . . . 229
153. .
Front Bearing Coolant Resistances . . . . . . . . . . 230
154. BalancePistonPressures . . . . . . . . . . . . . . . 232
155. . . . . .
Turbine Instrumentation . . . . . . . . . . 234
156 . . . . . .
Horsepower Correlation . . . . . . . . . . 237
157 . Mark 48-F Turbopump Hardware After Testing . . . . . . . . 239
158. . . . . . . . . .
Mark 48-F Pump Components After Testing 240
159. Mark 48-F Pump Third-Stage Front Wear-Ring Silver Plating
Flaking . . . . . . . . . . . . . . . . . . . 241
160 . . . .
Mark 48-F Balance Piston Low-Pressure Orifice After Testing 242
161. Mark 48-F Balance Piston Low-Pressure Orifice Rub Ring After
Testing . . . . . . . . . . . . . . . . . . . 243
162. . . . . . . . . . . . . .
Mark 48-F Bearings Posttest 244
163. . . . . . . . . . .
Mark 48-IF Turbine Components Posttest 245

ix

I
 TABLES

1. Mark48-FTurbopumpNominalDesignConditions . . . . . . . 7
2. Comparison of Two- and Three-Stage Pump Characteristics . . . . 12
3. Mark48-FPump .
Loss Parameters .
. . . . . . . . . . 35
4. Small. High-pressure LH2 Turbopump
NominalDesignParameters . . . .
. . . . . . . . . . 37
5. Turbine Design Operating Conditions.
. . . . . . . . . . 47
6. Gas Path Energy Coefficients. . .
. . . . . . . . . . 50
7. TurbineEnergyandLossDistribution . . . . . . . . . . 54
8. .
Turbine Nozzle and Rotor Blade Design . . . . . . . . . 56
9. Mark 48-F Shaft Seal Clearances . . . . . . . . . . . . 78
10. Mark48-FTurbopumpMaterialProperties . . . . . . . . . 86
11. .
Mark 48-F Pump Housing Stress Analysis . . . . . . . . . 91
12 . Mark 48-F Turbine Blade Configuration Summary . . . . . . . 105
13. Mark 48-F Turbine Manifold Predicted Low-Cycle Fatigue Life . . . 106
14. Gas Generator Injector Elements. . . . . . . . . . . . 119
15. Mark48-FTurbopumpWeights . . . . . . . . . . . . . 158
16. . .
LH2 Turbopump Gas Generator Test Summary . . . . . . . 162
17. LH2 Injector Unit No .
. 3 Water Flow Test Results . . . . . . 170
18. Injector Inspection Results. LH2 Turbopump
Injector Unit No . 3 . . . . . . . . . . . . . . . . 173
19. Mark 48-F TestData From Wyle Laboratories.
El Segundo.California . . . . . . . . . . . . . . . 195
20. Mark 48-F Turbine Test Data From Wyle Laboratories.
El Segundo. California . . . . . . . . . . . . . . . 196
21 . LH2 Turbopump Test Procedures List
Lima Stand - Rocketdyne PRA. . . . . . . . . . . . . 198
22 * Advanced Space Engine Mark 48-F Hydrogen
TurbopumpTestInstrumentation . . . . . . . . . . . . 203
23 . .
Mark 48-F Turbopump Redlines (1990 rad/s; 19.000 rpm) . . . . 206
24. .
Mark 48-F Turbopump Redlines (4710 rad/s; 45. 000 rpm) . . . . 207
25 . Mark 48-F Turbopump Redlines (6280 rad/s; 60. 000 rpm) . . . . . 208
26 . .
Mark 48-F Turbopump Redlines (9947 rad/s; 95. 000 rpm) . . . . 209
27 . Advanced Space Engine Mark 48-F Hydrogen
TurbopumpTestHistory . . . . . . . . . . . . . . . 210
28. Balance Piston Position . . . . . . . . . . . . .
. . 231
29 . Turbine Test Data. . . . . . . . . . . . . . . . . 235

x
 SUMMARY

The o b j e c t i v e o f t h i s p r o g r a m w a s t o e s t a b l i s h t h e t e c h n o l o g y f o r small, h i g h -
p r e s s u r e ,l i q u i dh y d r o g e n (LH2) pumping c a p a b i l i t y . Turbopumps i n t h i s cate-
gor y are n e e d e d f o r a p p l i c a t i o n s i n small, h i g h - p e r f o r m a n c e ,r e u s a b l e , versa-
t i l e , s t a g e d - c o m b u s t i o nr o c k e te n g i n e s .

To a c c o m p l i s h t h e a b o v e o b j e c t i v e , a n a l y s i s a n d d e s i g n e f f o r t w a s expended
toproducespecificationsandshopdrawingsinsufficientdetailtopermit
f a b r i c a t i o no f t e s t h a r d w a r e . The d e s i g ni n c l u d e s a t h r e e - s t a g ec e n t r i f u g a l
pump w i t h r a d i a l d i f f u s e r s a n d i n t e r n a l c r o s s o v e r s . Power t o t h e pump i s
d e v e l o p e db y an a x i a l - f l o w ,t w o - s t a g e ,r e a c t i o n - t y p et u r b i n e ,u s i n gt h e
c o m b u s t i o np r o d u c t so f LH2 a n dl i q u i do x y g e n( L 0 2 ) .R o t o ra x i a lt h r u s t
c o n t r o l i s p r o v i d e db yi n c o r p o r a t i n g a s e l f - c o m p e n s a t i n g ,d o u b l e - a c t i n g
b a l a n c ep i s t o n as a n i n t e g r a l p a r t o f t h e t h i r d - s t a g e i m p e l l e r rear s h r o u d .
The r o t o r i s s u p p o r t e do n a p a i r o f b a l l b e a r i n g s o n e a c h e n d . A l l bearings
are c o o l e d by r e c i r c u l a t i n g LH2 i n t e r n a l l yt h r o u g h them. A c o n t r o l l e d - g a p ,
s h a f t - r i d i n g s e a l i s u s e dt op r e v e n tt u r b i n eh o tg a s e sf r o me n t e r i n gt h e
pump r e g i o n . The n o m i n a ld e s i g ns p e e do ft h er o t o r w a s e s t a b l i s h e d a t 9947
r a d / s( 9 5 , 0 0 0 rpm) .
H a r d w a r e f o r twoturbopump a s s e m b l i e s was f a b r i c a t e d . Two t y p e so fi m p e l l e r s
were i n c l u d e d : (1) a ni n t e g r a li m p e l l e r w h o s ef l o wp a s s a g e s were formedby
e l e c t r i c a l - d i s c h a r g em a c h i n i n g ( E D M ) , a n d ( 2 ) a s p l i ti m p e l l e rw h i c h was
f a b r i c a t e d by m a ch i n i n g i n two p i e c e s , t h e nw e l d i n gt of o r mt h ea s s e m b l y .
O n l yt h ei n t e g r a li m p e l l e r s were u t i l i z e d d u r i n g t h e t e s t i n g c o v e r e d b y t h i s
report.

A h o t - g a sg e n e r a t o r was d e s i g n e d w i t h a f i l m - c o o l e d bodyandan injector

s i m i l a r t ot h ee n g i n ep r e b u r n e rt o makemaximum u s eo fe x i s t i n gc o m b u s t i o n
technology. The g a sg e n e r a t o r w a s t e s t e do n LIMA s t a n di nt h eP r o p u l s i o n
Res earchAre a a t R o c k e t d y n e ' sS a n t aS u s a n aF i e l dL a b o r a t o r y (SSFL) f o r a
t o t a lo f1 5 t e s t s r e s u l t i n g i n a c c e p t a b l e h o t - g a st h e r m a lg r a d i e n t sa n d satis-
f a c t o r yh a r d w a r ec o n d i t i o n .

The t u r b i n e w a s c a l i b r a t e d a t W i l e y L a b o r a t o r i e s u t i l i z i n g g a s e o u s n i t r o g e n
(GN2) as t h e d r i v i n g medium.The o u t p u t w a s m e a s u r e dw i t h a t o r q u e m e t e r .
The t u r b i n e e f f i c i e n c v w a s measured a t 79%compared w i t h a p r e d i c t e d d e s i g n
v a l u eo f7 5 % .

The LH2 t u rb o p u m pa s s em b l ya l s o was t e s t e d a t LIMA s t a n d of Rocketdyne'sPro-

p u l s i o nR e s e a r c h Area. Ten t e s t s were conductedononeturbopumpassembly,
a c c u m u l a t i n g a t o t a l time of 884 s e c o n d s .L i q u i dh y d r o g e n was u s e d as t h e
pump f l u i d , a n d t h e t u r b i n e was p r o p e l l e db ya m b i e n t - t e m p e r a t u r eg a s e o u s
hydr oge n ( G H 2 ) . The t e s t sp e e dr a n g e du pt o9 7 3 9r a d / s( 9 3 , 0 0 0r p m ) . Pump
d i s c h a r g ep r e s s u r e sr a n g i n g up t o 2883 N / c m 2 ( 4 1 8 2p s i a ) ,a n df l o w r a t e s up
t o 0.032 m 3 / s (509 gpm) were g e n e r a t e d .

I
 A n a l y s i so ft h ef l u i dd y n a m i cd a t ar e v e a l e dt h a t , a t s p e e d sb e l o w 8376 r a d / s
(80,000 r p m ) , t h e g e n e r a t e d pump h e a d w a s as p r e d i . c t e d a n d t h e pump i s e n t r o p i c
e f f i c i e n c y w a s s l i g h t l yh i g h e rt h a np r e d i c t e d . A t s p e e d sa p p r o a c h i n gt h e
d e s i g n l e v e l , t h e p e r f o r m a n c e of t h e pump f i r s t s t a g e d e t e r i o r a t e d somewhat,
c a u s i n gt h eo v e r a l lh e a dt of a l lb e l o wt h ep r e d i c t e dv a l u e . The d a t a a l s o
disclosedhigher-than-predictedtemperaturesforthecoolant of b o t h b e a r i n g
sets.

The m e c h a n i c a lo p e r a t i o no ft h et u r b o p u m pg a v ee v i d e n c eo f a basicallysound
design. The e n t i r e i n i t i a l t e s t s e r i e s w a s performedon a s i n g l eb u i l d ,a n d
t h es p e e dl i m i t a t i o no f 9739 r a d / s( 9 3 , 0 0 0 rpm) was i m p o s e do n l yt h eb yd r i v e
g a ss u p p l y . No e v i d e n c e of s t r u c t u r a lf a i l u r eo rd e t r i m e n t a lr o t o rv i b r a -
t i o n s w a s p r e s e n t .D i s a s s e m b l y of t h et u r b o p u m pr e v e a l e do n l ym i n o rh a r d w a r e
discrepanices.

2
 INTRODUCTION

Systemstudieshavebeenconductedtodetermine the f e a s i b i l i t y o f d e v e l o p i n g
a reusablevehicleforperformingfuture Air F o r c e a n d NASA s p a c e m a n e u v e r i n g
missions. These s t u d i e s have shown t h a t , o v e r t h e t h r u s tr a n g eo f interest,
h i g h - p r e s s u r e ,s t a g e d - c o m b u s t i o n - c y c l ee n g i n e so f f e r the h i g h e s t s p e c i f i c
i m p u l s ea n dp a y l o a dc a p a b i l i t y . A review o f t h e v e h i c l e a n d e n g i n e s y s t e m
studyresults.indicatesthat a s i n g l e - b e l l - n o z z l e ,s t a g e d - c o m b u s t i o n - c y c l e
e n g i n e a t 88,964 (20,000 p o u n d s ) t h r u s t l e v e l i s near optimum f o r t h e DOD
and NASA m i s s i o n r e q u i r e m e n t s .

Thispr o g ra m w a s i n i t i a t e d t o p r o v i d e t h e r e q u i r e d h y d r o g e n turbopumptech-
n o l o g yb a s ef o rs u b s e q u e n td e v e l o p m e n to f a high-performance,staged-combus-
tionrocketengine.

Technology items o f p a r t i c u l a r i n t e r e s t d u r i n g t h e c o u r s e o f t h e c u r r e n t d e v e l -
o p m e n tp r o g r a mi n c l u d ef a b r i c a t i o no fi m p e l l e rp a s s a g e sb y EDM; s p l i t i m p e l l e r
d e s i g na n df a b r i c a t i o nt e c h n i q u e s ;b a l a n c i n go f small, h i g h - s p e e d , m u l t i p a r t
s h a f t s ;h y d r o g e n - e m b r i t t l e m e n tp r o t e c t i o n ;b a l a n c ep i s t o nd e s i g na n do p e r a t i o n ;
h i g h DN b e a r i n g s ;a n da s s e m b l ya n dm e a s u r e m e n tp r o c e d u r e sf o r small turbopump
a s s e m b l i e s .I na d d i t i o n , work w a s p e r f o r m e do nc o n c e n t r i c - e l e m e n t L02/LH2
injectors.

The o b j e c t i v e s o f t h i s p r o g r a m were t o d e s i g n , f a b r i c a t e , and t e s t a h i g h -

p r e s s u r e LH2 t u r b o p u m pc a p a b l eo fm e e t i n gt h ep e r f o r m a n c er e q u i r e m e n t so ft h e
8 8 , 9 6 4 N (20,COO p o u n d s )t h r u s t ,s t a g e d - c o m b u s t i o n - c y c l ee n g i n e ;d e m o n s t r a t e
i t s b a s i cc a p a b i l i t y ;a n di d e n t i f ya n y areas w h e r e a d d i t i o n a l e f f o r t d u e t o
t e c h n o l o g y l i m i t a t i o n s i s r e q u i r e d t o p l a c e a f u t u r ee n g i n ep r o g r a mo n a solid
basis.

R o c k e t d y n eh a sa s s i g n e dt h ed e s i g n a t i o n "Mark 48-F Turbopump" t o t h e small,

h i g h - p r e s s u r e , LH2 t u r b o p u m pd e s i g ng e n e r a t e du n d e rt h i sc o n t r a c t . The two
terms w i l l b e u s e d i n t e r c h a n g e a b l y t h r o u g h t h i s r e p o r t .

3
 DISCUSSION

ANALYSIS AND DESIGN

ASE E n g i n e C o n f i g u r a t i o n

The o b j e c t i v e o f t h i s p r o g r a m was toestablishthetechnologybasefor small,

h i g h - p r e s s u r e LH2 pumping c a p a b i l i t y f o r a p p l i c a t i o n on t h e AdvancedSpace
Engine(ASE).The b a s i cp e r f o r m a n c ep a r a m e t e r sf o rt h e ASE h a v eb e e ne s t a b -
l i s h e d i n a preliminarydesigntask,theresults ofwhich are r e p o r t e d i n R e f . 1.

A s c h e m a t i co ft h e ASE i s p r e s e n t e di nF i g . 1. I t i s a staged-combustion-
c y c l ee n g i n eu s i n g LH2 and LO2 as p r o p e l l a n t s . Themajorcomponentscomprising
t h e e n g i n e are two , l o w - p r e s s u r e g a s - d r i v e n b o o s t pumps ; two, h i g h - p r e s s u r e
pumps; a p r e b u r n e r ; a r e g e n e r a t i v e l y c o o l e d c o m b u s t i o n c h a m b ' e r - a n d n o z z l e ;
dump c o o l e dn o z z l ee x t e n s i o n ;a n dv a l v e s .

The s m a l l , h i g h - p r e s s u r e LH2 turbopump e f f o r t p e r f o r m e d u n d e r t h i s c o n t r a c t

w a s d i r e c t e dt o w a r de s t a b l i s h i n gt h et e c h n o l o g yf o rt h em a i nh y d r o g e nt u r b o p u m p .

TurboDumD Reauirements

The p e r f o r m a n c er e q u i r e m e n t sf o rt h e Mark48-F turbopump a r e l i s t e d i n T a b l e 1.

The pump i s r e q u i r e d t o d e l i v e r 2 . 7 4 k g / s( 6 . 0 4l b / s e c )o f LH2 s t a r t i n g w i t h
a ni n l e tp r e s s u r eo f 49 N / c m 2 ( 7 1 p s i a ) p r o v i d e d by t h el o w - p r e s s u r e pump, t o
a d i s c h a r g ep r e s s u r e of3140 N / c m 2 (4560 p s i a ) . The p r o p e l l a n tg a sf o rt h e
t u r b i n e i s a m i x t u r eo ff r e eh y d r o g e na n d steam, r e s u l t i n g f r o m t h e c o m b u s t i o n
of LH2 and LO2. The g a s i s p r o v i d e d a t a t e m p e r a t u r eo f1 0 3 3 K (1860 R) andan
i n l e t p r e s s u r e of2360 N/cm2 ( 3 4 2 0p s i a ) . The t o t a lg a sf l o w r a t ea v a i l a b l e
i s 3 . 0 2k g / s( 6 . 6 6l b / s e c ) . T h eh o r s e p o w e rr e q u i r e m e n to ft h e pump i s matched
by a d j u s t i n gt h ep r e s s u r er a t i oa c r o s st h et u r b i n e .S i n c et u r b i n ep r e s s u r e
ratiohas a stronginfluenceontheattainableenginecombustion pressure i n
a s t a g e dc o m b u s t i o nc y c l e , i t i s t ob em a i n t a i n e d a t t h el o w e s tp o s s i b l el e v e l .
A s n o t e di nT a b l e 1 , t h em e c h a n i c a lo p e r a t i n gr e q u i r e m e n t si n c l u d e dm u l t i p l e
s t a r t s w i t hl o n go p e r a t i n gd u r a t i o n sa n dp o t e n t i a l l yl o n gc o a s t times between
operations.

The v a l u e sn o t e di nT a b l e 1 d e v i a t es l i g h t l yf r o mt h er e q u i r e m e n t se x p r e s s e d
i nt h eo r i g i n a lc o n t r a c t wo rks t a t e m e n t .R e f i n e dc o m p u t e rr u n so ft h ee n g i n e
balanceindicatedminorshiftsintherequired pump d i s c h a r g e p r e s s u r e , t u r b i n e
i n l e tt e m p e r a t u r ea n dp r e s s u r e , as w e l l as t u r b i n eh o t - g a sf l o w r a t e . The
r e v i s e d v a l u e s were i n c o r p o r a t e d i n t h e r e q u i r e m e n t s w i t h t h e NASA p r o j e c t
manager ' S a p p r o v a l .

I na d d i t i o nt ot h ep e r f o r m a n c ec r i t e r i an o t e di nT a b l e 1 , t h ec o n t r a c t work
statementincludedcertaingroundrulesrelatingprimarilytothestructural
a n a l y s i sa n dm e c h a n i c a ld e s i g no ft h et u r b o p u m p .T h e s eg r o u n dr u l e s are en-
c l o s e d i n Appendix A.

5
Figure 1. ASE System Schematic
 TABLE 1 MARK 48-F TURBOPUMP
NOMINAL D E S I G NC O N D I T I O N S

Pump SI
UEnnig
U
t slni si ths

TY Pe fuga1 Centri
Propel lant
LH2
p r e sI n
s luer te 49 N/cm2 71 p s i a
I nt 1eemt p e r a t u r e 21-23 K 38-41 R
D i s cphraersgseu r e 3140 N/cm 4560 p s i a
kg/s 2.74
Mass f l o w 6 . 0 4l b / s e c
Number o f s t a g e s 3
T u r b ine

W o r k i n gf l u i d 02/H2 c o m b u s t i opnr o d u c t s (H2 x H20)

I n l e tt e m p e r a t u r e 1033 K 1860 R
I n l e tp r e s s u r e 2360 N/cm2 3420 p s i a
P r e s s u r er a t i o Minimum n e c e s s a r yt od e v e l o p pump
horsepower requi rements
Flowrate 3.02 k g / s 6.66 l b / s e c
Number o f s t a g e s 2
Type admission Full

Turbopump

Capable o fo p e r a t i o na tp u m p e d - i d l ec o n d i t i o n s ,i . e . ,a p p r o x i m a t e l y 5 t o 10%
fu.1 1 t h r u s t

O f f - d e s i g no p e r a t i o n : +20% Q/N a t f u l l t h r u s t down t o 30%

Q/N a t 20% N
Service 1i fe between overhauls: “ 3 0 0t h e r m a c
l ycles or IO h o u r sa c c u m u l a t e d
r u nt i m e
Servi ce-f ree 1 if e : 560 t h e r m a lc y c l e so r 2 h o u r sa c c u m u l a t e d
r u nt i m e
Maximum s i n g l e r u n d u r a t i o n : 2000 seconds
Maximum t i me between f i r i n g s
d u r i n gm i s s i o n : 14 days
Minimum t i m eb e t w e e nf i r i n g s
duringmission: 1 minute
Maximum s t o r a g e t i m e i n o r b i t
(dry) : 5 2 weeks

“ T h e r m a lc y c l ed e f i n e da se n g i n es t a r t( t oa n yt h r u s tl e v e l )a n ds h u t d o w n .

7
 Certainelementsoftherequirementsnotedabovehad a particularly significant
i m p a c to nt h et e c h n o l o g yr e q u i r e m e n t so f the t u r b o p u m p a n d t h e e n s u i n g d e s i g n
c o n f i g u r a t i o n .I nt h e area o ft h e pump, t h ec o m b i n a t i o no fl o wf l o w r a t ea n d
h i g hd i s c h a r g ep r e s s u r ei m p o s e d a difficult impeller fabrication task because
o f the r e l a t i v e l y n a r r o w p a s s a g e s r e q u i r e d c o m p a r e d w i t h t h e o u t e r d i a m e t e r .
The d e s i r e f o r h i g h e f f i c i e n c y , c o m p a c tp a c k a g i n g ,a n dl i g h tw e i g h tp l a c e dt h e
r o t o rs p e e di n t ot h e9 4 2 3t o 10,470 r a d / s( 9 0 , 0 0 0t o 100,000 rpm) r a n g e ,p u s h-
i n g b e a r i n g DN v a l u e t o t h e 2 .O x lo6 mm rpm limit n o t e d i n the DesignGround
Rules(AppendixA). The b e a r i n g o p e r a t i o n a t h i g h DN v a l u e s i n a turbopump
i n s t a l l a t i o n as w e l l as t h e d y n a m i c b e h a v i o r o f t h e r o t o r a t h i g hs p e e d sn e e d e d
t ob ed e m o n s t r a t e d .

B e c a u s eo ft h eh i g ho p e r a t i n gs p e e di n v o l v e d ,t h eb e a r i n g sw o u l dn o tb ea b l e
t ot a k ea na p p r e c i a b l ea x i a lt h r u s tl o a d .T h i sc o n d i t i o nd i c t a t e dt h a ta n
a x i a lt h r u s tb a l a n c ed e v i c eb ee m p l o y e d . The o p e r a t i n gc h a r a c t e r i s t i c so f
s u c h a d e v i c ea l s or e q u i r e de v a l u a t i o n . In t h et u r b i n e ,t h ep e r f o r m a n c e of a
small t u r b i n e w i t h a h i g h - p o w e rd e n s i t ya n dl o w - p r e s s u r er a t i o( a p p r o x i m a t e l y
1 . 4 ) n e e d e dt ob ed e m o n s t r a t e d .

From a s t r u c t u r a l c o n s i d e r a t i o n , t h e r e q u i r e m e n t f o r 300 t h e r m a lc y c l e s w a s
s i g n i f i c a n t i n t h a t i t e s t a b l i s h e dl o w - c y c l ef a t i g u e c r i t e r i a a n de v e n t u a l l y
n e c e s s i t a t e di n c o r p o r a t i n g a l i n e r i n t h e t u r b i n e m a n i f o l d t o l i m i t t h e maxi-
mum t h e r m a l g r a d i e n t s i n s t r u c t u r a l walls.

-
Turbopump D e s c r i p t i o n

The c o n f i g u r a t i o no ft h e Mark 48-F turbopump i s shown i nF i g . 2 . The t u r b o -

pump a s s e m b l yr e q u i r e m e n t s are e s t a b l i s h e do nR o c k e t d y n ed r a w i n g RS009601E, a
copyofwhich i s includedinAppendix B.

The p u m p i n g e l e m e n t s c o n s i s t o f t h r e e c e n t r i f u g a l i m p e l l e r s c o n t a i n i n g s i x f u l l
and s i x p a r t i a l v a n e s , a radialdiffuseraftereachimpeller,andaninternal
c r o s s o v e rp a s s a g ef o l l o w i n gt h ef i r s t -a n ds e c o n d - s t a g ed i f f u s e r s .L i q u i d
h ydr ogen i s i n t r o d u c e d t o t h e pump a n dd e l i v e r e df r o mt h e pump t h r o u g h a s c r o l l -
s h a p e di n l e t a n dd i s c h a r g e ,r e s p e c t i v e l y . The pump e n do ft h er o t o ra s s e m b l y
i s formed by t h ei m p e l l e rh u b s ,w h i c h are p i l o t e d r e l a t i v e t oe a c ho t h e ra n d
m a i n t a i n e da x i a l l yt i g h tb y a central tie bolt. ' Thetwo pump c r o s s o v e r s are
mountedonthe pump t h r o u g ht h ee x t e r n a l l ya c c e s s i b l ef l a n g e s .A l t h o u g ht h i s
featureresultsinadditionalexternal s e a l j o i n t s a n dw e i g h t , it facilitates
m e a s u r i n g a l l s i g n i f i c a n ti n t e r s t a g ep r e s s u r e l e v e l s . The c a v i t i e sb e t w e e n
t h ec r o s s o v e r sa n dt h ee x t e r n a lh o u s i n g s are s e a l e d f r o m t h e m a i n f l o w p a s s a g e s
by a x i a lf l a n g e s e a l s , a n dt h e y are v e n t e dt ot h e pump i n l e t . Thus, t h ee x t e r -
n a l f l a n g e s e a l s are s u b j e c t e d t o pump i n l e t p r e s s u r e o n l y , a n ds h o u l dn o t
p o s e a l e a k a g ep r o b l e m .I n t e r n a lr e c i r c u l a t i o na r o u n dt h ei m p e l l e r s i s mini-
mized by s t e pl a b y r i n t h s e a l s i nt h ef r o n ta n d r e a r s h r o u d s . The s e a l l a n d s
are p l a t e d w i t h s i l v e r t o p r e v e n t h a r d m e t a l - t o - m e t a l r u b b i n g , a n d still faci-
litatemaintainingcloseradialclearances.

8
I
 The t u r b i n e i s . a t wo -s t a g e r e a c t i o n t y p e w i t h an o v e r a l l p . r e s s u r e r a t i o o f
1 . 4 4 3 . A ppro x i m at e l y 52% ofpower i s d e v e l o p e d i n the f i r s t s t a g e a n d 48%
i n t h es e c o n ds t a g e . The wheels are a t t a c h e d t o t h e s h a f t b y t h r e e body-bound
s t u d sw h i c ha l s o transmit the t o r q u e . Axial h o l e s are i n c o r p o r a t e d i n t h e
diskstoprovide a path for the shaft seal l e a k a g e , w h i c h i s u s e d as a c o o l a n t .
Thedownstream s i d e o f t h e s e c o n d - s t a g e w h e e l is coveredwith a s h i e l d t o r e d u c e
h e a t i n ge f f e c to ft h ee x h a u s tg a so nt h ed i s k . Low-cycle f a t i g u e n e c e s s i t a t e s
i n c o r p o r a t i n g a s h e e t metal l i n e r i n t o t h e i n l e t m a n i f o l d t o r e d u c e t h e r m a l
g r a d i e n t sd u r i n g s t a r t a n d c u t o f f . The l i n e r i s a p p r o x i m a t e l y1 . 5 7 mm (0.062
inch)thick,andincludesbleedholestoequalizethepressureoneitherside.

Axial t h r u s t c o n t r o l i s m a i n t a i n e d b y u s i n g a self-compensatingbalancepiston
i n c o r p o r a t e di nt h eb a c ks h r o u do ft h et h i r d - s t a g ei m p e l l e r . To o p e r a t e t h e
balancepiston,fluidfromthedischargeofthethird-stageimpeller i s passed
through a h i g h - p r e s s u r eo r i f i c e a t t h et i po ft h ei m p e l l e r ,t h e nt h r o u g h a low-
p r e s s u r eo r i f i c el o c a t e dn e a rt h eh u bi n t ot h e r e a r b e a r i n gc a v i t y . From t h e
b e a r i n gc a v i t y ,t h ef l u i d i s r e t u r n e dt ot h ei n l e to ft h es e c o n d - s t a g ei m p e l l e r
throughanannularpassagebetweentheshaftandtheimpellerhubs.

The r o t o r i s s u p p o r t e d r a d i a l l y b y two p a i r s o f d u p l e x , a n g u l a r - c o n t a c t , 20 mm
b a l lb e a r i n g s ,a x i a l l yp r e l o a d e dt op r e v e n tt h eb a l l sf r o ms k i d d i n g . The rear
b e a r i n g s are r e t a i n e d a x i a l l y t h r o u g h a s p r i n g - l o a d e dc a r t r i d g e s o t h a tt h e y
w i l l a l s oa b s o r bt r a n s i e n t a x i a l r o t o rl o a d s .C o o l i n go ft h e pump e n db e a r i n g s
i s a c c o m p l i s h e db yb l e e d i n g LH2 f r o mt h eh u b area b e t w e e n t h e f i r s t - a n d s e c o n d -
s t a g ei m p e l l e r s ,p a s s i n gt h ef l u i dt h r o u g ha na n n u l a rp a s s a g e a t t h ec e n t e ro f
t h e f irst-s t a g e i m p e l l e r t o t h e pump e n d , t h e n i n reverse d i r e c t i o n t h r o u g h
t h eb e a r i n g sa n db a c kt ot h ee y eo ft h ef i r s t - s t a g ei m p e l l e r .C o o l i n go ft h e
t u r b i n ee n db e a r i n g s i s e f f e c t e d by b l e e d i n g c o o l a n t f l u i d f r o m t h e pump d i s -
c h a r g e , i n t r o d u c i n g i t t o a n area o n t h e t u r b i n e s i d e o f t h e b e a r i n g s , a n d
a l l o w i n g i t t of l o wt h r o u g ht h eb e a r i n g sw h e r e i t j o i n st h eb a l a n c ep i s t o n
f l u i da n dr e t u r n st ot h ee y eo ft h es e c o n d - s t a g ei m p e l l e r .A d d i t i o n a lc o o l a n t
is p r o v i d e df o rt h e rear b e a r i n g s by t h e f l u i d w h i c h l e a k s t h r o u g h t h e pump
sideoftheshaft seal.

To s e p a r a t e t h e pump a n dt u r b i n er e g i o n s , a c o n t r o l l e d - g a p ,s h a f t - r i d i n g seal
i s e m p l o y e d .S i n c et h ep r e s s u r eo nt h e pump s i d e o f t h e s e a l i s l o w e rt h a no n
t h et u r b i n es i d e ,t h em i d d l eo ft h es e a l i s p r e s s u r i z e d w i t h LH2 s u p p l i e df r o m
t h e pump d i s c h a r g e .I nt h i sm a n n e r , a p o s i t i v ef l o wo fl i q u i dh y d r o g e nt o w a r d
t h et u r b i n e i s e n s u r e d ,a n de n t r yo fh o tg a si n t ot h e pump i s p r e v e n t e d . A s
n o t e da b o v e ,t h e LH2 w h i c hl e a k st h r o u g ht h es h a f t s e a l t o w a r dt h e pump i s
u s e dt ol u b r i c a t et h eb e a r i n g s . The f l u i d w h i c hl e a k st ot h et u r b i n e i s used
t o c o o l t h et u r b i n ed i s k s .

ConfigurationSelection

The b a s e l i n e c o n f i g u r a t i o n o f t h e t u r b o p u m p was d e f i n e d by t h e S t a t e m e n t o f
Work as a t h r e e - s t a g e , c e n t r i f u g a l pump poweredby a t w o - s t a g e ,f u l l - a d m i s s i o n
turbine. To s e l e c tt h ed e s i g nw i t h i nt h a tc o n c e p td e f i n i t i o nw h i c hb e s t meets
t h eo b j e c t i v e so ft h ep r o g r a m ,s e v e r a la l t e r n a t i v e s were e v a l u a t e d . The p r i n -
cipaloptionsandtheireffect ontheturbopump are d i s c u s s e d i n t h e f o l l o w i n g .

10
 Number of Pump S t a g e s .I na c c o r d a n c ew i t h the S t a t e m e n to f Work as n o t e d
a b o v e ,t h ea n a l y s i sa n dd e s i g ne f f o r t w a s r e s t r i c t e d t o a t h r e e - s t a g e pump.
Priortotheactualcontracteffort, a t w o - s t a g ev e r s i o no ft h e pump w a s
e v a l u a t e db yR o c k e t d y n e ,a n dt h er e s u l t so ft h a ts t u d y are i n c l u d e d h e r e f o r
reference .
Table 2 p r e s e n t s a summary o ft h ep r i n c i p a ld e s i g np a r a m e t e r sg e n e r a t e d in
t h ep r e l i m i n a r ya n a l y s i s of t h et w o - s t a g e pump. F o rc o m p a r i s o n ,t h ev a l u e s
obtainedforthethree-stageconfiguration are i n c l u d e d .

The t w o - s t a g ec o n c e p t w a s attractive fromthestandpointthat it offeredthe

p o s s i b i l i t yo f a s i m p l e rd e s i g n ,f e w e r numberof p a r t s ,a n dl o w e rc o s t . On
t h eo t h e rh a n d , i t was e n c u m b e r e dw i t ht h r e em a j o rd i s a d v a n t a g e s .P r o d u c i b i l i t y
o ft h es h r o u d e d impellers p r e s e n t e d d i f f i c u l t i e s i n view o f t h e small d i s -
c h a r g e w i d t h , 2 .O rmn ( 0 . 0 7 9 i n c h ) , a n d r e l a t i v e l y l a r g e t i p d i a m e t e r , 12.19 c m
( 4 . 8 i n c h e s ) .F u r t h e r m o r e ,t h e t i p s p e e do ft h e i m p e l l e r w a s v e r yh i g h , 6 4 0 m / s
(2100 f t / s e c ) , p u s h i n g t h e limits o f t h e a v a i l a b l e material s t r e n g t h l e v e l s .
F i n a l l y ,b e c a u s eo ft h el o w e r - s t a g es p e c i f i cs p e e d a t which a t w o - s t a g e u n i t
o p e r a t e s ,t h ea t t a i n a b l ee f f i c i e n c y w a s lower ( 5 3 . 4 % ) . W i t ht h et h r e e - s t a g e
configuration,severalpotentiallydifficultaspectsofthedesign were a l l e v i -
a t e da n db e t t e rp e r f o r m a n c e was o b t a i n e d ; t h e r e f o r e , i t r e p r e s e n t s a more
a d v a n t a g e o u sa p p r o a c h .

S p e e dS e l e c t i o n . The p r i m a r yh y d r o d y n a m i cc o e f f i c i e n t s , i m p e l l e r t i p speed,
a n dr o t a t i o n a ls p e e d were a p p r o x i m a t e l y t h e same f o r t h e c o n f i g u r a t i o n s u n d e r
p r a c t i c a lc o n s i d e r a t i o n .V a l u e sf o rt h e s e parameters c o u l db es e l e c t e df o r
t h ei n i t i a li t e r a t i o nb e f o r ed e t a i ld e s i g nf e a t u r e s were f i x e d . The head
c o e f f i c i e n tv a l u e ($ = 0 . 5 7 6 ) f o r t h e i m p e l l e r w a s s e l e c t e dt oo b t a i nh i g h
e f f i c i e n c ya n dt oe n s u r e system s t a b i l i t y . Once t h es t a g eh e a dc o e f f i c i e n t
w a s s e l e c t e d ,t h er e q u i r e di m p e l l e r t i p s p e e d was f i x e d by t h e f o l l o w i n g
relationship :

where

u2 = i m p e l l e tri p
speed
g = g r a v i t a t i o n a cl c e l e r a t i o n
I)= s t a ghee acdo e f f i c i e n t
H = h e a dr e q u i r e dp e rs t a g e t o d e l i v e rt h es p e c i f i e dd i s c h a r g ep r e s s u r e

The d e s i r e d i m p e l l e r t i p s p e e d v a l u e c a n b e a t t a i n e d a t several r o t o r s p e e d
l e v e l s by s e l e c t i n g a n a p p r o p r i a t e t i p d i a m e t e r .T h es p e e dr a n g ei n v e s t i g a t e d
f o rt h i sa p p l i c a t i o ne x t e n d e df r o m 7853 t o 1 3 , 0 8 8 r a d / s ( 7 5 , 0 0 0 t o 125,000 rpm) .
W i t h i nt h es p e e dr a n g es t u d i e d ,t h es t a g es p e c i f i cs p e e dv a r i e df r o m

3 1/2
r a d / s (m / s )
0.20 t o ( 50 5. 303 t o 900 rpm gpm1/2/ft 3 / 4 )
( J / k g ) 3’4

11

I
 TABLE 2. COMPARISON OF TWO- AND THREE-STAGE PUMP CHARACTERISTICS

_I
I
-~"- __ ~~

Two Stage ThreeStage

Rotor Speed 10,470 rad/s 9950rad/s

( 1 00,000 rpm) (95,000 rpm)
ImpellerTipWidth 2.00 mm 3.81 mm
(0.079inch) (0.150inch)
I m p e l l e rT i pD i a m e t e r 12.19 cm 10.31 c m
( 4 . 8i n c h e s ) 4.058 i n c h )
I m p e l l e rT i p Speed 640 m/s 513 m/s
( 2 1 OO f t / s e c ) ( 1 683 f t / s e c
S t a g eS p e c i f i c Speed
500 q) f t R
I

Pump Horsepower 1896 kW

2543hp)
Pump O v e r a l lE f f i c i e n c y 58%

12
T h e s e v a l u e s were s u b s t a n t i a l l y b e l o w t h e s p e c i f i c s p e e d v a l u e t h a t r e s u l t s
i n t h e maximum a t t a i n a b l e e f f i c i e n c y f o r c e n t r i f u g a l pumps; c o n s e q u e n t l y ,
t h e pump e f f i c i e n c yi n c r e a s e dw i t hh i g h e rv a l u e so fs p e e d . Thus, f r o mt h e
s t a n d p o i n to fe f f i c i e n c y ,t h eh i g h e s tp o s s i b l es p e e d w a s d e s i r a b l e .W i t hh i g h e r
speeds,theimpellerdiameterdecreasedand the t i p w i d t h i n c r e a s e d , which w a s
d e s i r a b l ef r o m a w e i g h t / e n v e l o p ea n dp r o d u c i b i l i t yc o n s i d e r a t i o n as w e l l . The
u p p e rs p e e d limit w a s d e f i n e d b y the DN ( d i a m e t e r , mm x s p e e d , rpm) v a l u e of
theturbineendbearing,whichreachedthe maximum s p e c i f i e d i n t h e S t a t e m e n t
of Work ,N D( = 2 x lo6) a t 10,470 r a d / s (100,000 rpm) . S u b s e q u e n t l y , the
s p e e d w a s r e d u c e d t o a n o m i n a ld e s i g nv a l u eo f 9946 r a d / s (95,000 rpm) t o
s a t i s f y the h0-hour l i f e r e q u i r e m e n t w i t h t h e t u r b i n e r o t o r b l a d e s w h i c h c o u l d
notbe m e t at thehigherspeed level.

Pump I n l e t Type.The r a d i a l - e n t r y ,v o l u t e - t y p ei n l e tc o n f i g u r a t i o no ft h e pump

w a s s e l e c t e dt oo p t i m i z ee n g i n ep a c k a g i n g . I t w a s a n t i c i p a t e dt h a tt h e low-
p r e s s u r e pump w i l l h a v e a s c r o l l - s h a p e d v o l u t e w i t h a radialdischarge,and
that the high-pressure fuel turbopump w i l l b e m o u n t e d o n t h e e n g i n e w i t h pump
i n l e t s i d e down. Under t h e s ec o n d i t i o n s ,t h ef l u i d i s t r a n s f e r r e df r o mt h e
l o w - p r e s s u r e pump t o t h e h i g h - p r e s s u r e pump most e f f i c i e n t l y , b o t h f r o m t h e
standpointoffluidfrictionandengineweight,with a radialinletonthe
h i g h - p r e s s u r e pump.

A v o l u t e - t y p ei n l e t was used t o p r o v i d e p r e w h i r l at thefirst-stageimpeller

inlet. The i m p e l l e ri n l e tp r e w h i r lp e r m i t t e d a l a r g e ri m p e l l e rd i s c h a r g e
b l a d ea n g l ef o rr e d u c e d stress as w e l l as a r e d u c e d i n l e t r e l a t i v e v e l o c i t y
f o ri n c r e a s e di m p e l l e re f f i c i e n c y . T h ev o l u t e - t y p ei n l e tp r o v i d e d low l o s s e s ,
p e r m i t t e dt h eb e a r i n g st ob el o c a t e do u t b o a r do ft h ei m p e l l e ri n l e t ,a n d
resulted in engine installation flexibility.

I m p e l l e rT y p e . The u s eo fs h r o u d e dv e r s u so p e n - f a c ei m p e l l e r s was e v a l u a t e d .
O p e n - f a c ei m p e l l e r s are easier t of a b r i c a t ea n d are c a p a b l e o f h i g h e r t i p
s p e e d s ;h o w e v e r ,t h el o wf l o w r a t e sb r i n ga b o u t a v e r y low i m p e l l e r b l a d e
h e i g h ti nt h i s turbopump. A s a r e s u l t ,t h ec l e a r a n c eb e t w e e nt h ei m p e l l e r
v a n e sa n dh o u s i n gw o u l dh a v et ob eh e l di m p r a c t i c a l l yc l o s et om a i n t a i nh i g h
p e r f o r m a n c e .F u r t h e r m o r e , small c h a n g e s i n t h e a x i a l p o s i t i o n o f t h e r o t o r
w o u l db r i n ga b o u tl a r g es h i f t si n pump p e r f o r m a n c e . I n c o n s t r a s t ,w i t h a
s h r o u d e di m p e l l e r ,t h e r e i s noneed t oh o l dt h ea x i a lc l e a r a n c ec l o s e ,a n d
per f or m an c e i s i n d e p e n d e n to fr o t o rp o s i t i o n .D e s p i t et h ef a c tt h a tt h e
i m p e l l e rh u bh a dt ob el o n g e rt oc a r r yt h es h r o u dc e n t r i f u g a ll o a d sa n d
f a b r i c a t i o n w a s more d i f f i c u l t , p e r f o r m a n c e c o n s i d e r a t i o n s d i c t a t e d t h a t
s h r o u d sb eu s e d . An i m p o r t a n ts i d eb e n e f i to fa d d i n gt h es h r o u d s was t h a t
t h es t i f f n e s so ft h ei m p e l l e r was i n c r e a s e d w h i c h , i n t u r n , r e d u c e d t h e rela-
t i v ed e f l e c t i o ni nt h eb a l a n c ep i s t o n . This w a s of p a r t i c u l a rs i g n i f i c a n c e
b e c a u s eo ft h eh i g h - p r e s s u r el o a d si n v o l v e d .

D i f f u s e rT y p e . The u s eo fr a d i a l - v a n e dd i f f u s e r s as o p p o s e dt o an o p e nv o l u t e
w i t ho n eo r two t o n g u e s was e v a l u a t e d . The r a d i a l - v a n ec o n f i g u r a t i o n was
s e l e c t e df o rt h r e er e a s o n s :( 1 )b yr e d u c i n gt h ev e l o c i t yo ft h ef l u i di nt h e
volutetoapproximatelyone-halfoftheimpellerdischargevelocity,fluid
frictionlosses,which are p r o p o r t i o n a l t o . v e l o c i t y s q u a r e d , were r e d u c e d ;
(2) thepressurearoundtheperipheryoftheimpeller w a s m o r eu n i f o r mw i t h

13
 a v a n e dd i f f u s e r ,t h e r e f o r et h er a d i a ll o a d s were smaller-; and (3) the d i f f u s e r
v a n e s p r o v i d e d an e f f i c i e n t t i e f o r t h e p r e s s u r e v e s s e l f o r m e d b y the v o l u t e
walls, t h e r e b y r e d u c i n g t h e h o u s i n g w a l l t h i c k n e s sr e q u i r e m e n t .

T u r b i n eO r i e n t a t i o n . The c o m p a r a t i v ee f f e c to fo r i e n t i n gt h et u r b i n ef l o w
t o w a r d t h e pump o r away f r o m t h e pump w a s a n a l y z e df r o m a x i a l t h r u s t , p e r f o r -
mance, a n ds t r u c t u r a lc o n s i d e r a t i o n s . The pump o rt u r b i n ep e r f o r m a n c e was
n o t a f f e c t e d by t u r b i n e f l o w d i r e c t i o n , b u t t h e r e w a s a s i g n i f i c a n t e f f e c t on
n e tt o t a lt h r u s t . The a x i a lt h r u s to ft h es e l e c t e dd e s i g nc o u l db eb a l a n c e d
s a t i s f a c t o r i l yo n l yi ft h et u r b i n ef l o w w a s d i r e c t e d away f r o mt h e pump. From
a m e c h a n i c a la n ds t r u c t u r a ls t a n d p o i n t , i t w a s f o u n dt h a tt h e least c o m p l i c a t e d
a n dm o s te c o n o m i c a ld e s i g n ,f r o mc o s ta n dw e i g h ts t a n d p o i n t ,c o u l db eo b t a i n e d
bysupportingthefirst-stagenozzleonthe pump h o u s i n g a n d o r i e n t i n g t h e
f low away f r o mt h e pump. T h i sd e s i g nh a dt h ea d v a n t a g et h a ti n l e ta n de x h a u s t
manifolding w a s n o t a n i n t e g r a l p a r t o ft h ec r i t i c a lw o r k i n gc o m p o n e n t so f
t h et u r b i n e . A s a r e s u l t ,t h em a n i f o l d i n gc o u l db em o d i f i e dt oa c c o m m o d a t e
anyfutureenginepackagingneedswithoutaffectingeitherthefluid-dynamic
o rs t r u c t u r a lb e h a v i o ro ft h et u r b i n e . T h et u r b i n e - t o - p u m ph o u s i n gc o n n e c t i o n
w a s made i d e n t i c a lt ot h ev i s u a l i z e df l i g h t w e i g h td e s i g n .T h i s way, a l l t h e r m a l
c o n d i t i o n s t h a t may i n f l u e n c e f l i g h t d e s i g n o p e r a t i o n s are d u p l i c a t e d i n t h i s
t e c h n o l o g yt a s k .

Pump Hydrodynamic Analysis

Pump I n l e t Design. A s n o t e da b o v e ,t h e pump i n l e t c o n f i g u r a t i o n w a s s t r o n g l y

i n f l u e n c e d by t h e AdvancedSpaceEngine ( A S K ) d e s i g nl a y o u t ,w h i c hr e s u l t e d
i n optimumpackagingwith a s c r o l l - s h a p e di n l e t . A s c r o l l - s h a p e di n l e tc a n
beaccommodated e i t h e r w i t h a n o p e n - v o l u t e - t y p e a p p r o a c h , o r o n e i n w h i c h
v a nes a r e i n c l u d e d t o p r o v i d e s t r u c t u r a l s u p p o r t a n d g u i d e n c e t o t h e f l o w .
The l a t t e r c o n c e p t was s e l e c t e d b e c a u s e i t p r e s e n t s a means f o r i m p a r t i n g
p r e w h i r lt ot h ef l u i de n t e r i n gt h ef i r s t - s t a g e impeller. P r e w h i r l ,i nt u r n ,
f a c i l i t a t e s a l a r g e r i m p e l l e r d i s c h a r g eb l a d ea n g l e ,w h i c h i s d e s i r a b l ef r o m
thestandpointofproducibility.

F i g u r e 3 shows t h d e i m e n s i o nos f
t h el e a d i n ga n dt r a i l i n ge d g e so ft h e
i n l e tc a s c a d e . A s a l r e a d ym e n t i o n e d ,
t h e s ev a n e s are a l s o n e e d e d f o r s t r u c -
t u r a lr e a s o n s . Twenty p e r c e n to ft h e

T
v o l u m ec o n t a i n i n gt h ev a n e s i s needed
t os a t i s f y stress r e q u i r e m e n t sT . his
s e t s t h ev a n et h i c k n e s sF. i g u r e 4

1 1
shows t h e v a n e s y s t e m r e s u l t i n g i n 5.583
a n a c t u a l metal volumeof 20.7%. (2.200 i n . )
F i g u r e 5 shows t h ev a n ea n g l e varia-
t i o n ,a n dF i g . 6 shows t h e area
v a r i a t i o na l o n gt h ef l o wp a t hf r o m
A t o B (Fig. I).
( 4.130
l . 6 i cm
in.)

t
Figure 3 . Pump I n l e t Vane

14
I -

-
i
TANGENTIAL

AXIAL

0.366 RAD (21O)

Figure 4. Mark 48-F Pump Inlet Vane Configuration

15
 .

0,

0.

W
0.
z
a
W
n
5
rn

0.

A + + + . . .

0. t l . . . . .

1 .oo
DISTANCE, INCHES
L I I 1
0 1.0 2.0 2.54
DISTANCE, cm

Figure 5 . Mark 48-F Pump I n l e t Vane A n g l eV a r i a t i o n

16
 I . 390
. . . . I . . . .I . . . .
1.380

1.370
. . . . . . . . . . . . . . .
8.1 1.360

N
E 1.340
u
.. 8.i
. . .
5
oz
a 2
-
i
1.330
rr
a
1.320
. . . . . . . . . . . . . .
1.310
. . . . . . . . . . . . .
8.1 1.300
. . . . . . . . . . . . . . . .

1.290
. . . . . .

1 .2a0
0.25 0.50 0.75 1.
INCHES
I I I I
0 1.0 2.0 2.54
D I S T A N C E , crn

Figure 6. Mark 48-F Pump Inlet Variation at Guide 'Vanes

17
 I m p e l l e rD e s i g n . The r e q u i r e d i s e n t r o p i c s t a g e h e a d r i s e to satisfythedis-
c h a r g ep r e s s u r eo f 3144 N/cm2 ( 4 5 6 0p s i a ) i s 1 5 3 , 0 0 0 J/kg ( 5 1 , 3 3 4f e e t ) .W i t h
an o p e r a t i n gs p e e do f9 9 4 7r a d / s( 9 5 , 0 0 0 rpm) a n d a d e l i v e r e d f l o w r a t e o f
0.0396 m 3 / s (627.5 gpm) t h es t a g es p e c i f i cs p e e d i s 6 9 5 .S i n c et h es p e e d
c a n n o tb ei n c r e a s e dd u et ob e a r i n ga n dt u r b i n el i m i t a t i o n s ,t h eo n l y way t o
o p t i m i z ee f f i c i e n c y i s t ou s e a h i g hh e a dc o e f f i c i e n t .H o w e v e r ,p r o d u c i b i l i t y
h a s i n t h i s case an o v e r r i d i n g i n f l u e n c e .

To o b t a i n a h i g h s t r e n g t h / w e i g h t r a t i o , t i t a n i u m w a s s e l e c t e d as t h e i m p e l l e r
material. The t e c h n o l o g y exists t op r o d u c ec o m p l e xs h r o u d e dt i t a n i u mi m p e l l e r s
b yc a s t i n g ;h o w e v e r ,t h ef r a c t u r et o u g h n e s so fs u c h a c a s t i n g a t LH2 tempera-
t u r e s i s h i g h l ys u s p e c t .O t h e ra p p r o a c h e st op r o d u c i n g a complexshrouded
i m p e l l e r , s u c h as d i f f u s i o n b o n d i n g a n d powder m e t a l l u r g y , w o u l d r e q u i r e a n
e x t e n s i v ea n de x p e n s i v ed e v e l o p m e n te f f o r tt h a t w a s n o tw i t h i nt h es c o p eo f
t h i s program. A s a r e s u l t ,t h ed e c i s i o n w a s made t o f a b r i c a t e t h e i m p e l l e r s
by e i t h e rp a n t o g r a p h i n go re l e c t r i c a ld i s c h a r g em a c h i n i n g (EDM). Bothof
t h e s e meansimpose a l i m i t a t i o n on t h e n u m b e r o f b l a d e s t o b e u s e d as w e l l as
thedischargeangleandwrapangle.

F o r a h i g hh e a dc o e f f i c i e n t , a l a r g e n u m b e ro fb l a d e s i s d e s i r a b l e .S t r i c t l y
f rom a hydr o d y n a m i cp o i n to f view, t h e optimum i m p e l l e r w o u l d h a v e c o n t a i n e d
sixfullblades,sixpartialblades,and a s e c o n d set o f 1 2 p a r t i a l b l a d e s
a t t h e d i s c h a r g e (6 + 6 + 1 2 ) , w i t h a d i s c h a r g ea n g l eo f0 . 5 2r a d i a n so f( 3 0
d e g r e e s ) .T h i sw o u l dh a v ey i e l d e d a h e a dc o e f f i c i e n to fa p p r o x i m a t e l y0 . 6 5
( F i g .1 6o f NASA R e p o rt SP 8 1 0 9 ) .S u c ha ni m p e l l e r ,h o w e v e r ,c a n n o t ,b e
m a n u f a c t u r e db yt h em e t h o d ss e l e c t e da b o v e .P r o d u c i b i l i t yr e q u i r e dt h e number
o fb l a d e st ob er e d u c e dt o 6 + 6 w i t h a d i s c h a r g eb l a d eo f0 . 6 5r a d i a n( 3 7 . 5
d e g r e e s ) . The f l o wr a n g e i s s l i g h t l yr e d u c e d( F i g .7 )a n d ,d u et ot h el o w e r
numberofblades, a h e a dc o e f f i c i e n to fa p p r o x i m a t e l y0 . 5 8c a nb ee x p e c t e d .
T h i sr e d u c e st h eo b t a i n a b l ee f f i c i e n c yb e c a u s et h ei m p e l l e rd i a m e t e ri n c r e a s e s .

I m p e l l e rI n l e t . The i m p e l l e ri n l e td i a m e t e r m u s tb es e l e c t e d s o t h a tt h e
r e q u i r e ds u c t i o ns p e c i f i cs p e e d l i e s w i t h i nt h er a n g eo fa v a i l a b l ee x p e r i e n c e .
Due t o t h e s i z e , h o w e v e r , t h e p r o d u c i b i l i t y o f t h e i m p e l l e r h a s a major
influence. To o b t a i n s u f f i c i e n t NPSH m a r g i nt oe n s u r et h a tt h e pump meets
t h es u c t i o nr e q u i r e m e n t s ,t h ei n l e td i a m e t e rs h o u l db e a s l a r g e as p o s s i b l e .
P r o d u c i b i l i t y ,h o w e v e r , s e t s a l i m i t s i n c e , by i n c r e a s i n g t h e i n l e t e y e
d i a m e t e r ,t h eb l a d ea n g l eb e c o m e sf l a t t e r . A s a r e s u l t ,m a c h i n i n g becomes
more d i f f i c u l t . The h u bd i a m e t e r a t t h ei m p e l l e ri n l e t w a s e s t a b l i s h e d as
3.1 c m ( 1 . 2 2 i n c h e s ) , t h e minimum v a l u ea l l o w e db ym e c h a n i c a ld e s i g nc o n s i d e r a -
t i o n s . The e y ed i a m e t e r w a s d e t e r m i n e d as 4 . 8 3 c m ( 1 . 9 0i n c h e s )a f t e r a study
i n w h i c hh y d r o d y n a m i cg o a l sa n dp r o d u c i b i l i t yl i m i t a t i o n s were r e c o n c i l e d . To
assess t h e r e q u i r e d i m p e l l e r s u c t i o n s p e c i f i c s p e e d , t h e f o l l o w i n g a p p r o a c h
was t a k e n : I t wasassumed t h a t ’t h er e q u i r e d i m p e l l e r NPSH i s e q u a l t o 4 x cm2/
2 g. The f a c t o r 4 i s s e l e c t e dt oa c c o u n tf o rt h er e l a t i v e l yt h i c ki m p e l l e r
b l a d el e a d i n ge d g e ,w h i c h i s n o ts h a p e di na c c o r d a n c ew i t ht h er u l e so fi n d u c e r
l e a d i n g - e d g ed e s i g n .T a k i n gt h ec a l c u l a t e dl e a k a g ef l o wi n t oa c c o u n t ,t h e
a x i a li n l e tv e l o c i t y i s 4 4 . 7 m / s ( 1 4 6 . 5f t / s e c )w h i c hr e s u l t si n a required
NPSH o f
NPSH = 3J9/8k1g
req
= 406 m ( 1 3 3 2f e e t )

18
 6000
400(I -

5000

3000l -

a 4000

2 0 0 cj -

2
a 2000

00 -
1000

0- 0
2 4 6 8 IO
I N L E T FLOW, LB/SEC
I I I I I I
0 1 .o 2.0 3.0 4.0 5.0
INLET FLOW k d s

Figure 7. Mark 48-F Head-Flow C h a r a c t e r i s t i c s With 0.523

and 0 . 6 5 4 R a d i a n (30 and 37.5 d e g r e e s )
I m p e l l e rD i s c h a r g eA n g l e s

19

I
 I m p e l l e rB l a d i n g .W i t hi n l e ta n dd i s c h a r g eb l a d ea n g l e se s t a b l i s h e d , the
m a j o r c o n c e r n w a s t o o b t a i n a b l a d e s h a p e which would r e s u l t i n an a c c e p t a b l e
v e l o c i t yd i s t r i b u t i o na n dw h i c hc o u l db em a n u f a c t u r e d . As s t a t e da b o v e ,t h e
0.65 r a d i a n ( 3 7 . 5 d e g r e e s ) d i s c h a r g e a n g l e a n d t h e t i p w i d t h o f 3 . 8 1 mm (0.15
inch), is acceptable. The q u e s t i o n ,h o w e v e r , s t i l l r e m a i n s how much wrap
a n g l e (0) can b ei n c o r p o r a t e d . From t h em a n u f a c t u r i n gp o i n to f view a small
w r a pa n g l e is d e s i r e d ,f r o mt h eh y d r o d y n a m i cp o i n to f view a l a r g e ro n e . The
l o w e r limit o f 0 i s d i c t a t e db yt h eb l a d el o a d i n g .T h e r e f o r e , several b l a d e
d e s i g n s were e v a l u a t e d w i t h t h e r e s u l t t h a t a w r a pa n g l eo f 2.4 r a d i a n (135
d e g r e e s ) w a s s e l e c t e df o rt h ef u l lb l a d e sa n d 0.9 r a d i a n (52 d e g r e e s ) for t h e
p a r t i a l .T h i ss a t i s f i e sb o t hm a n u f a c t u r i n ga n dh y d r o d y n a m i cc o n s i d e r a t i o n s .

F i g u r e 9 shows t h eb l a d et h i c k n e s sd i s t r i b u t i o n .F l u i dv e l o c i t y relative t o
theimpellerblades at theinnerandouter stream t u b e s a r e g i v e n i n F i g . 10
and 11, a n dp r e s s u r el o a d i n gp r o f i l e i s i n d i c a t e di nF i g . 1 2 . C r o s ss e c t i o n s
o ft h ei m p e l l e rf l o wp a s s a g e ,w i t h wrap a n g l ed i s t r i b u t i o n sf o rt h ef u l la n d
p a r t i a l v a n e s , are i n c l u d e d i n F i g . 1 3 and 14.

Cr os s overDes ig n . The c r o s s o v e rd e s i g n i s b a s e do nt h er e s u l t so fa ne x p e r i -
m e n t a lp r o g r a mt h a t w a s c o n d u c t e df o rt h e SSME h i g h - p r e s s u r et u r b o p u m p . The
crossoverdesignwhichyieldedthehighestefficiencyused a radial diffuser
f ollow edby a 3 . 1 4 - r a d i a n (180 d e g r e e s )v a n e l e s st u r n .A f t e rt h et u r n ,t h e
f l o w e n t e r e d a t a n d e md i f f u s e r( t w ob l a d e rows g u i d i n g t h e f l o w t o t h e e n t r a n c e
o ft h ef o l l o w i n gs t a g e ) .F i g u r e 8 shows t h ec o n c e p ts c h e m a t i c a l l y .

The f i r s t s t e p , t h e r e f o r e , was t o
definethediffuserwhichfollows
RAD IAL
t h e i m p e l l e r andwhich i s i d e n t i c a l
f o r a l l t h r e es t a g e s . The d i f f u s e r
i n l e t d i a m e t e r was set a t 11 c m
( 4 . 3 6i n c h e s ) ,w h i c hr e s u l t si n a
gapof3.8 m (0 . 1 5i n ch )b et wee n
i m p e l l e r d i s c h a r g ea n dd i f f u s e r
i n l e t .T h i sv a l u er e p r e s e n t e da n
a c c e p t a b l ec o m p r o m i s eb e t w e e nt h e
t e n d e n c yt om i n i m i z e t h e g a pt o
m a i n t a i n low h y d r o d y n a m i c l o s s e s
a n dt h ed e s i r et om a i n t a i n a suffi-
c i e n t l yl a r g ec l e a r a n c et oa v o i d
l a r g ep r e s s u r ef l u c t u a t i o n s
t h e impeller v an e s .
on
Figure 8 . RadiaD
l i f f u s e ra n dC r o s s o v e r

The d i f f u s e r i s a l s o a s t r u c t u r a l member r e q u i r i n g a p p r o x i m a t e l y 40% metal

v o l u m e .A f t e rs e v e r a li t e r a t i o n s ,t h i sc o n d i t i o n was s a t i s f i e d by u s i n g 11
v a n e sw i t h a d i s c h a r g ed i a m e t e ro f1 3 . 9 cm ( 5 . 4 8i n c h e s ) .

The i n l e t a n de x i tw i d t ho ft h ed i f f u s e r i s s e t a t 3.8 mm (1.5 i n c h ) . The f lo w

l e a v e st h e impeller a ta na n g l eo f0 . 1 4r a d i a n ( 8 . 2 d e g r e e s )f r o mt a n g e n t i a l ,
r e s u l t i n g i n a cu componentof367 m / s (1204 f t / s e c ) a n d a cucomponentof53
m / s (174 f t / s e c ) . B a s e do nt h e s ef l o wc o n d i t i o n s ,t h ed i f f u s e rp a s s a g e is
c a l c u l a t e du s i n gR o c k e t d y n e ' sd i f f u s e rp r o g r a m . The r e s u l t s a r e shown i n

20
 0.200

A PARTIAL BLADE, S I X T H ORDER, 4'<6<26

4.0
0.150

E
E 3.0

0.100

2.0

0.050 -
1 .o

0 0 - 1 I I I I I
0 20 40 60 80 100 120 140

WRAP ANGLE,
DEGREES
I I I
0 1 .o 2.0
WRAP ANGLE,
RADIANS

Figure 9. Mark 48-F Fuel Impeller Vane Thickens Distribution

 0 10 20 30
50 40 60 70 80 90 100
INLET D I SCHARGE
P E R C E N TM E R I D I O N A L E N G T H

Figure 10. Fuel Impeller Relative Velocities, Inner Streamtube

 800

7 00
I
A
I
600

500

400

3 00

200

-I
0 T R A I L I N GF A C E
100 A CENTERL INE (AVG)
O D R I V I N GF A C E

1 NLET D I SCHARGE
PERCENTMERIDIONALLENGTH

.Figure 11. Fuel Impeller Relative Velocities, Outer Streamtube

N
w
3 00
- 6 VANES -I-- 12 VANES -

10 20 30 40 50 60 70 80 90 1
INLET D I SCHARGE
PERCENTMERIDIONALLENGTH

Figure 12. Fuel Impeller Pressure Loading

 HUB
- HUB
/
I

t 2.25 rad t t

2 "
L2.26 rad
( I 30') Rl ( 1 30°) R2

CL
PUMP
-
1 PUMP

- x2
SUCT I ON S I DE PRESSURE S I DE
FULLBLADE FULLBLADE

F i g u r e 13. I m p e l l e rC r o s s - S e c t i o nL a y o u t With F u l l Blade

Wrap A n g l e s
0.52 r a d (30°)
0.52 r a d (30')
SHROUD - HUB
P SHROUD r?
-I

7r/2 r a d (90') - T/2

t
R3

t
CL CL
PUMP
- {- x3
PRESSURESIDE
I PUMP

- x4
S U C T I O NS I D E
P A R T I A LB L A D E PART I AL BLADE

Figure 14. Impeller Cross-Section Layout With Partial

Blade Wrap Angles
F i g . 15 t h r o u g h 18. F i g u r e 15 shows t h e v a n e a n g l e v a r i a t i o n a l o n g t h e d i f f u s e r
p a s s a g e ,a n dF i g . 1 6p r e s e n t st h e area. F i g u r e 1 7 shows t h e p r e s s u r e d i s t r i b u -
tiononthevanesuctionandpressureside,andFig.18illustratesthediffuser
cascade .
The r a d i a l v a n e d d i f f u s e r is f o l l o w e d b y a v a n e l e s s t u r n i n g p a s s a g e i n w h i c h
t h er a d i a ld i r e c t i o no ft h ef l o w i s t u r n e d 2 . 8 r a d i o n s( 1 6 2d e g r e e s )t og u i d e
t h ef l u i di n w a r dt o w a r dt h ee y e of t h e n e x t i m p e l l e r . The t u r n i n gp a s s a g e
i s f o l l o w e db yt w or o w so fv a n e s ,w h e r et h ef l u i d i s f u r t h e rd i f f u s e d . At the
e x i t f r o m the f i n a l row o f b l a d e s , t h e f l u i d is directed a t an angle such that
theimpellerbladeanglesestablishedforthefirststagecanbeusedfor all
stages. The number of v a n e si ne a c ho ft h e two b l a d er o w s i s set a t 1 7 . The
turninginthefirst row i s 0. 3 3 9r a d i o n s( 1 9 . 4d e g r e e s )w h i c h ,w i t h a solidity
o f2 . 0 8r e s u l t si n a d i f f u s i o nf a c t o ro f0 . 5 8 9 . The t u r n i n g i n t h e s e c o n d row
i s set t o 0 . 7 2r a d i a n( 4 1 . 3d e g r e e s )w h i c h ,w i t h a solidityof1.53resultsin
a diffusionfactorof0.603.

Volute. The v o l u t e w h i c h f o l l o w s t h e d i f f u s e r o f t h e t h i r d s t a g e i s f o l d e do v e r
away f r o mt h et u r b i n e .T h i st y p ei Ss e l e c t e db e c a u s e it r e s u l t si n a stable
s e c o n d a r yv o l u t ef l o wp a t t e r na n d ,c o n s e q u e n t l y ,a n optimum e f f i c i e n c y .

The c a l c u l a t e d v e l o c i t i e s at thethird-stagediffuserexit are:

Circumferentialvelocity C = 183 m / s (600 f t / s e c )

U
Radialvelocity C = 4 1 m / s (134 f t / s e c
m
Absolute velocity C = 1 8 7 m / s (615 f t / s e c )
Velocitydirection = 0.219 r a d i a n( 1 2 . 6d e g r e e s )

The v o l u t e area d i s t r i b u t i o n w a s c a l c u l a t e d i n 0 . 3 5 r a d i a n ( 2 0 d e g r e e s )w r a p
angleintervals,using a r e c o v e r yf a c t o ro f0 . 7 0a n d a b l o c k a g e f a c t o r of
0.70.The r e s u l t i n g area d i s t r i b u t i o n is shown i n F i g . 1 9 .

Pump P e r f o r m a n c eP r e d i c t i o n . The o v e r a l l pump h e a d r i s ea n de f f i c i e n c y was

calculatedbasedontheisentropicenthalpy rise o b t a i n e d f r o m a c t u a l
properties.

The i s e n t r o p i c h e a d r i s e is defined as:

J x Ahis
His
where

= I s e n t r o p i ch e a d r i s ef r o ma c t u a lf l u i dp r o p e r t i e s ,J f k g( B t u / l b )
J = M e c h a n i c ael q u i v a l e n t of h e a t (1.0 i n SI u n i t s , 7 7 8 i n
Englishunits)
= H e a d r i s e J, / k g( f t - l b / l b )
His

27
 n
22
w- .2

. 1 _. 0.25 0.50 0.75

P O S I T IOIJ/CHORD LENGTH

F i g u r e 15. Mark 48-F Pump D i f f u s e rV a n eA n g l e

28
0 0.25 0.50 0.75
POSITION/CHORD LENGTH

Figure 16. Mark 48-F Pump Diffuser Area

29
 POSITION/CHORD LENGTH

Figure 1 7 . Mark 48-F Pump Diffuser Pressure Diagram

30
 ,208 RAD
,276 RAD '\

(15 ,85'1

,117 RAD
(6 ,7 0 )
D I A = 11,07 CM (5048 IN)
(4,36 IN)

, IJUMBER OF VANES = 11
DIFFUSION FACTOR = ,583
, PRESS, RECOVERY = 3 , 2 x lo6 N/M* (464 PSI )

Figure 18. Mark 43-F Pump D i f f u s e rD e s i g n

31
W 0.40
N 2.5

0.32
2.0

NE 1.5 -z.0.24
v
u
L .
4
cz
5e
a a 0.16
1 .o

0.5

a 0 I. 1 I I I I I J

0 40 80
320 120
280 160
240 200 360
ANGULARPOSITION,DEGREES
I
0 7r 2n
ANGULARPOSITION,RADIANS

Figure 19. Mark48-F Pump V o l u t e Area D i s t r i b u t i o n

Withthat,theefficiency is calculated
p2

is = - = (see F i g . 20)
t
.c
T h ep r o c e s s i s assumed t o b e a d i a b a t i c .
Theisentropicenthalpy rise r e p r e s e n t s 2
0
t h ei d e a l pump ( w i t h o u tl o s s e s ) . The c
m
l o s s e s are assumed t o go i n t o h e a t i n g , L:
U
c
resulting in an actual temperature W
Ahls
T2act * I
To e s t a b l i s h t h e t h e o r e t i c a l p e r f o r -
T.
mance o f t h e pump, t h ee n e r g ya d d e d
t o t h e f l u i d i s c a l c u l a t e ds u c c e s s - Entropy, s
i v e l y a t each pump e l e m e n t as w e l l as
thelossesincurred as a r e s u l t o f
f r i c t i o n i, n t e r n a l e a k a g e , e t c . The
F i g u r2
e 0M . o l l i eD
r iagram
predicted state p o i n t s i n t h e a d i a b a t i c
c o m p r e s s i o n p r o c e s s a r e shown o na n
h - sd i a g r a mi nF i g . 2 1 . B a s e do nt h i sa n a l y s i s ,t h ei s e n t r o p i ce f f i c i e n c y
o f t h e pump w a s c a l c u l a t e d as 58% b y t h e r e a l t i o n s h i p :

h2 - hl
s =
h3 - h l

- 76 - ( - 9 8 ) = 58%
( E n g l i suhn i t s )
200 - ( - 9 8 )

T h i sa p p r o a c hy i e l d sl o w e rv a l u e st h a nu s i n gt h ep l o y t r o p i cp r o c e s sa n d , at
t h e same time, i s more r e p r e s e n t a t i v e of t h e r e a l p r o c e s s ,w h i c h is closer to
c o n s t a n tv o l u m e . The l o s s e su s e di nc o m p u t i n gt h e pump c h a r a c t e r i s t i c a r e
summarized i nT a b l e3 , . a n dt h e pump map i s shown i nF i g . 22. A summary of
t h ep r i n c i p a l pump d e s i g np a r a m e t e r s i s i n c l u d e di nT a b l e 4 . F i g u r e s 23
t h r o u g h2 6 , p r e s e n tt h ep r e s s u r e ,t e m p e r a t u r e ,i n t e r n a lf l o w ,a n df l u i dd e n s i t y
l e v e l s c a l c u l a t e d a t s i g n i f i c a n ts t a t i o n so ft h et u r b o p u m p .

Tur bineA ero t h erm o d y n am i cAn a l y s i s

TheMark 48 t u r b i n ed e s i g nr e p r e s e n t sa na d v a n c e m e n ti nt h es t a t e - o f - t h e - a r t
w i t hr e g a r dt ot u r b i n eh o r s e p o w e rd e v e l o p e d r e l a t i v e t ot u r b i n es i z ea n dw e i g h t .
T h i st u r b i n ed e s i g n was i n f l u e n c e d p r i n c i p a l l y by t h e o p e r a t i o n a l c o n s t r a i n t s
o ft h es t a g e d - c o m b u s t i o n - c y c l et y p ee n g i n ef o rw h i c ht h i sc o m p o n e n t i s being
investigated. The d e s i g np r e s s u r er a t i oa n d mass f l o wr e q u i r e m e n t sh a dt h e
g r e a t e s te f f e c to nt h ec o n f i g u r a t i o n .P r e s s u r er a t i o w a s minimized t o a v a l u e

33
 ~ ~ ~ ~~ ~ ~~~~

3RD STAGE EXIT

200

180 3 R D IMPELLE
4 x 10 STATIC EXIT
160
3RD STAGE

140
2ND STAGE

120
2ND IMPELLER
STATIC E X I T
100
I
2 x 10'
80

.
Y
m
-J
60
2N D STAG E
s-
a 40
-1
9
fz 20
w

0 0

-20

40

-60

80
-2 x 2OE

-1 00

1 2 3 4

ENTROPHY - BTUILB-OR
I I I
5000 10,000 15.000
ENTROPHY, J/kg-K

F i g u r e2 1L. i q u i dH y d r o g e n Pump M o l l i e r
Diagram

34
I --

TABLE 3. MARK 48-F PUMP LOSS PARAMETERS

~" ~

Impel le1 Di f fuser

Vane1,ess I
Space Vol Ute
-
Blockage 0.9 10.85
Roughness 0.00006: o.000063 0.000063 0.000063
Momentum Loss - - - 0.00198
Coefficient
Incidence Loss 0.00239 - 0.0007
Coefficient
Skin Friction 0.00826 0.01 139 0.02313 0.01221
Loss Coefficient
Diffusion Loss 0.00023 - 0.01386
Coefficient
Exit Diffuser - - 0.001 19
Loss Coefficient
-." - .. .. .. .. . -
;tQ = 653 g p m ; N = 95,000 rpm
"- __ _ _ - .. ". .. . - .. . .. -_.___---

35
 r I I I I"
I
Isentropic .SO
401 -

35
I
!
30
' t

w
- w
.)
I
cn I
+I cn I

2 20
w
a w
3 c4
2500 3
cn
2
a
v)

2 15
a

1500 10
I

5 ~ ' 55,000
5 00 I I I I - I 1 I
0 1 2 3 4 5
INLET FLOW, kg/s
U"" I I 1 1 1

0 2 4 6 8 10 1'2
INLET FLOW, l b / s

Figure 22. Mark 48F Pump Performance

36
 TABLE 4 . SMALL, HIGH-PRESSURE LH2
TURBOPUMP NOMINAL DESIGN PARAMETERS

SI Units EnglishUnits
_____-

Number of S t a g e s 3 3
I m p e l l e rI n l e tT i pD i a m e t e r 4.826 crn 1.90 inches
I m p e l l e rI n l e t Hub D i a m e t e r 3.'099 cm 1.22 i n c h e s
I m p e l l e rI n l e tA n g l ea tT i p 0.28 r a d i a n 16 degrees
I m p e l l e rI n l e tA n g l ea t Hub 0.45 r a d i a n 26 degrees
Number o f I m p e l l e r Vanes a t I n l e t 6 6
Number o fI m p e l l e rV a n e sa tD i s c h a r g e 12 12
I m p e l l e rD i s c h a r g eD i a m e t e r 10.31 un 4.058 i n c h e s
I m p e l l e rD i s c h a r g eA n g l e 0.655 r a d i a n 37.5 d e g r e e s
I m p e l l e rD i s c h a r g eW i d t h 3.81 mn 0.150 i n c h
I m p e l l e rT i pS p e e d 512.97 n / s I683 f t / s e o
Vaned D i f f u s e rI n l e tD i a m e t e r 11.07 un 4.36 i n c h e s
Vaned D i f f u s e rD i s c h a r g eD i a m e t e r 13.91 cm 5.48 i n c h e s
Number o f D i f f u s e r Vanes II 11
D i f f u s e rP a s s a g eW i d t h 3.81 mm 0.150 i n c h
C r o s s o v e rI n l e tD i a m e t e r 13.72 cm 5.4 i n c h e s
C r o s s o v e rF i r s t - R o wD i s c h a r g eD i a m e t e r 9.779 cm 3.9 i n c h e s
C r o s s o v e rS e c o n d - R o wD i s c h a r g eD i a m e t e r 6.35 cm 2.5 i n c h e s
C r o s s o v e rI n l e tA n g l e 0.206 r a d i a n 11.8 d e g r e e s
C r o s s o v e rF i r s t - R o wD i s c h a r g eA n g l e 0.471 r a d i a n 27 d e g r e e s
C r o s s o v e rS e c o n d - R o wI n l e tA n g l e 0.394 r a d i a n 26.6 d e g r e e s
C r o s s o v e rS e c o n d - R mD i s c h a r g eA n g l e 1.047 r a d i a n s 60 d e g r e e s
I s e n t r o p i cH e a d / S t a g e 15,647 m 51.334 f e e t
O v e r a l Il s e n t r o p i c Head 41.415 m 135,876 f e e t
S t a g eH e a dC o e f f i c i e n t 0.576 0.576
I m p e l l e rI n l e tF l o wC o e f f i c i e n t ( F i r s tS t a g e ) ? : 0.159 0.159
I m p e l l e rI n l e t F l m C o e f f i c i e n t ( S e c o n da n dT h i r dS t a g e ) * 0.194/0.1675 0. 19W0.1875
I m p e l l e rD i s c h a r g eF l o wC o e f f i c i e n t( F i r s tS t a g e ) " 0.071 0.071
I m p e l l e rD i s c h a r g e F l o w C o e f f i c i e n t( S e c o n da n dT h i r dS t a g e ) 0.086 0.086
S t a g eI s e n t r o p i cE f f i c i e n c y 70.0% 70.0%
Overa I1 I s e n t r o p i c E f f i c i e n c y 58% 58%
S h a fS
t peed 9946 r a d / s 95,000 rpm
Pump Power 1896 kW 2543 h p
Requ i r e d NPSP 406 m 1332 f e e t
~-
* V a l u eb a s e d cn z e r o b l o c k a g e

37
 EXIT: 3148 N/cm 2

d
F i g u r e 23. Mark 48 F u e l Turbopump Static Pressures (SI Units)
 EXIT: 4567 PSlA

F i g u r e 23. Mark 48 Turbopump S t a t i c Pressure (English Units)

 EXIT: 60 K

54
28 43

Figure 24. Mark 48-F Turbopump Fluid Static

Temperature (SI Units)
 EXIT: 108' R

98O
50' 78'
I I 1783' 7 r 1730'

Figure 24. Mark

48-F
Turbopump Fluid Static
Temperature(English Units)
 n
2.895 3.338
0 2.742
"...
-.
3.023

Figure 25. Mark 48-F Turbopump Flows ( S I U n i t s )

 6.377

n
7.352 (3 6.040 LBlSEC

A
6.242

Figure 25 . Mark 48-F Turbopump Flows (English Units)

 --
3
EXIT: 69.9 kglm

F i g u r e 26. Mark 48 F u e l Turbopump F l u i dD e n s i t i e s ( S I Units)

 (3- EXIT: 436 LB/FT3

...

A
Figure 26.. Mark 48 Fuel Turbopump Fluid Densities (English Units)
 o f1 . 4 4 3 (T-T)* t o maximize t h r u s t c h a m b e r d e s i g n p r e s s u r e , a n d o v e r a l l e n g i n e
per f or mance . The t u r b i n e d e s i g n s p e e d a n d power , which were f i x e d b y t h e h y d r o -
gen pump r e q u i r e m e n t s i n t h i s t u r b o p u m p , are r e s p e c t i v e l y 9947 r a d / s( 9 5 , 0 0 0
rpm) and2543horsepower. The p r e b u r n e rp r o v i d e st u r b i n e L02/LH2 w o r k i n gf l u i d
a t a t o t a l i n l e t p r e s s u r eo f2 3 5 8 N/cm2 ( 3 4 2 0 p s i ) , a t o t a l i n l e t t e m p e r a t u r e
of 1 0 3 3 K (1860 R ) , and a mass f l o w r a t eo f 3..02 k g / s( 6 . 6 6l b / s e c ) . A tabula-
t i o no fp r i n c i p a lt u r b i n ep a r a m e t e r sa p p e a r si nT a b l e 5.

The g a s p a t h d e s i g n w a s e v o l v e d w i t h L02/LH2 c o m b u s t i o n g a s p r o p e r t i e s e s t a b -
l i s h e d by t h e J o i n t Army-Navy-Navy-NASA-Air F o r c ec o m m i t t e e . A t t h e1 . 4 4 3
(T-T) d e s i g np r e s s u r er a t i o ,t h et u r b i n ei s e n t r o p i ca v a i l a b l ee n e r g y [Ah,,
T-S**] i s 8 5 8k J / k g(3 6 9B t u / l b ). The r e q u i r e dt u r b i n ep o w e rc a n n o tb e
developedby a s i n g l e - r o wc o n f i g u r a t i o n ;f o rt h es u b s o n i cg a sp a t hc o n d i t i o n s
i n t h i s a p p l i c a t i o n , a t w o - s t a g er e a c t i o nd e s i g n was selected.

The d i s t r i b u t i o n o f t h e 1 . 4 4 3 p r e s s u r e r a t i o s a c r o s s t h e f o u r g a s - p a t h e l e m e n t s
is c r i t i c a l i n t h i s t y p e , s m a l l - s i z et u r b i n ec o n f i g u r a t i o n .I nt h ef i n a ld e s i g n ,
t h e power s p l i t b e t w e e n t h e f i r s t a n d s e c o n d s t a g e s i s 5 2 %a n d4 8 % ,r e s p e c t i v e l y .
The d e s i g nv e l o c i t yr a t i o [U/CO, T-TI w a s f i x e d a t 0.483. A t t h e 9947 r a d / s
( 95,000 rpm) d e s i g n s p e e d , t h e p i t c h l i n e v e l o c i t y i s 442 m/s (1451' f t / s e c ) ; t h e
t u r b i n ep i t c hd i a m e t e r i s c o n s t a n t a t 8.89 cm ( 3 . 5 0i n c h e s ) .F i g u r e 27 d e p i c t s
t h et u r b i n ev e l o c i t yd i a g r a m a t d e s i g nc o n d i t i o n s ;t h ef i r s t -a n ds e c o n d - s t a g e
v e l o c i t y d i s t r i b u t i o n w a s a t t a i n e dw i t h2 9 . 7 %a n d2 6 . 0 %r e a c t i o n ,r e s p e c t i v e l y .

The w o r k i n g f l u i d t o t a l e f f e c t i v e e n e r g y [Ah,], a t e a c hg a s - p a t hs t a t i o n , con-

s i s t s o f t h e sum o ft h ee f f e c t i v eg a se x p a n s i o ne n e r g y [Ah,,], a n dt h ee f f e c t
k i n e t i ce n e r g y [Ahev] of t h ef l u i d . The e f f e c t i v ee x p a n s i o ne n e r g yi nt h e
nozzlesandreactionblading was c a l c u l a t e d b y a d j u s t i n g t h e i s e n t r o p i c a v a i l -
a b l ee n e r g y [Ah,] f o rt h ep r e s s u r er a t i o ( s )e x i s t i n ga c r o s se a c hg a s - p a t h
e l e m e n t ,a n df o rt u r b u l e n c ea n df r i c t i o nl o s s e sw i t ha p p l i c a b l ee x p a n s i o n
e n e r g yc o e f f i c i e n t s [G2]. The ene r g ya n d loss c o e f f i c i e n t su s e df o rt h i s
d e s i g n were e v o l v e dd u r i n gp r e v i o u sr o c k e tt u r b i n ed e v e l o p m e n tp r o g r a m s ,a n d
were s e l e c t e d as a f u n c t i o n o f n o z z l e a n d r o t o r d e f l e c t i o n a n g l e s a n d w i d t h s ,
a n df l o wc o n d i t i o n s .

The w o r k i n g f l u i d k i n e t i c e n e r g y [Ah,] a t t h ee n t r a n c eo f a n o z z l eo rr o t o r is
e q u i v a l e n tt ot h ef l u i dv e l o c i t y a t t h a ts t a t i o n . The h v i s n o r m a l l yc o r r e c t e d
forfrictionlosseswith a k i n e t i c e n e r g y l o s s c o e f f i c i e n t [q2] , a n d f o r i n c i -
denceand i n l e t r e l a t i v e Mach number l o s s e s .

The t o t a l e f f e c t i v e e n e r g y [Ah,] a v a i l a b l e t o t h e n o z z l e a n d r o t o r g a s p a t h s
i s made up o ft h e sum o ft h ee f f e c t i v ee x p a n s i o ne n e r g y [Ah,,]. The n o z z l e
andbladinginletrelativevelocities are a l l s u b s o n i c ,a n dn o Mach number
c o r r e c t i o n s were n e c e s s a r y . The e x p a n s i o ne n e r g ya n dk i n e t i ce n e r g yc o e f f i -
c i e n t s ,w h i c h were a p p l i e d t o t h e Mark 48-F t u r b i n e d e s i g n , a p p e a r i n T a b l e
6. A s t a t i o n - t o - s t a t i o nt a b u l a t i o no ft h et u r b i n eg a s - p a t hd e s i g np r e s s u r e

$ < T o t a lt ot o t a l
*?;Total t o s t a t i c

46
 TABLE 5. TURBINE DESIGN OPERATING
CONDITIONS

SI U n i t s English Units
1. Configuration Two-ReactionStages
2. W o r k i n gF l u i d L02/LH2

I
3. T u r b i n eT o t a lI n l e tP r e s s u r e (P,) 3420 p s i a
4. T u r b i n eT o t aIln l eTt e m p e r a t u r e( T ) 1033 K 1860 R
tl 2358 N/cm2
5. T u r b i n eP r e s s u r eR a t i o (PRt)(T-T) 1.443
6. T u r b i n e Mass F l o w r a t e (W,) 3.02 Kg/s 6.66 1 b/sec
7. T u r b i n e Speed, (N) 9947 r a d / s 95,000rpm
8. P i t c hD i a m e t e r (Dm) 8.89 cm 3.50 inches
9. P i t c hL i n eV e l o c i t y (Urn) 442m/s 1451 f t / s e c
'0. V e l o c i t yR a t i o , Two Stage (U/Co) (T-T) 0.483
11. T u r b i n eE f f i c i e n c y (qt), % (T-T) 75.4
12. TurbineHorsepower(hpt) 1829 kW 2543 hp

47

I
 Figure 27. Mark 48-F T u r b i n eV e l o c i t yD i a g r a m (SI Units)

48
 17
1451 FTISEC

1451 FTISEC

F i g u r e 27. Mark 48-F Turbine V e l o c i t yD i a g r a m( E n g l i s h Units)

49
 TABLE 6 . GAS PATH ENERGY COEFFICIENTS
~ "" ~ "" . .

Expans i o n Kinetic
E n e r g yC o e f f i c i e n t (92 ) E n e r g yC o e f f i c i e n t (I2))
..---. ..- - . . .. . .

F i r s tS t a g e
N o z z l e Vanes 0.916 0.000
Rotor B 1 ades 0.832 0.665

Second S t a g e
N o z z l e Vanes 0.890 0.780
Rotor B 1 ades 0.841 0.681

a n dt e m p e r a t u r ed i s t r i b u t i o nd a t ae s t a b l i s h e df o rt h i sd e s i g n a p p e a r si nP i g .
28. The r e s u l t a n tp l o to fp r e d i c t e dt u r b i n ee f f i c i e n c y ,f o rv e l o c i t yr a t i o s
r a n g i n gf r o m 0 t o 0 . 6 0 , i s d e p i c t e di nF i g .2 9 . A t d e s i g nc o n d i t i o n s ,t h e
predictedturbineefficiency i s 75.35% (T-T) .
A t a b u l a t i o no ft h et u r b i n eg a sp a t he n e r g ya n d loss distributionappearsin
Table 7 . It:c o n t a i n st h ei s e n t r o p i ce n t h a l p yd r o pf o re a c hg a s - p a t he l e m e n t ,
t% a d j u s t m e n t s f o r e x p a n s i o n e n e r g y a n d k i n e t i c e n e r g y l o s s e s , a n d a n a c c o u n t -
i n go fa v a i l a b l ee n e r g ya n dt h er e s u l t i n ge n e r g ye q u i v a l e n to ft u r b i n ew o r k .
F o rt h et o t a l 832 k J / k g . ,( 3 5 9 . 4B t u / l b (T-T) [ 8 5 8k J / k g ,3 6 9B t u / l b (T-S)]
i s e n t r o p i ca v a i l a b l ee n e r g yt ot h et u r b i n e , a t d e s i g np r e s s u r er a t i oa n d
s p e e d ,t h ee n e r g ye q u i v a l e n to ft h et u r b i n ee x i te n e r g y l o s s i s 2 2 . 3k J / k g
( 9 . 6B t u / l b ) . The t u r b i n e e x i t e n e r g y i s n o tc h a r g e dt ot h et u r b i n eb e c a u s e
t h ee n g i n es y s t e ms u b s e q u e n t l yu t i l i z e s i t i nt h es e c o n dp h a s eo fc o m b u s t i o n
i nt h et h r u s t chamber.Gas-path l o s s e sa c c o u n tf o r1 5 0 k J / k g -( 6 4 . 4B t u / l b ) ,
andthediagramefficiencyadjustments i s equivalentto60.4kJ'/kg(26Btu/lb) .
T h e r e f o r e ,f o r a t o t a l 8 3 2k J / k g(3 5 9 . 4B t u / l b ) (T-T) a v a i l a b l ei nt h et u r b i n e
g a sp a t h , 629 k J / k g( 2 7 0 . 8 1B t u / l b ) a r e u t i l i z e dt od e v e l o pt h ed e s i g ns h a f t
h o r s e p o w e r ,f o r a 75.35% (T-T) p r e d i c t e dt u r b i n ee f f i c i e n c y . A r e h e a to f 4180
J / k g (1.8 B t u / l b ) i s e x p e r i e n c e di nt h eg a sp a t h .

I na d d i t i o nt ot h ea e r o t h e r m o d y n a m i cr e q u i r e m e n t s ,t h et u r b i n ed e s i g n w a s in-
f l u e n c e d by stress a n d m a n u f a c t u r i n g c o n s t r a i n t s a s s o c i a t e d w i t h t h e small
h i g h l yl o a d e dt u r b i n ed e t a i lp a r t s . A d a t a summary d e s c r i b i n gt h en o z z l ea n d
b l a d ef i n a ld e s i g nc o n f i g u r a t i o n sa p p e a r si nT a b l e .
8 The n o z z l ev a n ea n d
b l a d e p r o f i l e s were l a i d o u t f o r p i t c h - l i n e s t a t e c o n d i t i o n sa n dv e l o c i t i e s ;
t h er e s u l t a n ts h o r tb l a d i n gd i dn o tr e q u i r e a n ya d j u s t m e n t sf o rr a d i a l - f l o w
v a r i a t i o n si nt h er e s p e c t i v ef l o wc h a n n e l s ,a n d are t h e r e f o r e s t r a i g h t s e c t i o n s
f r o mr o o tt ot i p .A n a l y t i c a lp r e d i c t i o n so ft h ep r e s s u r ea n ds u c t i o np r o f i l e
v e l o c i t yd i s t r i b u t i o n s ,f r o mt h el e a d i n g -t ot r a i l i n g - e d g ep l a i n s , were e s t a b -
l i s h e da n dn ou n a c c e p t a b l ea c c e l e r a t i o n s were f o u n dt oe x i s t .P r o f i l e so ft h e
n o z z l ev a n e sa n dr o t o rb l a d e s are d e p i c t e d i n F i g . 30 t h r o u g h 3 3 ; t h e c o r r e s -
p o n d i n gp l o t so ft h ev e l o c i t yd i s t r i b u t i o nf o rt h e s eg a s - p a t he l e m e n t sa p p e a r
i nF i g . 34 t h r o u g h 37.

50
 .-

MK48-F T U R B l FIE GAS PATH WORK1 NG F L U ID - L 0 2 L H 2

/ \ A
c J

1 -R

SPEED: 9947 rad/s I

STAT ION
2
PRESSURE, N/cm
TOTAL 23 58 21 15 1959 1747 1635
STAT I C 1936 2054 1696 1618

TEMPERATURE, K
TOTAL 1033 1008 994 969 957
STAT I C 1001 99 1 962 954

STAGE 1 2
PRESSURERAT IO ( T - T ) 1.204 1.199
REACTION, % 29.7 26.0
U/C, (T- S ) 0.462 0.476
POWER, % 51.9 48.1

Figure 28. Mark 48-F Turbine Pressure and Temperature Distribution (SI Units)
 M K 4 8___
"" - F TURBINE
WORKING
PATH
GASFLUID-L02 / LH2

SPEED N,

STAT1ON
PRESSURE, P S l A
3068
TOTAL 3420 2841 2534 2371
STAT I C 2979 .2808
2347 2460
TEMPERATURE, R
1815
TOTAL 1722 1860 1744 1789
STATIC 1801 173 1783 1 17 17
STAGE
1 2
PRESSURERATIO (T-T) 1.204 1.199
REACT1ON, % 29.7 26.0
U/C, , ( T - S ) 0.462 0.476
HORSEPOWR, (70) 1320 ( 51.9 1 1223 (48.1)

F i g u r e 28. Mark 48-F T u r b i n eP r e s s u r ea n dT e m p e r a t u r eD i s t r i b u t i o n( E n g l i s hU n i t s )

 i
/ i ~-[ u / c ~( 2,- s t a g e ) POINT0.4831
’ DES.IGN
I
I

k+ 1
I
=
I

i
. I

I
! i
I
! I
Dm...X !

-
U -- 229.2
- i
I

‘0-R (T-T)
!
t
I1
!

i I
0 0.1 0.2 0.3 0.4 0.s 0.6 0. I

VELOCITY RATIO, -
U
; (Total -To-Total )
‘0-R

Figure 29. Mark 4 8 - FT u r b i n Ee f f i c i e n c y

 TABLE 7. TURBINE ENERGY AND LOSS DISTRIBUTION
(SI UNITS)

Gas P a t hL o s s e s

E f f e c t i v eE f f e c t i vEe n t e r i n g
Isentropic Expans ion Kinetic Kinetic Energy
E n t h a l p y (At?,), E n e r g y (Ah,,), E n e r g y( A h e v ) , E n e r g y( A h e v ) , LOSS(AhL),
kJ/kg kJ/kg k J/kg kJ/kg kJ/kg

FN
i ros zt -zSl et a g e Vanes 296.6 323.8 27.2
23.1 45.8 68.9

F i r s t - S t a g e Rotor B l a d e s 136. 1 113.3 22.8

21.3 27.3 6 .O

S e cNoonzdz- lSet a g e Vanes 264.9297.3 33.0

44.9 66.0 21.1

BlaS
d e scRoont o
d r- S t a g e 104.0 87.4 16.6

€ x i t E n e r g yL o s s ,J / k g 22.3

(3) T u r b i n eD i a g r a mE f f i c i e n c yA d j u s t m e n t ,J / k g
i
I

( A h(S
Dq)ita g r a m ) = (857.6)
10.804)
689.5
I ( A h s () r l A
t djustment) = (857.6)(0.734) = 629.5
60.0
60.06

I (4) E q u i v a l e nLt e a k a g eE n e r g y Loss k J / h g 0

Losses (l)+(2)+(3)+(4) = A h kL J, / k g 232.1

T u r b i n eE f f i c i e n c y

Ah = 629.5 k J / k g
work

Ahisentropic - Ahwork
= 857.6 - 629.5 = 228.1

+ AhL = 629.5 + 232.1 = 861.6

Ahwo r k
Gas P a t hR e h e a t = 232. 1 - 228.1 = 4 . 0

629'5 = 0.7535 (T-T)

't = 857.6 - 22.3

nt = m
629'5 = 0.734
 TABLE 7. TURBINE ENERGY AND LOSS DISTRIBUTION
(ENGLISH UNITS

Gas PathLosses

Effective Entering Effective

Isentropic Expans i o n K i n e t i cK i n e t i c Energy
E n t h a l p y (Ah,), E n e r g( A
y h e sE) ,n e r g( A
y h e vE) ,n e r g y (Ah,,), Loss (AhL),
Btu/lb Btu/lb Btu/lb Btu/lb Btu/lb

First-Stage Nozzle Vanes 139.31 127.64 11.67

29.64 19.69 9.96
F i r sBt R
-l a
Sodttaeogsr e 58.57 48.74 9.83
11.74 9.15 2.60

Second-Stage Nozzle Vanes 128.17 114.00 14.17

19.34 28.39 9-05
S e c o nB
dRl-aSodtta
eog
sr e 44.75 37.62 7.13
E x i tE n e r g y Loss, B t u / l b 9.60

T u r b i n eD i a g r a mE f f i c i e n c yA d j u s t m e n t ,B t u / l b

(AhS) (Tit Diagram) = (369)(0.804) = 296.81

270.81
( A h s )( n tA d j u s t m e n t ) = (369)(0.734) = 16.00 26.00

E q u i v a l e n tL e a k a g eE n e r g y Loss, B t u / l b 0.00

Losses (1)+(2)+(3)+(4) = A h LB, t u / l b 99.99

TurbineEfficiency

= 270.81 B t u / l b
A hwo r k
Ahisentropic - Ahwork = 369.0 - 270.81 = 98.19 B t u / l b

Ahwork + AhL = 270.81 + 99.99 = 370.8 Btu/lb

Gas P a tR
heheat = 99.99 - 98.19 - 1.8 Btu/lb

't =
270'81 6)
( 3 9.0-9.
= 0.7535 (T-T)

270.81 -
nt = 369.0- - 0.7339 (T-5)
 TABLE 8. TURBINE NOZZLE AND ROTOR
BLADE DESIGN
( 9 9 4 7 rad/s; 95,000 rpm)

~~

1 2

Stage N- 1 1 -R N-2 2-R

____"

P i t c hD i a m e t e r (DM), crn 8.89 8.89 8.89 8.89

Number o f E l e m e n t s (Z) 41 52 41 52
H e i g h t , cm 0.71 1 0.737 0.762 0.838
2
T h r o a tA r e a , cm 4.55 6.50 5.34 8. I 4
i n l e tA n g l e ,r a d i a n 1.57 0.65 1.24 0.70
E x i tA n g l e ,r a d i a n 0.30 0.40 0.31 0.42
P i t c hL i n eV e l o c i t y ( U ) , m/s - 442 - 442
L e a d i n g Edge, rnm 2.39 1.12 0.69 1.12
T r a i 1 i n g Edge(R) , mm 0. I 8 0. I 8 0.18 0. I 8
""

( S I Units)
" J

" . .. . . .- . - . - - __ 2 -
Stage N- 1 1 -R N-2 2-R
-- - - " -- -. .. . . . . . " .- . .___

P i t c hD i a m e t e r (DM), inches 3.500 3.500 3.500 3.500

Number o f E l e m e n t s ( Z ) 41 52 41 52
H e i g h ti ,n c h 0.280 0.290 0.300 0.330
2
T h r o aA
t r e a i,n . 0.705 1 .008 0.827 1 .261
i n l e tA n g l e ,d e g r e e s 90 37.5 70.8 40
E x i tA n g l e ,d e g r e e s I7 23 I8 24
P i t c hL i n eV e l o c i t y (U), ft/sec - 1451 - 1451
L e a d i n g Edge, inch 0.094 0.044 R = 0.027 0.044
(El 1 ipse) (El 1 ipse) (El 1 ipse)
T r a i l i n g Edge ( R ) ,

N = 95,000 rpm
inch
"
0.007
"" 1
. "
0.007
__
0.007 0.007

(Engl ish Units)

__

56
 \ '\

Figure 3 0 . Mark 48-F T u r b i n eF i r s t - F i g u r e 31. Mark 48-F T u r b i n eF i r s t -

St ag eNo z zl e Vane Shape S t a g eR o t o rB l a d eS h a p e

Figure 3 2 . Mark 48-F T u rb i n eS e c o n dF - igure 33. Mark 48-F Turbine

Second-
S
Ntoa zgzel e Vane SS RB
Shtolhaatap
go
dperee

57
4000

3000

SUCT I ON SURFACE

1000

' 36
VANE
WIDTH,
INCH
J I I I I
0 2 4 6 8

VANEWIDTH, mm

Figure 34. Mark 48-F T u r b i n e First-Stage Nozzle

1 ooc

SUCTIONSURFACE

1-

50c

1000 - PRESSURESURFACE

C I I I I I I I I
0.04 0.03 0.12 0.16 0.20 0.24 0.28 0.32 0.

BLADE
WIDTH,
INCH
1 I I I I
0 2 4 6 8
BLADEWIDTH, mrn

Figure 35. Mark 48-F Turbine First-Stage Rotor

m
0

!L
00
0
I
0.04
I
0.060.16
0.16
1
0.12
1
0.24
0.24 0.20
VANE WIDTH, INCH
1
0.28 0.32
I
0.36

0 2 4 6 8
BLADE WIDTH, mm

Figure 36. Mark 48-F T u r b i n e Second-Stage Nozzle

 I

4000

V
1
% 300C
\

i
SUCTIONSURFACE

W
5
J
a
V
0
J 1000 PRESSURESURFACE

BLADE
WIDTH,
INCH

0 2 4 6 a
BLADE W I DTH, mrn

F i g u r e 37. Mark 48-F TurbineSecond-Stage Rotor

 Axial T h r u s tC o n t r o l

F o r a high- s p ee dt u rb o p u m pwi t hh y d r o g e n - c o o l e db e a r i n g s , it i s mandatory t o

b a l a n c e t h e a x i a l forces w i t h o u t a s k i n g t h e b e a r i n g s t o c a r r y p a r t of t h i s
axial l o a d .D u r i n gt h ed e s i g ns t u d y , a l a r g e number o f d i f f e r e n t turbopump
d e s i g nc o n c e p t s were s t u d i e d . The r e s u l t w a s t h a t t h e a x i a l t h r u s tc o u l db e
balancedonlybyusing a balancepistonandflowingtheturbinegases away
f r o m t h e pump.

The a x i a l f o r c e s o f t h e t h r e e pump s t a g e s a r e b a l a n c e d as c l o s e as p o s s i b l e
againsttheturbine a x i a l f o r c e s by s e t t i n g t h e i m p e l l e r wear r i n g d i a m e t e r s
s o t h a tt h er e m a i n i n gf o r c e s are m i n i m i z e d .T h i sr e m a i n i n ga x i a lf o r c e is
t h e nb a l a n c e db y a b a l a n c ep i s t o nw h i c h is integralwiththethird-stage
impeller. Axial t h r u s tb a l a n c i n gd e v i c e sa l w a y sr e d u c e pump e f f i c i e n c yd u e
t ot h eu n a v o i d a b l el e a k a g el o s s e s as w e l l as t o t h e d i s k f r i c t i o n l o s s e s .
T h e r e f o r e ,t h ei n t e g r a ld e s i g nc o n c e p t i s u s e ds i n c e i t a v o i d s t h e a d d i t i o n a l
diskfrictionlossesinherentwith a s e p a r a t eb a l a n c ep i s t o n ,a n dm a i n t a i n s
t h e numberof i n t e r n a lr e c i r c u l a t i o np a t h s a t a minimum. F i g u r e 38 shows t h e
b a l a n c ep i s t o nf l o wl o o p .B e c a u s eo fc o n s t r a i n t s on t h ea v a i l a b l er a d i a l
s p a c e ,t h eh i g h - p r e s s u r eo r i f i c e , as a s s e m b l e d ,d o e sn o ti n c l u d e a radial
o v e r l a pf e a t u r eb e t w e e nt h er o t a t i n ga n ds t a t i o n a r y members.The positive
d i a m e t r a lc l e a r a n c eo f0 . 0 7 6 mm (0.003 i n c h ) w h i c h e x i s t s a t assemblybetween
t h o s e twocomponents i s r e d u c e dt oz e r ob yd i f f e r e n t i a lc o n t r a c t i o nd u r i n g
c h i l l d o w n .S u b s e q u e n t l y , as a r e s u l to fc e n t r i f u g a lg r o w t h o f t h ei m p e l l e r ,
a no v e r l a po f0 . 1 2 7 mm (0.005 i n c h ) i s r e a l i z e d a t t h en o m i n a lo p e r a t i n gs p e e d
o f9 9 4 7r a d / s( 9 5 , 0 0 0 .
rpm)

The t o t a l b a l a n c e p i s t o n a x i a l t r a v e l a t o p e r a t i n gt e m p e r a t u r ea n dn o m i n a l
s p e e d i s 0.254 mm (0.010 i n c h ) .F i g u r e 39 shows t h en o m i n a lf o r c e sa c t i n g
on t h ei m p e l l e r sa n dt h et u r b i n e .F i g u r e 40 shows t h en e tb a l a n c ep i s t o n
restoringforceandflowas a functionofthebalancepistonposition.

Bear ing D es ig n

The Mark 48-F b e a r i n g s a r e 20 mm b o r e , a n g u l a r - c o n t a c t b a l l b e a r i n g s a r r a n g e d

i n two s p r i n g - p r e l o a dp a i r s . The f o r w a r dp a i r i s l o c a t e di m m e d i a t e l yi nf r o n t
o ft h ef i r s t - s t a g ei m p e l l e r ;t h ea f tp a i r i s l o c a t e db e t w e e nt h et h i r d - s t a g e
i m p e l l e ra n dt h es h a f t s e a l . Both p a i r s a r e c o o l e db yr e c i r c u l a t i n gl i q u i d
hydr ogen.

The Mark 48-F and Mark 48-0 b e a r i n g s a r e i d e n t i c a l .D u a lu s eo ft h e same

bearing i s t e c h n i c a l l yf e a s i b l et h eb e a r i n gl o a d i n ga n ds p e e d s are compatible
w i t hb o t ht h ed e s i g ns p e e do ft h ef u e l pump 9947 r a d / s( 9 5 , 0 0 0 rpm) and t h a t
o ft h el i q u i do x y g e n pump, 7329 r a d l s (70,000 rpm) . Economy i np r o c u r e m e n t
was a l s o e f f e c t e d b y p u r c h a s i n g o n l y o n e t y p e o f s p e c i a l l y d e s i g n e d b e a r i n g .

The i n t e r n a l g e o m e t r y o f t h e b e a r i n g w a s o p t i m i z e df o r9 9 4 7r a d / s( 9 5 , 0 0 0 rpm)
a n df o r m a l i z e di n t ot h eR o c k e t d y n eS o u r c eC o n t r o lD r a w i n g , RES1174 ( F i g . 4 1 ) .
T h e r e w a s no e x i s t i n g b e a r i n g w i t h s a t i s f a c t o r y d e t a i l s , so a s p e c i a l b e a r i n g
was d e s i g n e d a n d f a b r i c a t e d w i t h t h e f o l l o w i n g f e a t u r e s .

62
 PUMP DISCHARGE
HIGH PRESSURE ORIFICE
BALANCE PISTON CAVITY

BALANCE PISTONSUMP

Figure 3 8 . Mark 48-F Balance P i s t o n F l u i d Flow Path

 573 573

NET: 33.5 33.5

- 17.1
+”

16.3
T
33.3
__t

0.16
-c

43.7 60.8 136.5

120 mn ’I

1.51

F i g u r e 39. Mark 48-F Turbopump Axial Forces

(SI U n i t s )
 128,790
128,790
”
d

NFT: 7525 7525

- - -
__c

3850 3675 7489

339

Figure 39. Mark 48-F Turbopump Axial Forces (English Units)

 210
45

190

v)

5 40
3,
24

L4
U
"
w
U
- 170
cr: n:
0 0
L L

"
E
35 U
150
a? n:
0 0
k
z
k
v)
w
a'
30 z
130
E
3 v)
H H
n. a
w w

'
U
%

2
25
U
z
2 110
2

90
20

POSITION/TOTAL TRAVEL

Figure 4 0 . Mark 48 F u e l Pump B a l a n c eP i s t o n

66
 . . . .
-
CHARACTERISTIC
. . ENGL I s i UNITS S I UNITS
-
"

ENVELOPE D&
+mb
BORE e78725 DIAe 20 mn
Q!JTER DM* 39 nm
WIDTH (INDIVIDUAL RINGS) IO mn
(ACROSS BEARING)
INTERNAL GEOMETRY -
PITCHDIA. 1.175 DIA.(REF.) 2 9 . 8 mn
RACE RADII (CUTER RACE) 52'yoFBALLDIA.(REF.)
(INNERRACE) 5 9 0 F @ALLDIA.(REF.)
DIAMETRALCLEARANCE(UNFITTED) e0020 TO e0023 IN. 0.051 TO 0.05E
(OPE RATING) e 0 0 1 1 TO e0014 IN. (REF.) 0.028 TO 0.03f
BALLCOMREh4ENT(NUMBER) TEN
(DIAMETER). .1875'DIA.(NOMINAL) 4.76 mn
SHOULDER HEIGHTS (OUTERRACE) 2 0 b W BALLDIA.(REF.)
(INNER RACE) 23(kOF BALL DIA.(REF3
CAGECLEARANCES (BALL POCKET) -020 TO -025 IK 0.51 TO 0.64 r:
(GUIDING LAND) ,003 TO ,009 IN. 0.08 TO 0 . 2 2 n
MATERIALS -
RACE5 CEVM 440-C RC58-62
BALLS CEVM 440-C RCa-64
CAGE GLASSFABRIC
SUPPORTEDTEFLON..(ARMALOt
U G F WEE THlCKNFg (AT
PITCH DIAJ .IS IN. (REF.) 3.96 mn

8. IDENTIFYFACES "A* h"B"

7. BALLS SHALLBEAFBMA
GRADE 5
G BEARING TOLERANQS NOT S H O ~ NSHALL BE PEF
5. CLEAN d PACKAGE FOR LIQUID HYDROGEN SEF
4. THEARMALONCAGESHALLMEETREQUIRMENTS
3. ONLYTHEITEMDESCRIBEDONTHIS I N G WHEh
SUPPLIERLISTED, IS APPROVED BYROCKETDYNE,
I N THEAPPLICATIONSPECIFIEDHEREON. A SVBC
USEDWITHOUTPRIORTESTING & APPROVAL BY I
2. THEITEMSHALLBEDURABLY&-LEGIBLYMARKEC
ADDITIONTHEROCKETDYNECONTROL I M G NO. SH
1. MFG. SHALL P R E M ANY.NEW ' M S REQD 6 ASS
d SHALLOBTAIN.ROCKETDYIjEENGRNG.REVIEW C
""
 .

SI UNITS

20 mn
39 rm
IO mn

29.8 mn

351 TO 0.058 mm
028 TO 0.036 mn

4.76 mn

5 1 TO 0.64 mn
38 TO 0 . 2 2 mn

3.96 mn

;ALL BE PER ABEC 7.

DROCENSERVICE. (CLEAN 6 DRY)
:QUIRMENTS OF RBOI30-013
5 Dwc WHEN PROCURED FROM THE
SXIRCE C NTROL
DRAWING
ROCKETDYNE, C A W A MRK, CALIF. FOR .USE
E.ON. A SUBSTITUTEITEM SHALL NOT BE
'ROVAL BY ROCKETDYNE.
BLY .MARKEDPER MIL-STD-130. IN
W G NO. SHALL BE MARKED ON THE ITEM.
REQD b ASSIGN W R T m.PER MIL-DIOOO
IC. REVIEW OF PROPOSED CHANGES.
"

4
67

I
1. B e a r i n gS i z e . The dimensionsofthedynamiccomponents were minimized
t or e d u c et h ei n e r t i a lf o r c e s due t os p e e d as f a r as p o s s i b l ee v e n
thoughtheliquidhydrogen pump b e a r i n g s DN v a l u e o f 1 . 9 x lo6 i s
w i t h i n t h e state oftechnologyforliquidhydrogen-cooledbearings.

The p i t c h d i a m e t e r a n d o u t e r race o u t e r d i a m e t e r were made d i f f e r e n t

than those existing for a s t a n d a r d metric e n v e l o p e t o accommodate,
a t minimum s i z e , t h e t h i c k e r i n n e r race c r o s s s e c t i o n r e q u i r e d t o
withstandthebolttensionloadinthe Mark48-F turbopump.'The
t h i c k e r i n n e r race is a l s o less prone t o b r i t t l e f r a c t u r e f r o m t e n s i l e
a n d t h e r m a l stresses.

2. B a l l Complement. A b a l ld i a m e t e ro f4 . 7 6 2 5 nun (0.1875inch) was

selectedinpreferencetotheoff-the-shelfbearingsizeof5.556 mm
(0.21875inch) t or e d u c et h ec e n t r i f u g a lf o r c ea n de x t e n dt h ef a t i g u e
l i f e o ft h eo u t e r race. Thenumberof b a l l s w a s set a t 1 0 t o m a i n t a i n
a web t h i c k n e s s i n t h e c a g e o f o v e r 3 . 8 1 nun ( 0 . 1 5 0 i n c h ) t o p r o v i d e
a d e q u a t e wear l i f e a n d c a g e s t r e n g t h .

3. Race R a d i i . The race r a d i i , which are e x p r e s s e d as c u r v a t u r e ( % of

b a l l d i a m e t e r ) , were s e l e c t e d t o o b t a i n maximum f a t i g u e l i f e c o n s i s t e n t
w i t hp r a c t i c a lm a n u f a c t u r i n gl i m i t a t i o n s . The o u t e r race conforms
c l o s e l yt ot h eb a l ls u r f a c ew i t h a 5 2 %c u r v a t u r e . Lower curvatures
( c l o s e rc o n f o r m i t y ) i s a v o i d e db e c a u s ee x c e s s i v en o n r o l l i n ga c t i o n will
o c c u ri nt h eb a l l - r a c ec o n t a c t .I na d d i t i o n ,c o n t a c ta n g l e w i l l vary
r a p i d l y f o r small c h a n g e s i n b e a r i n g i n t e r n a l c l e a r a n c e d u e t o manu-
f a c t u r i n gt o l e r a n c e s ,p r e s sf i t s ,a n dt h e r m a le x p a n s i o n .

The b e a r i n g ' s f a t i g u e l i f e i s maximized i f t h e l i v e s o f t h e i n n e r and

o u t e r races are e q u a l .T h e r e f o r e ,t h ei n n e r race c u r v a t u r eo f5 3 %
w a s s e l e c t e dt ob a l a n c et h e race l i v e s . Use of a h i g h e r ( l e s s con-
f o r m i n g )c u r v a t u r eo nt h ei n n e r race i s a r e v e r s a lo fc o m m e r c i a l
p r a c t i c e f o r l o w-sp e e db e a r i n g s . It w a s d o n eh e r et om a i n t a i nr e a s o n -
ablelife,contactangle,andclearancefortheoverallbearingwhile
m a x i m i z i n gt h ef a t i g u el i f eo ft h eo u t e r race, which i s a d v e r s e l y
a f f e c t e d by b a l l c e n t r i f u g a l f o r c e s a t h i g h s p e e d s .

4R
. ac eSh o u l d e rHei g h t s . The race s h o u l d e r s were made deepenough to
containtheballcontact"prints" a t t h e c o n t a c t stress l i m i t e d a x i a l
load. This c o n f i g u r a t i o nt a k e sf u l la d v a n t a g eo ft h eb e a r i n g ' s
p o t e n t i a lc a p a c i t ya n d , a t t h e same time, d o e s n o t e x c e s s i v e l y restrict
t h ec o o l a n tf l o w area.
r-
-
5. CageDimensions. The c a g e i s o u t e rl a n dg u i d e d , so i t s o u t e rd i a m e t e r
i s d i c t a t e d by t h e o u t e r race i n n e r d i a m e t e r ( d e p e n d e n t o n b e a r i n g
p i t c hd i a m e t e r ,b a l ld i a m e t e r , a n ds h o u l d e rh e i g h t )a n da d e q u a t em i n i -
mum c l e a r a n c e . Cage d i a m e t r a lc l e a r a n c eo f0 . 0 7 6 m, ( 0 . 0 0 3i n c h )
minimum a t a m b i e n t t e m p e r a t u r e i s b a s e d o n e x p e r i e n c e w i t h l a r g e r
c r y o g e n i cb e a r i n g sa n ds c a l e dt ob e a r i n gs i z e . The c a g ei n n e rd i a m e t e r
 w a s s e l e c t e d t o m a x i m i z ec o o l a n tf l o w area a n d t o e n s u r e t h a t t h e
ball equators would meet the cylindrical section of the ball pockets
w i t h a minimum of0.254 mm (0.010 i n c h )m a r g i n . The b a l l i s . t h e n
p re v en t e dfro m" p l o wi n gun d e r " the c a g e . The r e s u l t i n g diametral
clearancebetweenthecageinnerdiameterandtheinner race o u t e r
d i a m e t e r is 1 . 7 7 8 mm ( 0 . 0 7 0i n c h ) t o 1.930 mm ( 0 . 0 7 6 i n c h ) , r e s u l t i n g
i n a minimum c o o l a n t f l o w area o f 86 - 6 mm2 ( 0 . 1 3 4 i n . 2, .
Thecage
a x i a l c r o s s - s e c t i o n a l area i s I 7 0 nun2 ( 0 . 2 6 3i n c h . 2 ) . To p r o v i d ea d e -
q u a t ec a g ew e a r - l i f ea n ds t r e n g t h ,t h ec a g e web t h i c k n e s s b e t w e e n t h e
b a l l p o c k e t s w a s h e l d t o 3.81 mm ( 0 . 1 5 0i n c h ) minimum i n s e l e c t i n g
t h e number of b a l l s ( 1 0 ) . The r e s u l t i n gn o m i n a lc a g e web t h i c k n e s s
a t t h e p i t c h d i a m e t e r i s 3.96 mm ( 0 . 1 5 6i n c h ) .

Thecage b a l l p o c k e t clearance w a s made l a r g e a t 0.51 t o 0 . 6 4 mm

( 0 . 0 2 0t o0 . 0 2 5i n c h )t op e r m i tb a l lp o s i t i o na d j u s t m e n t sd u r i n g
o p e r a t i o nw i t h o u te x c e s s i v ec a g ef o r c e s .A d e q u a t ep o c k e tc l e a r a n c e
h a sb e e nf o u n dt og r e a t l yr e d u c et h e a m o u n to fh e a tg e n e r a t e d at
t h ec a g ew h e r er a d i a ll o a d so rm i s a l i g n m e n t so c c u r .

6. Diametral C l e a r a n c e . The s p e c i f i e dd i a m e t r a lc l e a r a n c e as measured

onanunmountedbearing w a s basedonthevaluerequiredfordynamic
o p e r a t i o n ,w i t ha d d i t i o n a la m o u n t st oc o m p e n s a t ef o rt h ee x p a n s i o n
o ft h ei n n e r race due t o p r e s s f i t o nt h es h a f ta n dc e n t r i f u g a l
e x p a n s i o no ft h ei n n e r race a t s p e e d .

Analysis. The s e l e c t e db e a r i n gd e s i g n w a s a n a l y z e du s i n g a d i g i t a lc o m p u t e r
p r o g r a mw h i c hc a l c u l a t e sf o r c e s ,d e f l e c t i o n s ,a n d stresses f o r e a c h b a l l , a n d
o v e r a l lf o r c e s ,d e f l e c t i o n s ,a n df a t i g u el i f eo ft h ei n d i v i d u a l races a n dt h e
e n t i r eb e a r i n g . The s p r i n gp r e l o a d sr e q u i r e d€ o rs a t i s f a c t o r yo p e r a t i o no f
t h e b e a r i n g were c a l c u l a t e d u s i n g a n e m p r i c a l l y d e v e l o p e d r e l a t i o n s h i p o f
b a l ls i z e ,s p e e d ,c o n t a c ta n g l e ,a n dp i t c h diameter. The p r e l o a dr e q u i r e d
i s 4 3 1 N ( 9 7p o u n d s )f o rt h e LH pump b e a r i n g .
2
Inselectingthebearingdesign, a c o m p a r i s o n w a s made of t h e e f f e c t o n l i f e
o fu s i n gt h e minimum b o r e d i a m e t e r w i t h t h e r e s u l t i n g b e a r i n g p i t c h d i a m e t e r
a n dr e q u i r e dp r e l o a d .F i g u r e 42 p r e s e n t st h e B 1 ( 9 9 %s u r v i v a l )l i f ef o r a 19
mm b o r ea n d a 20 mm b o r eb e a r i n g . To o b t a i n a s t a n d a r d b o r e s i z e as w e l l as
p r o v i d e some m a r g i no nt h es h a f ts i z e , 20 mm w a s s e l e c t e d . A s c a nb es e e n
i nF i g .4 2 , no s u b s t a n t i a l b e n e f i t i n l i f e w o u l dh a v eb e e na c h i e v e db yu s i n g
a 1 9 mm b o r eb e a r i n g . The 1 0 , 4 7 6r a d / s (100,000 rpm) s p e e du s e di nt h e
Mark 48-F b e a r i n g a n a l y s i s was l a t e r r e d u c e d t o 9947 r a d / s( 9 5 , 0 0 0r p m ) ,b u t
t h i sc h a n g ew o u l dn o t a l t e r t h er e s u l t ss i g n i f i c a n t l y .F i g u r e 43 presents
theselecteddesign'sfatiguelife (shown h e r e as B 1 0 o r 90% s u r v i v a l l i f e )
as a f u n c t i o n o f a x i a l l o a d a t t h e Mark 48-F s p e e d o f 9947 r a d / s( 9 5 , 0 0 0r p m ) .
The p r e l o a d c r i t e r i o n r e s u l t e d i n a r e q u i r e d a x i a l l o a do f4 3 1 N (97pounds)
a t t h i sc o n d i t i o n .

Figure44presentstheanalyticalvaluesofradialstiffness(usedinshaft
d y n a m i ca n a l y s i s ) as a f u n c t i o no f a x i a l l o a da n ds p e e d .R a d i a ls t i f f n e s s
a f f e c t s s h a f t d y n a m i cres p o n s eand is a f f e c t e db ya x i a ll o a d ;t h e r e f o r e ,
p r o p e rd e s i g na n dd e f l e c t i o nc o n t r o lo ft h ep r e l o a ds p r i n g s are i m p o r t a n t .

69
 20 -

18.8 HOUR

R E Q U I R E DM I N I M U M
10 - P R E L O A DA T 1 0 , 4 7 0 r a d / s
(100,ooo RPM) \\

N= 1 0 0 , 0 0 0 RPM

1,
10 100
AXIAL
LOAD,
POUNDS

100 1000
A X I AL O A D , NEWTONS

Figure 42 . Mark 48-F B e a r i n g B

1
Life

70
 1.5 2 3 4 5 6 7 89103 1.5 2 3 4 5 6 7 8

3 4 5 6 7 8 910' 2 3 4 5 6 ?89103 2

Axial Load, Pounds

Figure 4 3 . Mark 48-F B e a r i n gL i f e vs Axial Load
U
ha

E 10

I I I I
40 60 80 100140 120 160
260 240 I80 220 200
AX I A L LOAD - L B
I 1 I I I I
200 400 600 a00 1000 1200
A X I A LL O A D - N

Figure 4 4 . Mark 48-F B e a r i n gS t i f f n e s sV e r s u s Axial Load

 F i g u r e 45 p r e s e n t s t h e e f f e c t o f s p e e d o n t h e relative axial d e f l e c t i o n s f o r
given axial loads. This r e l a t i o n s h i p w a s u s e di ns p e c i f y i n gt h et h i c k n e s s
o f t h e i n n e r race s p a c e r s s o t h a t b o t h t h e f o l l o w i n g w i l l b ea c h i e v e d :

1. A d e q u a t ep r e l o a d a t speed

2. Compensation f o rt h ei n c r e a s e dl o a d i n gb ys p e e de f f e c t s ,t h e r e f o r e
avoidingunnecessaryincreasein axial load with attendant reduction
in life.

T h et u r b o p u m pc o n f i g u r a t i o n i s s u c h t h a t i t w i l l accommodate n o t o n l y the extra-

l i g h t 20 nnn b e a r i n g s s e l e c t e d b y R o c k e t d y n e , b u t a l s o the h e a v i e r b a l l b e a r i n g s
a n dt h eh y b r i db e a r i n gs e l e c t e db yM e c h a n i c a lT e c h n o l o g y ,I n c . , in a parallel
b e a r i n gt e c h n o l o g yp r o g r a ms p o n s o r e db y L e w i s R e s e a r c hC e n t e r . The i n s t a l l a t i o n
o ft h et h r e eb e a r i n gc o n f i g u r a t i o n s is i l l u s t r a t e d i n F i g . 46 t h r o u g h 4 8 .

S e a lD e s i g n

Ingressofturbinepropellantgasintothe pump r e g i o n i s p r e v e n t e db y a con-

t r o l l e d - g a p ,s h a f t - r i d i n g s e a l . A l t h o u g ht h e pump a n dt u r b i n ef l u i d s are
c h e m i c a l l yc o m p a t i b l e ,t h et u r b i n ef l u i dc o n t a i n s steam, w h i c hw o u l df r e e z e
when i n c o n t a c t w i t h LH2; t h e r e f o r e , i t m u s t b e k e p t o u t o f t h e pump where
i t c o u l dh a v e a d e t r i m e n t a l e f f e c t , p a r t i c u l a r l y o n t h e b e a r i n g s .

S i n c et h ep r e s s u r eo nt h e pump s i d e o f t h e s e a l i s l o w e rt h a no nt h et u r b i n e
side,themiddleofthe seal i s p r e s s u r i z e d w i t h LH2 s u p p l i e df r o mt h e pump
d i s c h a r g e a s shown i n F i g . 4 9 . I n t h i s manner, a p o s i t i v ef l o wo f LH2 toward
t h e t u r b i n e is e n s u r e d , a n d e n t r y o f h o t g a s i n t o t h e pump i s p r e v e n t e d .
The LH2 t h a t leaks t h r o u g h t h e s h a f t s e a l t o w a r dt h e pump i s u s e d t o l u b r i c a t e
t h eb e a r i n g s ,a n dt h ef l u i dt h a tl e a k st ot h et u r b i n e i s used t o c o o l t h e
t u r b i n ed i s k s .

The f e e d p a s s a g e s t o t h e seal are o r i f i c e dt om a i n t a i n a p r e s s u r e level of

2 1 8 9 N/cm2 (3 1 7 5p s i a )c o m p aredw i t h1 3 8 0 N / c m 2 ( 2 0 0 0 p s i a )i nt h eb e a r i n g
area and 1 9 8 8 N / c m 2 ( 2 5 8 4 p s i a )o nt h et u r b i n es i d e . The sum o ft h el e a k a g e
a n dc o o l a n tb y p a s sf l o w r a t et o w a r dt h e pump w a s c a l c u l a t e d a t 0 . 0 6 5k g / s
( 0 . 1 4 4 l b / s e c ) . The l e a k a g et o w a r dt h et u r b i n e w a s p r o j e c t e dt ob e 0.026
k g / s( 0 . 0 5 8l b / s e c ) .

S h a f t S e a l D e t a i l Des i g n .
- The d e t a i l f e a t u r e s o f t h e s h a f t s e a l are i l l u s t r a t e d
i nF i g . 50. B o t hs e a l i n ge l e m e n t su t i l i z e a f l o a t i n g - r i n g ,c o n t r o l l e d - g a p
seal ring. The f l o a t i n g - r i n ge l e m e n tc o n s i s t so f an i n n e r Am-Cer-Met r i n g f o r
s t r e n g t ha n dt h e r m a le x p a n s i o n / c o n t r a c t i o nc o n t r o l . The o u t e rr i n g material
i s selectedtoprovidethe same t h e r m a le x p a n s i o na n dc o n t r a c t i o n r a t e as t h e
s h a f t m a t e r i a l , s o t h a t a c o n s t a n tc l e a r a n c eg a p i s m a i n t a i n e d a s t h et e m p e r a -
t u r ec h a n g e s . The o u t e rr i n g i s s u f f i c i e n t l ys t r o n g , r e l a t i v e t ot h ei n n e r
r i n g ,t oc o n t r o lt h ed i a m e t e ro ft h ec o m p o s i t er i n g . The i n n e rr i n g i s
m a i n t a i n e di nc o m p r e s s i v eh o o p stress w i t h a n i n t e r f e r e n c e f i t .

73

I
 .01

.Ot

E .oL
E
.
z
0
-
I-
V
w
-I
LL
w
n
-I
.02
a
-
X
a

- .02

-.001
0 1 2 3 4 5 6 7 8 9
A X I A L LOAD 100 LB U N I T S

0 1 2 3 4
A X I A L LOAD, kNEWTON

Figure 45. Mark 48-F B e a r i n gA x i a l Deflection v s Axial Load

74
 3:048 cm
( 1 .200")

t-
5.08 cm
7!
(2.0001')
Dl4 . DIA

Figure46. Mark 48-F Turbopump Rocketdyne

Bearing Ins tallation

0.123 . .. L L J !
2 . 7 1 cmJ
"f 1 .068")

-
Figure 47. Mark 48-F Turbopump MTI B a l l
Bearing I n s t a l l a t i o n
3.048 cm
I
- - - -- .
( 1 200").
i I
I

--
I
"- "

Figure 4 8 . Mark 48-F Turbopump Hybrid

Bearing Ins tallatlon

75

I
 SEALPRESSURIZING F L U I D

~ " "-
fT & BEARING COOLANT FLOW

SHAFTSEAL

Figure 4 9 . Mark 48-F Turbopump Shaft Seal Configuration

 PRESSURIZING
'ION TANG

"

I NCONEL X-750

Figure 50. Mark 48-F S h a f t Seal

77
 The l o a d i n d u c e d b y u n b a l a n c e d r a d i a l p r e s s u r e ( F i g . 51) i s s u p p o r t e d b y t h e
c o m p o s i t er i n gi nc o m p r e s s i v eh o o p stress. The r a d i a l d e f l e c t i o n c a u s e d by
t h ec o m p r e s s i v e stress i s p r o p o r t i o n a l t o r i n g r i g i d i t y . The r a d i a l s e c t i o n
andmodulus of e l a s t i c i t y are s e l e c t e d t o m i n i m i z e t h e d e f l e c t i o n . The i n i t i a l
clearance is adjusted to allow for the deflection and provide the desired
operating clearance.

The a x i a l f o r c e i n d u c e d b y d i f f e r e n t i a l p r e s s u r e ( F i g . 51) l o a d s t h e f l o a t i n g
r i n ga g a i n s tt h es t a t i o n a r yh o u s i n gt op r o v i d e a s t a t i c seal. A wave s p r i n g
i s p r o v i d e dt oe n s u r es u f f i c i e n tc o n t a c tl o a dt om a i n t a i n a s t a t i c seal. The
seal r i n g i s p a r t i a l l y p r e s s u r e b a l a n c e d by r e l i e v i n g t h e a x i a l c o n t a c t s u r -
f a c ea n dm i n i m i z i n gt h eh o u s i n g - t o - s h a f tc l e a r a n c et or e d u c et h eu n b a l a n c e d
a x i a l - p r e s s u r e - i n d u c e dl o a d . The f l o a t i n g - r i n ge l e m e n t i s r e s t r a i n e df r o m
r o t a t i o n w i t h two a n t i r o t a t i o n t a n g s t h a t e n g a g e s l o t s i n t h e h o u s i n g .

The s e a l r i n g c l e a r a n c e g a p was e s t a b l i s h e d by f i r s t p e r f o r m i n g a thermal

a n a l y s i st od e t e r m i n et h et e m p e r a t u r eg r a d i e n ti nt h et u r b o p u m ps h a f t seal
area.

A f i n i t e - e l e m e n t stress a n a l y s i s w a s p e r f o r m e d u s i n g t h e t e m p e r a t u r e d i s t r i -
butionandcentrifugalloadingtoestablishtheshaftoperatingdiameters.
The seal r i n g d e s i g n w a s e s t a b l i s h e d t o m a i n t a i n t h e r e q u i r e d o p e r a t i n g clear-
ancegap. The I n c o n e l X-750 r e t a i n i n gb a n d material h a sa p p r o x i m a t e l yt h e
same t h e r m a lc o n t r a c t i o na n de x p a n s i o n rate as t h e I n c o n e l 718 s h a f t material
t om i n i m i z et h eg a pc h a n g ed u et ot e m p e r a t u r e .

The s e a l r i n g d e s i g n was o p t i m i z e d b y u t i l i z i n g a computerprogram i n which

t h et e m p e r a t u r e ,p r e s s u r e , materials, and o v e r a l l d i m e n s i o n a l d a t a are i n p u t .
The c o m p u t e r c a l c u l a t e s t h e seal r i n g stresses a n d d e f l e c t i o n s f o r v a r y i n g
r a d i a l s e c t i o n s of t h er e t a i n i n gb a n da n di n s e r t . The s e a l r i n gd i m e n s i o n s
were t h e n s e l e c t e d , c o n s i s t e n t w i t h t h e p r o p e r stress l e v e l s , t o p r o v i d e t h e
minimum change i n c l e a r a n c e g a p . The s t a t i c a m b i e n t s e a l r i n gc l e a r a n c e
gaps were e s t a b l i s h e d , c o n s i s t e n t w i t t h e c l e a r a n c e d i f f e r e n t i a l s , t o p r o v i d e
t h er e q u i r e do p e r a t i n gc l e a r a n c eg a p s . The r e s u l t i n ga m b i e n ta n do p e r a t i o n a l
c l e a r a n c e s a r e l i s t e di nT a b l e . 9

TABLE 9. MARK 48-F SIlAFT SEAL CLEARANCES

Pump-Side Ring Turbine-Side Ring

SI English SI English
Units, Units, Units, Units,
mm inch mm inch

Nominal A m b i e n t Diametral 0.079 0.0031 0.074 0.0029

C 1e a r a n c e

Nominal O p e r a t i o n a l 0.046 0.0018 0.046 0.0018

D i amet ra1 C 1 e a r a n c e

78
 PRESSURE
LOAD

"

LOW PRESSURE
L-" UNBALANCED AX I AL
PRESSURE
LOAD

Figure 51. P r e s s u r eF o r c e so n a F l o a t i n g - R i n gS e a l

S t a t i cF l a n g eS e a l s . A l l s t a t i c f l a n g e seals a r e o ft h ep r e s s u r e - s e n s i t i v e ,
m e t a l - s p r i n gt y p ei l l u s t r a t e di nF i g . 5 2 . The s e a l s a r e d e s i g n e da n df a b r i -
cated for each specific application by t h e H y d r o d y n e D i v i s i o n o f DonaLdson
C o . ,I n c . The b a s e m a t e r i a l was I n c o n e l X-750, w i t h a 0.0076 mm (0.003 i n c h )
silverplatingappliedtoimprovesealingeffectiveness,

I m p e l l e r Wear R i n g s .I n t e r n a lr e c i r c u l a t i o no f LH2 a r o u n dt h ei m p e l l e rf r o n t
and rear s h r o u d s i s c o n t r o l l e d b y s t e p - l a b y r i n t h wear r i n g s as i n d i c a t e d i n
F i g . 5 3 . The n o m i n a ld i a m e t r a lc l e a r a n c eb e t w e e nt h er o t a t i n g numberand
s t a t i o n a r yp l a t f o r m i s s e t a t 0.20 mm (0.008 i n c h ) .W i t ht h i sc l e a r a n c e , some
r u b b i n gc o n t a c t i s e x p e c t e db e c a u s eo fe x c e n t r i c i t i e sa n dd e f l e c t i o n s . To
m o d e r a t et h ee f f e c t o f r u b b i n g , a 0.25 mm (0.010 i n c h ) t h i c k l a y e r o f s i l v e r
p l a t i n g i s a p p l i e dt ot h es t a t i o n a r yp l a t f o r m s .

Rotordynamics

C r i t i c a l s p e e d so ft h er o t o r were c a l c u l a t e d b yt h e lumped parametermethod

i n w h i c ht h er o t o r i s t r a n s f o r m e d i n t o a series o f mass p o i n t s w h o s es p a c i n g
a p p r o x i m a t e st h e mass d i s t r i b u t i o n of t h ea c t u a lr o t o r . The r e s u l t i n g c r i t i c a l
s p e e d s a r e p r e s e n t e d as a f u n c t i o n of t u r b i n e e n d b e a r i n g s p r i n g rates i n
F i g . 5 4 . The e f f e c to f t h e pump e n db e a r i n gs p r i n g r a t e is i n d i c a t e d i n a
p a r a m e t r i cf o r m . The p r e d i c t e dr a d i a ls p r i n g r a t e of t h eb e a r i n g s i s 49,000
N / m m (280,000 l b / i n . ) . A t t h i ss p r i n g r a t e , t h e f i r s t c r i t i c a l i s l o c a t e d a t

79
 / LOW PRESSURE
/ SIDE

HIGH PRESSURE SIDE

Figure 52. T y p i c a lS t a t i cF l a n g e Seal Configuration

S T A T : ONARY HOUS I NG ,

80
 I I
- " " ~ 2
1.5

!///// LLW

9.0-i A f T 'I I I

a*
9)
9) 6.0i
4 j Curve K, & K2 Spring Rate
rd
.rl N/mm lb/in-
w
*d

3.04
I

,
-
---
17,500
35,000
1x105
2x10,
b

I ---
I 87,500 5X1OJ
I I
Design Point
+1
0
I
2 . 0 1
I

1.5 i
I
104 "
--J"
- -
1o3 15 2 3 4 5 6 7 8 911. 05 4 2 3 4 5 6 7 8910'
Bearing
.. . .."_-.
Spring
... .."_."
Rate KAand
- .,. K4 (N/mm) Per Bearing
L
6
."
7 8 9 lo4# 2 3 4 5 6
LA

7
.-"-

8910' 2 3
1

; ;.x. IO5
Bearing Spring Rate Kg and K4 (lb/in) Per Bearing

Figure 54. Mark 48-F Turbopump Rotor C r i t i c a l Speeds

111lIl 1I l l11l1l1l1l

3 1 4 1r a d / s( 3 0 , 0 0 0r p m ) ,t h es e c o n d a t 5549 r a d / s ( 5 3 , 0 0 O , r p m ) , a n d t h e t h i r d
c r i t i c a l a t 1 4 , 5 5 0r a d / s( 1 3 9 , 0 0 0r p m ) . The n o m i n a l s p e e d o f t h e pump a t 95,000
rpm w i l l b e l o c a t e d b e t w e e n t h e s e c o n d a n d t h i r d c r i t i c a l withamplemargin
o ne a c hs i d e . The r o t o r mode s h a p e s a t t h e t h r e e c r i t i c a l s p e e d s are shown
i nF i g .5 5 .

The pump e n d o f t h e r o t o r i s f o r m e db yt h ei m p e l l e rh u b sw h i c h are p i l o t e d

r e l a t i v e t oe a c ho t h e r by i n t e r f e r e n c e f i t s . The c r i t i c a l s p e e dc a l c u l a t i o n s
are b a s e d o n b e i n g a b l e t o m a i n t a i n t i g h t a x i a l i n t e r f a c e s at theimpeller
hubs . To a c c o m p l i s ht h i s ,t h ei m p e l l e r s are p r e l o a d e d a x i a l l y w i t h a center
tie bolt. Theminimum tensioninthe t i e b o l t w a s e s t a b l i s h e d a t 50,000 N
( 1 1 , 2 3 0p o u n d s ) ,w h i c hi n c l u d e s a 50% m a r g i n o v e r t h e a n t i c i p a t e d s e p a r a t i n g
loadof33,310 N (7 4 8 9p o u n d s )(Fi g .3 9 )b e t w e e nt h ei m p e l l e r s . The minimum
preloadontheimpellersexistsafteraccountingfordifferentialcontraction
rates as w e l l as a x i a l s h r i n k a g e due t o P o i s s o n ’ s e f f e c t .

82
 I Pump End
1st
Stg.
Bearings
2nd
Stg. 3rd Stg.
Turb.End
5
BEARING SPRING RATES: 50,000 N/m (2.85X10 lb/in)

Turbine

+l.C T I
1

I I I I I I
-1.0

+1.b
+l. I I r I I

I 1 1 I
-1.

0 2 4 6 9 10 12 14
Axial Station, Inches

Fi g u r e 55. Mark 48-F Turbopump Rotor Mode Shapes

 MATERIAL
SELECTION

The materials s e l e c t e d f o r the m o r e s i g n i f i c a n t c o m p o n e n t s o f t h e Mark 48-F t u r -

bopump are i n d i c a t e d i n F i g . 56. I n T a b l e 10 , s p e c i f i c a t i o n sa n dp r o p e r t i e s
f o r these m a t e r i a l s a r e summarized.

The p r i n c i p a l c r i t e r i a f o rc h o o s i n gt h e materials i n t h e pump were: s t r e n g t h

and d u c t i l i t y a t LH2 t e m p e r a t u r e , resistance t o c o r r o s i o n , thermal c o n t r a c t i o n
c o e f f i c i e n t ,a n d ease o f f a b r i c a t i o n .

The i n l e th o u s i n g ,t h ef i r s t -a n ds e c o n d - s t a g ec r o s s o v e r s ,a n d the pump s e c t i o n

of t h eh o u s i n g were made of I n o n c e l7 1 8 .I n c o n e l7 1 8 i s a n i c k e l - b a s ep r e c i p i -
tationhardenablealloywhichhasbothexceilentstrengthandductility a t LH2
t e m p e r a t u r e s . A l l of t h e s ep a r t sn e e d e d a h i g h - s t r e n g t h material t o c a r r y t h e
l o a d sw i t ht h er e q u i r e ds a f e t ym a r g i n ;a l s o , i t w a s d e s i r a b l et om a i n t a i n common
t h e r m a lc o e f f i c i e n t st oc o n t r o l c r i t i c a l r a d i a l and a x i a l c l e a r a n c e s .S i l v e r
p l a t i n g w a s a p p l i e dt ot h ei n l e th o u s i n ga n dc r o s s o v e rl a b y r i n t hp l a t f o r m st o
permitlightcontactwiththerotatingpartsinthese areas w i t h a minimum of
l o c a lh e a t i n ga n d damage t ot h em a t i n gp a r t s .F o rt h e same r e a s o n ,t h es t a t i o n -
arylandofthebalancepistonhigh-pressureorifice was also silver plated.

High stresses i n d u c e d i n t h e i m p e l l e r h u b s a s a r e s u l t of c e n t r i f u g a l f o r c e s
d i c t a t e d t h a t a m a t e r i a l w i t hh i g hs t r e n g t h - t o - d e n s i t yr a t i ob eu s e d . A titan-
ium a l l o y c o n t a i n i n g 5 % a l u m i n u m a n d 2 . 5 % t i n w i t h e x t r a low i n t e r s t i t i a l ele-
ments was s e l e c t e d .T h i sh i g h - p u r i t ya l l o y w a s d e v e l o p e df o rt e m p e r a t u r e sr a n g -
i n gf r o m 200 I; (-100 F) t o 20 K (-423 F ) . To a c h i e v ea c c e p t a b l ed u c t i i i t ya n d
t o u g h n e s s a t 20 K (-423 F ) , t h e c o n t e n t o f t h e i m p u r i t y i n t e r s t i t i a l e l e m e n t s
( 0 2 , N 2 , H2) and t h e s u b s t i t u t i o n a l e l e m e n t Fe a r e h e l dt ol o w e rt h a nn o r m a l
l e v e l s bythepro d u ci n g mill. H e n c e ,t h ed e s i g n a t i o n "Extra Low I n t e r s t i t i a l "
(ELI) i s a p p l i e d t o t h i s ' a l l o y .

The h i g ho p e r a t i n gp r e s s u r ea n dt e m p e r a t u r e sd i c t a t e dt h eu s eo fR e n e ' 4 1 for

t h em a i ns t r u c t u r a l walls of t h et u r b i n em a n i f o l d .R e n e '4 1 i s a double-vacuum-
m e l t e d , precipitation-hardenable, n i c k e l - b a s ea l l o y A . l t h o u g hd i f f i c u l t of a b -
r i c a t e b e c a u s eo fs t r a i n - a g ec r a c k i n gi n w e l d h e a t - a f f e c t e dz o n e s , i t h a ss u p e r -
i o rs t r e n g t hi nt h eo p e r a t i n gt e m p e r a t u r ez o n eo ft h e Mark 48-F t u r b i n em a n i f o l d .

High t h e r m a l l yi n d u c e d stresses, p a r t i c . u l a r l yd u r i n ge n g i n ec u t o f f ,n e c e s s i t a t e d
t h eu s eo f a l i n e ri n s i d et h et u r b i n em a n i f o l d w a l l s t or e d u c et e m p e r a t u r eg r a d -
ients. The l i n e rd o e sn o tc a r r ys t r u c t u r a ll o a d s( i t i s p e r f o r a t e d ) .I n c o n e l
903, a' i r o n - n i c k e l - c o b a l t b a s e a l l o y w i t h low c o e f f i c i e n t o fe x p a n s i o n , was
c h o s e nf o rt h el i n e r material. I t h a sa ne x p a n s i o n r a t e of0.0087 mmm / m to
1033 K (1400 F ) comparedwith0.012 mm/mm w i t hm o s to t h e rh i g h - t e m p e r a t u r e metals
f o rt h e same t e m p e r a t u r er a n g e . I t i s a n t i c i p a t e dt h a tt h e r m a l l yo r i e n t e d prob-
lems w i t h t h e l i n e r w i l l b em i n i m i z e db yv i r t u eo ft h el o w e re x p a n s i o np r o p e r t i e s .

The p r o c e s s i n g o f t h e h o u s i n g ( d e s c r i b e d i n d e t a i l u n d e r " F a b r i c a t i o n " ) c a l l s

f o rh e a tt r e a t i n gt h eI n c o n e l 7 1 8 pump v o l u t e s e c t i o n and t h e p r i n c i p a l l y
R e n e l4 1t u r b i n em a n i f o l dt ot h e i rr e s p e c t i v e m a t e r i a l s p e c i f i c a t i o n s ,a n ds u b -
s e q u e n t l yj o i n i n gt h e s e two subcomponentsbywelding. To a c c o m p l i s ht h i sw i t h o u t

84
 CROSSOVERS FLANGE SEALS NOZZLE

INCONEL 718 1 INCONEL-X 7 liAYNES lB8 -/ I "

"

347 CRES 7182

INCONEL I-IAYNES 1 8 8 1 INCOLOY 903

TABS LOCK 302 CRES SPACERS 410

BOLTS FLANGE A286 INCONEL-X SEALS

SILVER PLATE
NUTS A286
WASHERS 302 CRES
SPRINGS INCONEL 718
LABY LANDS SILVER PLATE

Figure 56. Mark 48-F Materials Selection

 TABLE '10. MARK 48-F TURBOPUMP MATERIAL PROPERTIES
(SI UNITS)

-- . . .. -
-1
"

Room 'Te!mper a t u r e 1 opt 3t ing TemperaI t LIr e

-
1

T
IO-HourStress
FTY1 FTU ' FTY' FTU' e. Rupture,
Part Material Specificatior N/cm2 N/cmZ N/cm2 N/cm2 % N/cm2
." ~- .. .- - . " ._ ..- "" ".
Pump I n l e t Cover
Pump I n l e t
F i r s t Crossover lnconel 71( RB0170-153 103,400 124,000 lI9,OOO 143,000 12
Second Crossover
Pump V o l u t e
Shaft
Impellers
F i r s t - S t a g eN o z z l e
Ti tan
ium RBOl70-I 52 62,000 68,900
I 124,000 131,000 IO

1
Second-StageNozzlt Haynes 188 5772 38,000 86,000 21,000 55,000 26 29,600
HSG Trans i t i o n
Turbine Manifold Rene' 41 AMs 5712 go,000 117,000 75,000 87,000 4 52,000
Turbine Wheel Astroloy UDIMET 700 97.000 l3l.000 86,000 100.000 20
l a n i f o l dL i n e r
Jheel
Cover

". "
lnconel 903
lnconel 903
RBI 70- 196
RBI 70-196
103,000 124,000
1.03, ooo 180,000
1 ".
45,000
82,000
50,000
96,000
1 "
16
12
=20,700
69,000

(ENGLISH UNITS)

r"- .

1
_- . - -_ -

4-
r
Room Temperature OperatingTemperature
~. - " "_ ..
." "

FTU ' T, FTY ' FTU'

Part' Material t ks i ;' F ks i ks i
" __ -
t-""
t- - -

J-
"

!Pump I n l e t Cover
I Pump I n l e t
j F i r s t Crossover
' Second Crossover I
lnconel 718 RB0170-153 150 180 I
i
12 -32C I73 207 Ii
I Pump V o l u t e
Shaft I
I
I
Impellers Titanium RB0170-152 90 100 i 12 -390 180 I90 10 ;
F i r s t - S t a g eN o z z l e )
Second-StageNozzle
HSG Trans i t i o n
I
Haynes 188 AMs5772 55 125 45 1400 30 80 26 i
I
Turbine Manifold Rene' 41 AMS 5712 130 170 8 1400 126 4
Tu r b ine Whee I Astroloy UDIMET 700 140 190 16 1400 145 20
Y a n i f o l dL i n e r lnconel 903 R B I 70-196 150 I80 12 I400 73 16
Jheel
Cover I nconel 903 R B I 70- I96 I50 180 12 1200 I39 12

~ . .. .. . . .. . - .". .. . . ... .. ""

86
a n n e a l i n g t h e material on e i t h e r s i d e o f t h e f i n a l w e l d , a transitionpiece
made ofHaynes 188 was.welded t o b o t h . s e c t i o n s p r i o r t o h e a t t r e a t i n g . The
f i n a l weld w a s t h e n e f f e c t e d b y j o i n i n g H a y n e s 1 8 8 - t o - H a n y e s 188, w i t h i s n o t
affectedbyeithertheheattreatingorweldingoperations.

P o r t i o n s of t h e t u r b i n e m a n i f o l d t h a t are s u b j e c t e d t o h i g h - p r e s s u r e H2 and
w h i c h e x p e r i e n c e a h i g h s t r a i n l e v e l were p r o t e c t e d a g a i n s t h y d r o g e n e m b r i t t l e -
mentbyapplying 0.076- t o 0.25-mm (O..OC3- t o 0 . 0 1 0 - i n c h )t h i c kd e n s ec o p p e r
p l a t i n gt ot h ei n t e r i o rs u r f a c e s .T h r e a d e d areas were g o l dp l a t e d . A thicker
(0.25 t o 0 . 3 8 mm; 0.010 t o 0 . 0 1 5 i n c h ) c o p p e r p l a t i n g l a y e r w a s a p p l i e dt ot h e
h o u s i n g ,t u r b i n ew h e e lc o v e r ,a n ds e c o n d - s t a g en o z z l et o serve as a t u r b i n e t i p
seal r u b b i n g s u r f ace.

The t u r b i n e w h e e l i s s u b j e c t t o v e r y , h i g h e f f e c t i v e stresses f r o m c e n t r i f u g a l ,
power-bending,andthermalcomponents. To accommodate t h e s e stress l e v e l sa t
t h ee l e v a t e dt e m p e r a t u r e s ,A s t r o l o y w a s s e l e c t e d as t h ew h e e l m a t e r i a l . A s t r o l o y
i s a na g e - h a r d e n a b l e ,n i c k e l - b a s ea l l o yw h i c h ,i na d d i t i o nt op r o v i d i n ge x c e l -
l e n th i g h - t e m p e r a t u r ep r o p e r t i e s ,r e t a i n sa d e q u a t ed u c t i l i t yi nt h ec r y o g e n i c
t e m p e r a t u r er a n g e .

The t u r b i n ew h e e lc o v e r w a s made f r o mI n c o l o y9 0 3t ot a k ea d v a n t a g eo f i t s low

t h e r m a le x p a n s i o nc o e f f i c i e n ta n dt h e r e b ym i n i m i z et h ec h a n g ei ns e c o n d - s t a g e
seal clearance.

-____
Thermal Analysis

Heat t r a n s f e r a n a l y s i s was c o n d u c t e dt od e t e r m i n et h et h e r m a lp r o f i l e of c r i t i -
c a l pump a n dt u r b i n ec o m p o n e n t sd u r i n gt r a n s i e n ta n ds t e a d y - s t a t ec o n d i t i o n s .
The c h i l l d o w n r a t e o ft h e i m p e l l e r , s t a r t i n gw i t ha na m b i e n te n g i n e , was e s t a b -
l i s h e d .T h i s w a s ofconcernnotonlyfromhydrodynamicbutfrom a structural
c o n s i d e r a t i o n ,b e c a u s et i t a n i u ms t r e n g t h i s g r e a t l ya f f e c t e db yt e m p e r a t u r e
( F i g .5 7 ) . The a n a l y s i si n d i c a t e d( F i g .5 8 )t h a t ,w i t ht h ep r e d i c t e d powered
idle- modefl o wra t e of 2 2 2 of f u l l - t h r u s t f l o w , t h e i m p e l l e r r e a c h e d 39 K (-390 F )
i n 20 s e c o n d s .T h i s was a na c c e p t a b l e time i n t e r v a lf o rc h i l l d o w nf o rt h ee n g i n e ;
t h e r e f o r e ,t h e s t r e s s a n a l y s i sr e s u l t s ,w h i c ha r eb a s e do n 39 K (-390F)proper-
t i e s , were c o n s i d e r e dp r o p e r .

T h e r m a la n a l y s i so ft h et u r b i n ei n c l u d e ds f a r ta n dc u t o f ft r a n s i e n t s as w e l l a s
s t e a d y - s t a t ec o n d i t i o n s .O n e - d i m e n s i o n a la n a l y s i s wasused f o rt r a n s i e n t s , and
t w o - d i m e n s i o n a la n a l y s i sf o rs t e a d y - s t a t ec o n d i t i o n s . The r e s u l t si n d i c a t e d
t h a t ,b e c a u s eo ft h ei d l e - m o d eo p e r a t i o nw h i c hp r e c e d e se n g i n e starts, the start
t r a n s i e n t sd i dn o th a v ea na p p r e c i a b l ee f f e c t o nt u r b i n e life.

I nc o n t r a s t ,t h es h u t o f ft r a n s i e n t si n t r o d u c e d a s i g n i f i c a n tt h e r m a ls h o c kd u e
t o a h y d r o g e nl a g ,w h i c hp r o d u c e d a h i g ht h e r m a lg r a d i e n ta n dc o r r e s p o n d i n g l y
h i g hs t r a i ni nt h ep r e s s u r e w a l l s . To i n c r e a s et h el o w - c y c l ef a t i g u el i f e ,
a t h i n l i n e r w a s i n c o r p o r a t e di n s i d et h em a n i f o l dt os h i e l dt h ep r e s s u r e walls.
I t s e f f e c t was t oi n c r e a s et h e r m a lr e s i s t a n c e . With t h e l i n e r , t h e w a l l d i f f e r -
e n t i a lt e m p e r a t u r e wasreduced t o 518 K (600 F ) , as shown i n F i g . 59. F u r t h e r -
m o r e ,t h e maximum t h e r m a l s t r a i n w a s d e l a y e d u n t i l 2 s e c o n d s a f t e r c u t o f f when
t h es t r a i n sf r o mp r e s s u r el o a d s a r e low.

87
03
03

2.0

1.5

1 .(

0.5

( I
100 200 300 400 500
TEMPERATURE, R
L I I
0 100 200 300
TEMPERATURE, K

Figure 57. Titanium (5.0 A1-2.5 Sn) Strength Ratio vs Temperature

- +loo
-

LL

w
cc
- =
l-
-100
a
!x
W
a, I DLE
5 MODE
I-
E
w
J
-1 -200
-
w
n
x
-

-
-300

-
- -400
0 4 8 12 16 20 24
TIME, SECONDS

F i g u r e5 8 . Mark48-F I32 T u r b o p u m pI m p e l l e rA v e r a g eT e m p e r a t u r e
o r Time
 100% 20%
THRUST THRUST
I I

1000

1200

800 IO00

800

Y LL
600
W W 600
LC LC
3
I-
2
3
I- ._ - . .* . _. . - - " ."" " -. . . .I
. . . .
w
dw I
a a
ZT
W
+
r
W
c I
. . . . .. ~. """," - * * f . . . . i
I
400 I I I I I

200 I I .
I
20c

".
0.50 0.75 1.00 1.25 1.50 1.75 2.00
TIME, S

Figure . ASE T u r b i n e Manifold T r a n s i e n(tE n g i n e Shutdown)

The s t e a d y - s t a t e i s o t h e r m map c a l c u l a t e d f o r t h e t u r b i n e f i r s t - s t a g e d i s k is
p r e s e n t e di nF i g . 60. The d i s k t h e r m a l p r o f i l e i s b a s e do nu s i n gt h es h a f t
seal f l o w f o r d i s k c o o l i n g . The c o o l a n t i s r o u t e dt h r o u g ht h e f i r s t - andsecond-
s t a g ed i s kh u b st h r o u g h s m a l l b l e e d e rh o l e s . A c o v e r i s i n c o r p o r a t e dd o w n s t r e a m
of t h e s e c o n d - s t a g e w h e e l t o p r o v i d e a t h e r m a lb l a n k e t .

The t e m p e r a t u r e of t h e t u r b i n e b l a d e s d u r i n g s t e a d y - s t a t e c o n d i t i o n s is equal
t ot h eg a st e m p e r a t u r e .I d l e - m o d eo p e r a t i o nm i n i m i z e s the s e v e r i t yo f start
transients. In c o n t r a s t ,t h eh y d r o g e nl a gd u r i n gc u t o f fp r o d u c e s a substantial
t h e r m a lg r a d i e n t( F i g . 61), which.mustbeconsidered i n t h e stress a n a l y s i s and
p r o j e c t e d l i f e o ft h eb l a d e .

StressAnalysis

I n l e tH o u s i n g . A p l a t e a n a l y s i s of t h ei n l e t. h o u s i n g w a s p e r f o r m e da c c o u n t i n g
f o rp r e s s u r el o a d sa n df u l la x i a ll o a d sf r o mt h ec r o s s o v e r s ( 2 2 2 , 0 0 0 N , 50,000
pounds ) . The maximum c a l c u l a t e d stress w a s 515 x lo6 N / m 2 ( 7 4 , 6 0 0 p s i ) .T h i s
stress l e v e l , i n c o n j u n c t i o n w i t h t h e minimum u l t i m a t e s t r e n g t h o f I n c o n e l 718
of125 N/m2 (180 k s i ) , r e s u l t e d i n a c o n s e r v a t i v ef a c t o r of s a f e t y of 2 . 4 . The
stress l e v e l s i n t h e t o r u s d u e t o p r e s s u r e were n e g l i g i b l e ; t h e r e f o r e , t h e t o r u s
w a l l t h i c k n e s s w a s e s t a b l i s h e d by f a b r i c a t i o n c r i t e r i a .

Pump Housing. A summary of t h es t r u c t u r a la n a l y s i sp e r f o r m e d on t h e pump hous-

i n g i s p r e s e n t e di nT a b l e 11. A f i n i t e - e l e m e n ta n a l y s i s w a sp e r f o r m e do ft h e
c r i t i c a l zones. The i n i t i a l s i z i n g of t h eh a r d w a r e was d o n eu s i n g cast Inconel
7 1 8 m a t e r i a lp r o p e r t i e s .S u b s e q u e n t l y ,t h ed e s i g n w a s f i n a l i z e du s i n g a w r o u g h t ,
w e l d e ds t r u c t u r e ,b u tt h ew a l lt h i c k n e s s e s were r e t a i n e d a t t h e i r o r i g i n a l v a l u e s .
A s a c o n s e q u e n c e ,t h es a f e t yf a c t o r sw i t ht h eh i g h e r - s t r e n g t h material i n c r e a s e d
t ot h ec o n s e r v a t i v ev a l u e sn o t e di nT a b l e 11. T h e f i n i t e - e l e m e n tm o d e lo ft h e
pump h o u s i n g ,a n dc o n s t a n t - s t r a i na n dc o n s t a n t - s t r e s s map a r e i l l u s t r a t e d i n
F i g . 62 t h r o u g h 6 4 .

TABLE 11. MARE: 48-F PUMP H O U S I N G STRESS ANALYSIS

”-
1

Calculated Stress
Stress F a c t o ro f
Identification
”
N/cm ksi Safety
”

Maximum Combined S t r e s s 36,500 53 3.4

I n D i s c h a r g e , f r o m Pressure 19,300 28 6.4
I n Weld 25 17,200 4.3
I I

Comments: ( 1 ) Material: Inconel 718

( 2 )A x i a ld e f l e c t i o no fb a l a n c e p i s t o n high-
p r e s s u r e o r i f i c e r e l a t i v e t o r e a rb e a r i n g
s h o u l d e r = 0.0043 cm ( 0 . 0 0 1 7 i n c h )
L I

91
111l1l1111l1l11l1l11l11ll Il11l11111

.”
944K (1700R)
872 K (1570 R)

794K(1430R)

76K
(136R)-

7‘
F i g u r e 60. S t e a d y - S t a t eI s o t h e r m for Mark 45-F F i r s t
Turbine Disk

92
 1400 I
1000

800

. . . . . . . . . . . . "" . . . . . . .
600
W
ci
3
c . . . . . . . . . . . "*" "" . . . . . . . . . . .
a
z
W
a
l5
c . . , . . . . . +*d""." . . . . . . . . . . . . . . .

Y
400
-
-
0
0

200

-400w
-200

-AT = T
WALL - T~~~~~ ,
CENTER
0 . . . . . . . . .
7 : llC1S
.

0.50 0.75 1 .oo 1.25 I .50 1.75 2.00

TIME, S

F i g u r e 61. ME TurbineBladeTransient(Engine Shutdown)

 10-

rPR
7
3792 N/cm"
= (SSOO p s i

8-
E
u
L

VI
-
3
n
a
6-

3 i 9 2 N/cmL
(5500 p s i ) ---"
4-
m
./-
3489 N/cmi
(5060 p s i ) "
3185 N/cm2/ __
2- (4620 p s i )
I"" " - . .

0 1 2 3
D I M E N S I ON, I NCHES
I I I I
0 2 4 6 8
Z D I M E N S I O N , crn

Figure 62. Mark 48-F Pump Housing Finite-Element Model

94
 1

10-
4.0 -
r

-
3.8 -
3.6 -
3.4 -
-
8-
-
3.2 -
3.0 -
2.8 -
I

- 2.6 -
E
V

-
”

m
2.4 -
1 6- Ln -
n
a -n
3
2.2 -
-
a
= 2.0 -
-
1.8 -
1.6 -
”

4-
1.4 -
”

-
1.2 -
1.0 - Strain expressed as unit dimension
.per unit dimension
0.8 -
’

2- I I I I I
0 1.0 0.5 1.5 2.0 3.0 2.5
A X I A L DItZENSION,
INCHES
I I I I I
0 2 4 6 8
A X I A L DIMENSION, CM

F i g u r e 63. Mark 48-F Pump H o u s i n g Constant-Strain Map

 4.0

3.6
3.4
3.2

2
17,510 E cm
m (25,400 si)
w
E 2.6
-
z
2.4
v)

2 2.2
n
a
2.0
1.8
1.6
1.4

0.8
I 1 I I
0 0.5 1 .o 1.5 2.0 2.5 3.0
AX I AL D I HENS I ON, I NCHES
I I I I I

0 2 4 6 8
A X I A LD I M E N S I O N , cm

Figure 6 4 . Mark 48-F Pump Housing Constant-Stress M a p

The d e f l e c t i o n of t h e b a l a n c e p i s t o n h i g h - p r e s s u r e o r i f i c e r e l a t i v e t o the rear
b e a r i n gs h o u l d e r i s of i n t e r e s t inasmuch as t h i s a f f e c t s t h e t o t a l b a l a n c e p i s t o n
g a pa n dt h eb e a r i n g a x i a l p r e l o a d sd u r i n go p e r a t i o n . A s n o t e di nT a b l e 11, t h i s
d e f l e c t i o n w a s c a l c u l a t e d a t 0.0043 cm ( 0 . 0 0 1 7i n c h ) . The m a g n i t u d eo ft h ed e -
f l e c t i o n i s a c c e p t a b l es i n c ea p p r o p r i a t ec o m p e n s a t i o nc a nb ei n c l u d e di nt h e
turbopumpassembly t o o b t a i n t h e d e s i r e d o p e r a t i n g g a p a n d p r e l o a d .

C r o s s o v e r s .S t r e s sa n a l y s i s of t h ep u m p . c r o s s o v e r s w a s p e r f o r m e du s i n gf o r g e d
I n c o n e l7 1 8p r o p e r t i e s .T h er e s u l t s of t h ea n a l y s i s w e r e as f o l l o w s :

1. C r o s s o v e r sa n a l y z e df o r o t a t i o n
0 8 = 0 . 0 0 0 3 4 3r a d i a n( 0 . 1 9 7d e g r e e s )
0 Ringbending stresses = 38.6 N/m2 ( 5 6 0 0p s i )
2
2. Maximum b e n d i n g stress onenclosedchamber = 400 N / m ( 5 8 , 0 0 0p s i )
0 S a f e t yf a c t o r = 3.1
3. A x i a tl r a n s l a t i o na n a l y z e d
0 Assuming a l l l o a di nc a n t i l e v e rb e n d i n g
0 Axial t r a n s l a t i o n = 0 . 0 2 8 c m (0.011 i n c h )
Bending stress = 533.6 x lo6 N/m2 (77,400 p s i )
S a f ef tayc t o r = 2.3
0 P a r t of t h i sl o a da c t u a l l yc a r r i e db yi n l e th o u s i n g ,s i z e dt o
c a r r yt o t a ll o a d
4. C r o s s o v e rv a n e sa n a l y z e df o rs e p a r a t i n gl o a d
Maximum stress (70 x lo6 N/m2 (10,000 p s i )

T h u s ,t h e minimum f a c t o r o f s a f e t y i s more t h a na d e q u a t e a t 2 . 3 on u l t i m a t e
s t r e n g t h .N e i t h e rt h ee x t e n to fa n g u l a rr o t a t i o no ra x i a ld i s p l a c e m e n t are
e x p e c t e dt op r e s e n ta n yd i f f i c u l t yi nt h ef u n c t i o n i n go ft h e pump.

Impellers. A f i n i t e - e l e m e n ta n a l y s i s w a s performed of t h ei m p e l l e r su s i n g
5.OA1-2.5Sn f o r g e dt i t a n i u mp r o p e r t i e s . An o p e r a t i n gt e m p e r a t u r e of 39 K
(-390 F ) wasassumed.The f i n i t e - e l e m e n tm o d e l sa n dc o n s t a n t - s t r e s s maps of
e a c hi m p e l l e r a r e p r e s e n t e di nF i g .6 5t h r o u g h 68. The s a l i e n tc o n c l u s i o n s
fromtheanalysis were:

1. S e c o n d - s t a g ei m p e l l e rb a c k p l a t em o s t c r i t i c a l d u et ob a c k p l a t er e t u r n
holes
2 .P r e d i c t e db u r s ts p e e d a t o p e r a t i n gt e m p e r a t u r e = 1 3 , 6 5 0r a d / s
(1 3 0 , 4 0 0 rpm)
3 .A l l o w a b l eo p e r a t i n gs p e e d = 1 1 , 3 7 0 r a d / s ( 1 0 8 , 6 0 0 rpm)
4. Maximum stress i n c l u d i n g stress c o n c e n t r a t i o n = 8 2 3 x 106 N / m 2
(111,000 p s i )

97
 N = 10,491 rad/s (104,500 RPM)

Pr

I 1 1

0 1 2
DIMENSION, INCHES .
I I I I
0 2 4 6
DIMENSION, crn

Figure 65. Mark 48-F First- and Second-Stage Impellers

Finite-Element Model

98
 6

E
U
-
ln
-
3
n
a
ar

0
0 0.5 1 .o 1.5 2.0

AX I AL D I HENS I ON, I NCHES

I I I I
0 2 4 6

F i g u r e 66. Mark 48-F F i r s t -a n dS e c o n d - S t a g e Impellers C o n s t a n t -

S t r e s s Map

99
Y
0
0 N = 10,941 r a d / s (104,500 rpm)
n

PR = 2406 N/cm
(2490 psi)

PR = 2640 N/cm

PR = 2196 N/cm

PR = 18890 N/cm 2

I 1 I
0 1 2
D I HENS I ON, I NCHES
I I I I
0 2 4 6
D I M E N S I O N , cm

Figure 6 7 . Mark 48-F T h i r d - S t a g eI m p e l l e rF i n i t e - E le m e n t Model

 2.2

2.0

1.8

1.6

1.4
V
-
z
-
In
1.2
-
3

2 1.0
cc

0.8

0.6

0.4

0.2

I 1 1 1
0 2 4 6
A X I A LD I M E N S I O N , crn

Figure 68. 14ark 48-F Third-Stage Impeller Constant-Stress Map

101

"
 5. Average t a n g e n t i a l stress = 474 x lo6 N/m2 ( 6 8 , 8 0 0p s i )
6. S a f e t y f a c t o r a t maximum N o f1 0 , 9 4 1r a d / s (104,500 rpm) o n
b u r s t = 1.55 ( o n s t r e s s )

T u r b i n e Disk. S i m i l a r l y , a f i n i t e - e l e m e n ta n a l y s i s w a s a c c o m p l i s h e do n the
t u r b i n ed i s k s ,a c c o u n t i n gf o rp o w e r ,t h e r m a l ,a n dc e n t r i f u g a le f f e c t s . The
f i n i t e - e l e m e n tm o d e l i s shown i n F i g 6 . 9T . he critical f a c t o r i n designing
t h et u r b i n ed i s k s w a s l o w - c y c l ef a t i g u ed u et ot h e r m a le f f e c t s .F o rt h i s con-
s i d e r a t i o n , t h e maximum s t r a i n rather t h a n stress i s the c o n t r o l l i n g c r i t e r i o n .
Constantstrainlinescalculatedfor the f i r s t - s t a g e d i s k are p r e s e n t e d i n
F i g . 70. The maximum s t r a i n shown p e r m i t s a c y c l i c l i f e o fo v e r8 0 0c y c l e s ,
with a s a f e t yf a c t o ro f4 ,w h i c he x c e e d sb y a s u b s t a n t i a lm a r g i nt h e3 0 0 - c y c l e
minimum r e q u i r e m e n t .T h er e s u l t so ft h ea n a l y s i s are summarized i n t h ef o l l o w i n g :

1. F i r s td i s k i s t h em o r ec r i t i c a l l ys t r e s s e do ft h et w o .
2. Maximum s t r a i n i n t h e f i r s t - s t a g e d i s k = 0.0085 c m / c m

3. P r e d i c t e df i r s t - s t a g eb u r s ts p e e d a t maximum o p e r a t i n g
t e m p e r a t u r e = 1 3 , 5 8 0ra d / s( 1 2 9 , 7 0 0r p m ) .
4. A l l o w a b l ef i r s t - s t a g es p e e d a t maximum o p e r a t i n g
t e m p e r a t u r e = 11,300 r a d / s( 1 0 8 , 0 0 0r p m ) .
5 .F i r s t - s t a g e ,l o w - c y c l e - f a t i g u e limit = 800 c y c l e sw i t h
s a f e t yf a c t o ro f 4.

T u r b i n eB l a d e s .S t r e s sa n a l y s i so ft h et u r b i n eb l a d e sd i s c l o s e dt h a tb e c a u s e
o ft h eh i g ht e m p e r a t u r e sa n dc e n t r i f u g a l stresses, t h e1 0 - h o u rl i f er e q u i r e m e n t
was d i f f i c u l t t o meet w i t h o u tb l a d ec o o l i n g . An e f f e c t i v ec o o l i n gs y s t e mw o u l d
h a v ei n c r e a s e dt h ec o m p l e x i t ya n dc o s to ft h eh a r d w a r e ,a n dw o u l dh a v ei n t r o -
duced a severe p e r f o r m a n c ep e n a l t y ,p a r t i c u l a r l yc o n s i d e r i n gt h el o w pump flow-
rates involved.

The a l t e r n a t i v e sc o n s i d e r e di nt h ed e s i g n a r e p r e s e n t e di nT a b l e1 2 . The v a l u e s
a p p l yt ot h ef i r s t - s t a g eb l a d e sw h i c h a r e t h em o s tc r i t i c a lb e c a u s eo ft h eh i g h e r
t e m p e r a t u r e si m p o s e d . The f i r s ts i xa l t e r n a t i v e sl i s t e di nT a b l e1 2 were n o t
v i a b l ef r o mt h es t a n d p o i n to fp r o d u c i b i l i t y o r c a p a b i l i t y t o meet t h es p e e d ,
l i f e ,o rp e r f o r m a n c er e q u i r e m e n t s . A s a r e s u l t , t h en o m i n a lo p e r a t i n gs p e e d
o ft h er o t o r was red u c edfro m1 0 , 4 7 0r a d / s (100,000 rpm) t o 9 9 4 6r a d / s( 9 5 , 0 0 0
r p m ) ,a n dt h ei n t e g r a lb l a d ec o n f i g u r a f i o nw i t hh o l l o w ,s h r o u d e db l a d e s was
a c c e p t e df o rf i n a ld e s i g n .I n cases 7 t h r o u g h 1 0 , t h ec a p a b i l i t i e sw i t ht h e
a c c e p t e dd e s i g n as a f u n c t i o no ft e m p e r a t u r e ,s p e e d ,a n dl i f e a r e d e n o t e d . Case
10 d e s c r i b e st h er e s u l t so fo p e r a t i n gt h et u r b i n e a t maximum s p e e d maximum
t e m p e r a t u r es i m u l t a n e o u s l y .U n d e rt h i sc o n d i t i o n ,t h el i f e of t h et u r b i n eb l a d e
is l i m i t e d t o s l i g h t l y o v e r 1 hour.

I ft h et u r b i n e i s t ob eo p e r a t e d a t maximum s p e e df o r 10 h o u r s , t h e i n l e t tem-
p e r a t u r em u s tb el i m i t e dt o1 0 7 0 K (1925 R) maximum ( c a s e8 ) . T h ep r e d i c t e d
l i f e o ft h ef i r s t - s t a g et u r b i n eb l a d e when o p e r a t i n g a t n o m i n a l i n l e t t e m p e r a -
t u r e( 1 1 1 1 K ; 2000 R ) an dn o m i n a ls p e e d( 9 9 4 8r a d / s ,9 5 , 0 0 0 rpm) i s 400 h o u r s .

102
 (") INDICATESPRESSURE OR SHEAR A P P L I E D TO SURFACE

I I
ION, z DIHENS INCH 0 1.0000
I I I
z D I t l E N S I O N , cm 0 1 .o 2.0

Figure 69. Mark 48-F F i r s t -a n dS e c o n d - S t a g eT u r b i n e Disk F i n i t e -

E l e m e n tM o d e l

103
 1.60
4

1.40

1.30

3
1.20

t
.oo
1’1° c1

E
0
.
cn
L
0.70

.0011
-
.@00526

-
3
n

0.40L
a

0.30

o.20L
0.10
0
I
L B I

I I
1

I
1 1

1
i\ 1
1

I I I
0 -.a -.6 -.4 -.2 0 .2 .4 .6 .8

F i g u r e 70. Mark
48-F T u r b i n eF i r s t - S t a g eD i s k ,C o n s t a n t - S t r a i n Map
 TABLE 12.

(SI UNITS)
- -
P Itch
Flrst-Stage
RotorBlade B I ade E1 ade
T. -
ure. K
r
Dlamcter, Height. Attach- Conf I g- Life.
Ease
- cm
"
cm mcnt urat Ion lbterlal
-
hours Blade

I " "
Veld " " " "

2 8.89 0.864 F i r Tree Shrouded As t r o l oy IO 1078

Sol i d

3 8 .89 0.864 Integral Shrouded 1078

Sol i d
4 8.89 0.864 Shrouded 1078 10.470
Hollow
76.5

5 8.89 0.864 Unshrouded 1078 10,470 70. I

Hollow
6 9.35 0.737 Shrouded I078 9,947 76.2
Hollow

7 8.89 0.737 Shrouded 1078 9,947 75.5

Hollow
8 8.89 0.737 Shrouded 1036
Hol l o w
! 9.947 75.5

9 8.89 0.737 Shrouded 30 101 I 9.947 75.5

Hollow
IO 8.89 0.737 I Shrouded I I 1078 9.947 75.5
- L
Hol l o w
;Limited by d i s k s t r e s s

"
(ENGL
-I SIH UNITS)
7

Pitch
lameter,
'Irst-Stage
M o r Blade
Height,
llade
ittach-
Blade
Conf i g - L if e
-
Temperdlt u r e

a se
- Inches inch rent uration aterlal
"" -
hc3iurs Inlet IBlade rpm rpn

I " "
k l d " " " " "
, "

2 3.5 0.340 - i r Tree ihrouded stroloy I0 zoo0 R 1480 F 69,500 100.000* .

io1 i d 1540 F
3 3.5 0.340 *a 1 ihrouded 2000 R 1480 F 80,000

If
io1 i d 1540 F I

4 3.5 0.340 Shrouded 2000 R 1480 F 87,000

Hol l o w 1540 F
5 3.5 0.340 Unshrouded 2000 R 1480 F 98:00^0
Hollow 1540 F
6 3.68 0.290 Shrouded 2000 R 1480 F 9 I ,000 ' 95.000
Hollow 1540 F
7 3.5 0.290 Shrouded 2000 R 1480 F 93.500 I
Hollow 1540 F
I
8 3.5 0.290 Shrouded 1925 R 1405 F 104.500
Hollow ! 1465 F
9 3.5 0.290 Shrouded $0 1860 R 1360 F 104.500
Hol l o w 1400 F
10 3.5 0.290 Shrouded 2000 R 1480 F 104.500 V
Hollow 1540 F
- I
:Limited by d i s k s t r e s s
 I

TABLE 1 2 . MARK 48-F TURBINE BLADE CONFIGURATION SUMMARY

(SI UNITS)
"___
First-Stage
RotorBlade
Helght.
cm
"

0.864
Blade
Rttach-
nent

deld

F i r Tree
B I ade
Conf l g -
uratlon
"

Shrouded
Materia'
"

Astrolol
Life.
lours
"

IO
Tempe1 -
-
~

"
ure. I

Inlet

1111
Blade
-~
"

I078
J &x lmum
A I Iowablc
Speed 0
rad/s
"

7,277*
TurbinePerformance

rad/s

10.470
a t 1033 K

76.5
Remarks

A s t r o l o y Is n o tw e l d a b l e

Sol I d
0.864 Integral Shrouded
Sol i d
1111 1078 8,376 10,470 I 76.5 Maximum N tw l o w

0.864 Shrouded 1111 1078 9,109 10.470 76.5 Haximum N toolow

Hollow

0.864 Unshroudel 1111 1078 10.260 10,470 70.1 Efflciency l o w

Hollow

0.737 Shrouded 1111 1078 9,528 9,947 76.2 Maximum N too low
Hollow

0.737 Shrouded 1111 IO78 9,789 9.947 75.5

Hollow

Shrouded

1
0.737 I069 1036 75.5
Hol low T 10,941 9.947

Accepted c o n f i g u r a t i o n
0.737 Shrouded 30 1033 101 I 10.941 9,947 75.5
Hollow

0.737 / Shrouded
io1 l a r ,
t I 1111 1078 10.941 9,947 75.5
- - -
ilskstress

GL~I H UHITS)
'Irst-Stage
b t o r Blade
Height.
inch
B 1ade

uration bterlal
(1 -

I fe
)urs
Temperature

Inlet 11ade
'lax imum
llowable
Speed,
rpm
r TurbinePerformance
a t 1860 F
Jrnlnal Speed, ifficlency.
% Remarks
~ .. .
" " " " " " "
sistroloyisnotWeldable

0.340 Rstroloy IO 2000 R 1480 F 69,500 100,000* 76.5

Sol i d 1540 F

0.340 Int Ira1

Shrouded 2000 R 1480 F 80,000 76.5 Maximum N toolow
Sol i d 1540 F

0.340 Shrouded 2000 R 1480 F 87,000 76.5 Maximum N toolow

Hol l o w 1540 F

0.340 Unshrouded
Hollow
2000 R
1540 F
1480 F 98.000 T 70. I Efficiecrcylow

0.290 Shrouded 2000 R 1480 F 9 I ,000 95,000 76.2 Maximum N tw l o w

Hollow 1540 F

0.290 Shrouded 2000 R 1480 F 93.500 75.5

Hollow 1540 F

0.290 Shrouded 1925 R 1405 F 104,500 75.5

Hollow 1 1465 F

0.290 Shrouded 30 1860 R 1360 F 104.500 75.5

Hollow 1400 F

0.290 Shrouded T 1 2000 R 1480 F 104,500

T 75.5
Hollow 1540 F
I
irk stress
 The c a l c u l a t e d stress levels u s e d i n t h e a b o v e a n a l y s i s are:
2
C e n t r i f u g a l stress = 37,200 N / c m ( 5 4 , 0 0 0p s i )
2
Gas b e n d i n g stress = 4800 N / c m (6900 p s i )
2
Maximum stresses a t b l a d e r o o t = 42,000 N / c m ( 6 0 , 9 0 0p s i )

The c a l c u l a t e d stress levels o f t h e s e c o n d - s t a g e t u r b i n e b l a d e s were Similar:

2
C e n t r i f u g a l stress = 38,000 N / c m ( 5 5p, s1i0)0
2
Gas b e n d i n g stress = 3500 N / c m (5
p9s i0)0
2
Maximum stresses a t b l a d e r o o t = 41,500 N / c m ( 6 1 , 0 0 0p s i )

The t e m p e r a t u r e l e v e l s p r e s e n t a t t h es e c o n d - s t a g eb l a d ea r el o w e ra n d , as a
result,thepredictedlife is s l i g h t l yh i g h e r .

Tur bineM ani fo l d . The t u r b i n em a n i f o l d w a s a n a l y z e d ,u s i n g a finite-element

a p p r o a c h ,a c c o u n t i n gf o rp r e s s u r ea n dt h e r m a l l yi n d u c e dl o a d s .B e c a u s e of t h e r -
mal g r a d i e n t s a t e n g i n e c u t o f f , a n I n c o l o y 9 0 3 l i n e r w a s i n c o r p o r a t e dt oa t t e n -
u a t et h es t r a i nl e v e l si nt h es t r u c t u r a i walls. W i t ht h el i n e r , a low-cycle
f a t i g u e l i f e of 200 c y c l e s w a s a c h i e v e dw i t h a f a c t o r of s a f e t y of 4 . 0 . The
f i n i t e - e l e m e n tm o d e lf o rt h et u r b i n em a n i f o l d i s shown i n F i g . 7 1 , a n dt h e
c o n s t a n t - s t r a i n map i s i n c l u d e di nF i g .7 2 .T a b l e 13 p r e s e n t s summary
a of
t h e strain l e v e l sa n dp r e d i c t e dl i f ef o rt h ev a r i o u sp a r t so ft h em a n i f o l d

TABLE 13. MARK 48-F TURBINE MANIFOLD PREDICTED

LOW-CYCLE FATIGUE L I F E

r I I
Strain Low-Cycle F a t i g u e L i f e
Loca t i o n (nondimensional) W i t h 4.0 S a f e t y Factor
~ ".

Torus* 0.0068 850 cycles

E x h a u s tC y l i n d e r 0.0076 600 cycles
t n l e t Transition* 0.0093 200 cycles

I *With 0.16 mm (0.062 i n c h ) 1 iner

I
S p l i tI m p e l l e rD e s i g n
-
Experienceinfabricatingtheimpellerfromanintegralforgingrevealedthat,
b e c a u s eo fl a c ko fa c c e s s i b i l i t y , i t was d i f f i c u l t t o p r o d u c e p a r t s w h i c h con-
s i s t e n t l y m e t p r i n tr e q u i r e m e n t s . As a result,aneffort w a s i n i t i a t e d t o mod-
i f yt h ei m p e l l e rd e s i g nt oi m p r o v ep r o d u c i b i l i t y . T h ea p p r o a c ha d o p t e d was t o
f a b r i c a t et h ei m p e l l e r s i n two p i e c e s a n d , a f t e r t h e i n t e r n a l h y d r o d y n a m i c pass-
a g e s are g e n e r a t e d , j o i n t h e two h a l v e s .

106
 2.8

6- 2.4

2.0
E
U
L

4- 1.6
-n
3

a
E Pr = 2585N/crn2
(3750 p s i )
2-

1 -0.4 -, , , , , ,
1 .o 2.0
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 l 1 1
3.0 4.0 5.0 6.0
AXIAL DIMENSION, INCHES
I I I I I I I
4 6 8 IO 12 14 16
AXIAL DIMENSION, cm

F i g u r e 71. Mark 48-F Turbine Manifold Finite-Element Model

10

3.5

3.0

2.5

2.0
v,
w 1.5
I
u
z
- 1.0
t \ I-.0055

-Os5I
-1 .o

-2.0
I 1 I I I I I I I
-2.0 -1 .o 0 1 .o 2.0 3.0 4.0 5.0 6.0
A X I A L D II4ENS I ON, I NCHES
I I 1
-5 10 15
A X I A L DIMENSION, cm

B 7.65X10a4 C 1.5OX 1 Oa3 D 2.25X10a3 E2 . 9 9 ~ 1 0 ~ ~ F 3.73X10a3

H 5.22X10a3 J 5.95X10a3 K 6.7OX 1Oa3 L 7.45X10" M 8.11X1043

Figure 72. Mark 48-F T u r b i n eM a n i f o l dC o n s t a n t - S t r a i n Map

The d e s i g n l a y o u t w h i c h d e f i n e d the i n t e r f a c e b e t w e e n t h e p r e i m p e l l e r a n d m a i n
i m p e l l e r i s shown i n Fi g .7 3 . I n f o r m u l a t i n gt h ec o n f i g u r a t i o no ft h e inter-
f a c e , t h e r e were several i m p o r t a n t :c o n s i d e r a t i o n s ;t h em o s ts i g n i f i c a n to ft h e s e
a r e d i s c u s s e d i n t h ef o l l o w i n g :

The l o c a t i o n o f i n t e r f a c e w a s e s t a b l i s h e d b y the r e q u i r e m e n t of a c c e s s i b i l i t y
t ob o t hs u b c o m p o n e n t sa n dt om a i n t a i na na d e q u a t e stress d i s t r i b u t i o n . The
i n t e r f a c e i s l o c a t e d a t a p p r o x i m a t e l y 1.58 r a d( 9 0d e g r e e s )w r a pa n g l eo ft h e
f u l l 2.36 r a d (135 d e g r e e )w r a p .T h i sp r o v i d e se x c e l l e n ta c c e s s i b i l i t yt o
m a c h i n et h eh y d r o d y n a m i cp a s s a g e so fb o t hd e t a i l s ,a n dl e a v e ss u f f i c i e n th u b
material t os u p p o r tt h em a i ni m p e l l e r . The l o c a t i o n of t h ei n t e r f a c e i s immedi-
a t e l yu p s t r e a mo ft h el e a d i n ge d g e of t h e p a r t i a l vanes; t h e r e f o r e , o n l y t h e
f u l l v a n e s are i n v o l v e d i n t h e s p l i t . The f r o n ts h r o u dl a b y r i n t h s are a l l
l o c a t e do nt h ep r e i m p e l l e r ,a n dt h ew e l dj o i n t i s l o c a t e da d j a c e n tt ot h el a b y -
r i n t h s , a t a small d i a m et e rwh e r et h ea d d e d mass r e q u i r e d f o r t h e j o i n t d o e s
n o t p r e s e n t a stress problem.

Initially,theinterface was p l a n n e d as a m e c h a n i c a lg a p ,b u tt h ew e l dj o i n t
w a s added t o m a i n t a i n t h e a x i a l d e f l e c t i o n a t a na c c e p t a b l el e v e la n dt o elim-
i n a t e a p o t e n t i a lr e c i r c u l a t i o nl e a kp a t ha r o u n dt h ef r o n ts h r o u d . To e n s u r e
a C l a s s I w e l d ,t h ej o i n t i s u l t r a s o n i c a l l yi n s p e c t e d .P r o v i s i o n s are included
tofacilitateultrasonicinspection by i n c l u d i n g e x c e s s m a t e r i a l o u t s i d e t h e
weld,which i s removed a f t e r t h e i n s p e c t i o n i s accomplished.

The p r e i m p e l l e r i s i n s t a l l e d w i t h a c o m b i n a t i o no fh e a t i n ga n dp r e s s i n g . An
i n t e r f e r e n c ef i to f0 . 1 0 4t o0 . 1 1 4 mm ( 0 . 0 0 4 1t o0 . 0 0 4 5i n c h ) is maintained a t
thepilotingdiametertoensurepositivepilotingatalloperatingconditions.
A x i a l l y ,t h ep r e i m p e l l e r w i l l b o t t o m a t t h e hub. T o e n s u r et h e b e s t p o s s i b l e
c o n t a c t ,t h em a t i n g s u r f a c e s a t t h e hub a r e b e i n gh e l dt oa n0 . 0 0 2 5 mm ( 0 . 0 0 0 1
i n c h )n o r m a l i t y . The p r e i m p e l l e r i s p r e l o a d e da x i a l l yd u r i n g td w e l d i n go p e r a -
t i o n as a p r e c a u t i o n ;a l t h o u g h ,w i t ht h eh e a v yd i a m e t r a li n t e r f e r e n c ef i t , a
l o s si na x i a lc o n t a c t i s n o tp r o b a b l e .

T o o l i n g i s used t o p o s i t i o n t h e two p a r t s r e l a t i v e t o e a c h o t h e r d u r i n g t h e
a s s e m b l yp r o c e d u r et oe n s u r ep r o p e rm a t c h i n go ft h ev a n es u r f a c e s at the
interface.

The e f f e c t i v e stress a t t h ew e l d , composedof t a n g e n t i a l ,r a d i a l ,a n da x i a l

stresses, was c a l c u l a t e d a t 4 2 , 0 0 0 N / c m 2 ( 6 0 , 6 0 0 p s i ) . The t a n g e n t i a l stress
a t t h ew e l dj o i n t i s 49,000 N/cm2 (71,000 p s i ) , and i s t h em a j o rc o n t r i b u t o r
of t h e t o t a l e f f e c t i v e s t r e s s . T r e a t i n gt h ee f f e c t i v e stress as s t e a d y - s t a t e
stress a n du s i n gt h em e c h a n i c a lp r o p e r t i e so f a Class I , 5A1-2.5Sn E L I t i t a n i u m
GTA weldment ( a s w e l d e d ) a t 6 1 K ( - 3 5 0F )t e m p e r a t u r e ,t h eu l t i m a t ea n dy i e l d
f a c t o r s of s a f e t y a r e 2 . 4 7a n d2 . 3 7 ,r e s p e c t i v e l y .

The f i n i t e - e l e m e n t g r i d a n d i s o s t r e s s p l o t s o f t h e e f f e c t i v e stresses f o r t h e
e n t i r ei m p e l l e r a r e shown i nF i g . 7 4 and75.Figure 76 and 77 i n c l u d ea ne n -
l a r g e dg r i da n di s o s t r e s sp l o t so ft h ep r e i m p e l l e rs e c t i o n .

109
 PRESSURE S I D E
( F U L VL A N EP) R E I M P E L L E R
SEPARATION LINE

T O O L I N GP I NT OA L I G N
PRE-IMPELLERAND I HPELLER
F U L LV A N E SA TS E P A R A T I O N

DASHEDLINES SHOWS
PART CONTOUR DUR I NG

--"-"
..

Figure 73. Mark 48-F S p l i t , Impeller

 N = 10,940 r a d / s (104,500 RPH)

! 1
Figure 7 4 . Mark 48-F Third-Stage Impeller Underformed
Structure

111
 I
N = 10941 r a d / s
( 1 04,500 RPM)

2
75,800 N / c m
( 1 10,000 P S I )

c
1 l 1 1 1 1 i l
t ~ 1 1 1 1 1 1 1 1 1 1 1 I I ! ~ ; . ; ’ 1

Figure 75. Mark 48-F First-Stage Impeller

112
r

I
L.

F i g u r e 76. E n l a r g e d End of Preirnpeller

113
 N/cm : A = 678

G = 40675
B

H
=

=
6873

47430
C = 13540

J = 54255
D = 20337

K = 61012
E = 27090

L = 67836
F = 33780

M = 73766 I
.

Figure 77. ?lark 48-F Split Impeller Preimpeller Effective Stress

114
The t o t a l a x i a l d e f l e c t i o n o f t h e b a l a n c e p i s t o n h i g h - p r e s s u r e seal relative
t ot h el o w - p r e s s u r e seal i s less t h a n0 . 0 7 6 mm (0.003 i n c h ) a t 9946 r a d / s
( 9 5 , 0 0 0 rpm) w i t ht h ew e l d e di m p e l l e r .T h e r e f o r e , a t o t a lb a l a n c ep i s t o ng a p
can b e m a i n t a i n e d a t 0 . 2 5 4 mm (0.010 i n c h ) , which w a s u s e d i n t h e pump perform-
a n c ep r e d i c t i o n . The d e f l e c t e ds h a p eo ft h ei m p e l l e r i s shown i n F i g . 78.

A f a t i g u e a n a l y s i s of t h e i m p e l l e r w e l d j o i n t w a s made.Because of t h e o r i e n t a -
tionoftheweldjoint,there i s a n a x i a l g a pb e t w e e nt h ep r e i m p e l l e ra n dt h e
m a i ni m p e l l e r .T h i sr e s u l t si n a m e c h a n i c a ln o t c hf o rw e l dj o i n ts t r a i n si n
t h ea x i a ld i r e c t i o n . The maximum a x i a l s t r a i n r a n g e a t t h en o t c ha d j a c e n tt o
t h e w e l d i s 0.0048, u s i n g t h e s t r u c t u r a l f i n i t e - e l e m e n t m o d e l c a l c u l a t e d axial
s t r a i n and a n o t c hf a c t o ro f 3. B a s e do nt h ea b o v es t r a i nr a n g ea n dt h e low-
c y c l e f a t i g u e l i f e c a p a b i l i t y ,of a Class 1 GTA weld j o i n t o f5 - 2 . 5t i t a n i u m
a t 6 1 K (-350 F ) , t h e j o i n t c y c l e l i f e i s i n e x c e s s of 10,000 c y c l e s ,w h i c h
s a t i s f i e s t h e minimum r e q u i r e m e n to f1 2 0 0c y c l e s (300 d u t y c y c l e s times a s a f e t y
f a c t o ro f 4 ) .

GTAW j o i n t s h a v e b e e n e v a l u a t e d , a n d t h e p r e d i c t e d minimum s t r e n g t h v a l u e s h a v e
b e e nd e v e l o p e di na c c o r d a n c ew i t hF i g . 7 9 . T h e s ev a l u e s a r e b e i n gu s e d as
d e s i g np r o p e r t i e sf o rb o t h GTAW and EB weldments. The v a l u e s are c o n s i d e r e d
c o n s e r v a t i v es i n c e ,i n a l l c a s e s , p r o p e r t i e s of EB w e l d sh a v eb e e nd e m o n s t r a t e d
t o b es u p e r i o rt op r o p e r t i e sr e s u l t i n g from GTAW.

Gas G e n e r a t o r

The g a sg e n e r a t o r was d e s i g n e da s a p i e c e of s p e c i a l t e s t e q u i p m e n tt op r o v i d e
t h ed r i v eg a sf o r turbopump t e s t i n g . The r e q u i r e m e n t si m p o s e dt o meet t h eb a s i c
i n t e n to fs u c h a facility i t e m were: (1) s t a b l e o p e r a t i o n a t a l l o p e r a t i n g
p o i n t s , ( 2 ) r e p e a t a b l eh i g hp e r f o r m a n c e , ( 3 ) u n i f o r me x h a u s tg a st e m p e r a t u r e
p r o f i l e , ( 4 ) r e l i a b l ei g n i t i o n , and ( 5 ) d u r a b i l i t y a n dl o n gl i f e .

The g a s g e n e r a t o r d e s i g n u s e s s e p a r a t ei n j e c t o r andcombustorassemblieswhich
a r e a t t a c h e dw i t h a b o l t e df l a n g e( F i g . 8 0 ) . The i n j e c t o rh a s 1 5 c o a x i a li n j e c -
t i o ne l e m e n t s ,w h i c h a r e d e s i g n e df o rs t a b l eo p e r a t i o n ,h i g hp e r f o r m a n c e ,a n d
c o m p l e t em i x i n g . The n o m i n a lo p e r a t i n gp a r a m e t e r sf o rt h ei n j e c t i o ne l e m e n t s
a r eg i v e ni nT a b l e 1 4 . A n a l y s i s of t h ee l e m e n td e s i g n ,u s i n gt h eR o c k e t d y n e
Steady- S t a t eC o m b u s t i o nM o d e l ,i n d i c a t e dc o m p l e t ec o m b u s t i o nw i t h i n a distance
of 8.89 c m ( 3 . 5 i n c h e s )f r o mt h ei n j e c t o rf a c e( F i g . 8 1 ) . The o u t p u tf r o mt h i s
model was a l s ou s e dt oc o n d u c t a P r i e ma n a l y s i st oe v a l u a t et h es e n s i t i v i t y of
t h ec o m b u s t i o np r o c e s st ot r a n s v e r s ea c o u s t i c modes i nt h ec o m b u s t o r . The
r e s u l t so ft h i sa n a l y s i si n d i c a t e dt h eg a sg e n e r a t o r w i l l h a v es t a b i l i t ys u p e r -
iortothe 5-2 and J-2s e n g i n e s( h i g h e rA ) ,w h i c he x h i b i t e dd y n a m i cs t a b i l i t y
t o a l l b u ti n t e r m e d i a t es i z e bombs ( F i g . 8 2 ) . The i n j e c t o re l e m e n t was a l s o
d e s i g n e dw i t ha d e q u a t ei n j e c t i o np r e s s u r ed r o p( P / P c = 0 . 1 3 )t oi s o l a t et h e
gasgener a t o rfro mfee d -s y s t e m -c o u p l e d modesof instability.

The i n j e c t i o n e l e m e n t s are a s e l f - c o n t a i n e dd e s i g ni nw h i c he a c he l e m e n t is
b u i l t as a b r a z e da s s e m b l yf o ri n d i v i d u a lc a l i b r a t i o n( F i g .8 3 ) . The e l e m e n t s
have a r e c e s s e do x i d i z e rp o s tw i t hf o u rc e n t e r i n gd e v i c e sf o rp o s i t i v ea l i g n m e n t
w i t h i nt h ef u e ls l e e v e . Narrow s l i t s a r e used a t t h e e n t r a n c e o f t h e f u e l s l e e v e

115
116
 200

160

100

120

80

40
-400 - 300 - 200 - 100 0 100
TEMPERATURE, F
1 I I
0 100 200 300
TEMPERATURE, K

Figure 79. Titanium (5.0 A1-2.5 Sn) Predicted Minimum Tensile Strength
 INLET

c" LH2 INLET

Figure 80. LH 2 Turbopump Gas Generator

118
TABLE 1 4 . GAS GENERATOR INJECTOR ELEMENTS

Nominal Operating Parameters SI Units Engl ish Units

Number of Elements 15
Flowrate/Element 0.20 kg/s 0.44 1 b/sec

Oxidizer Injection Velocity 24.4 m/s 80 ft/sec

Fuel Injection Velocity 190.5 m/s 625 ft/sec

M i n i m u m Fuel Sleeve Gap 3.8 x 0.015 inch

Number o f Center Devices 4

 100

80

70

C 60
a,
W
I
Q)
a 50

40

30

20

0 I "
"
1
" - !.. ". " L"
0 0.5 1 .o 1.5 2 .o 2.5 3 .O 3.5
(0.013) (0.025) (0.038) (0.051) (0.064) (0.076) (0.089)

D i s t z 3 c e from I n j e c t o r Face, inches (m)

F i g u r e 81. Gas GeneratorCoaxialElement

1000

GAS GENERATOR

100

J-2

10

J-2s

.1
0 0.25
(. 00625)
0 I STANCE
FROM INJECTORFACE, 1 NCHES (M)

F i g u r e 82. Gas GeneratorPriem Analysis

El I

SECT1 ON €-E
E d -007 POST 1 REQD ON -101
-043 POST 1 REQD ON -141

-009 SLEEVE 1 REQD ON -101

-045 SLEEVE 1 REQD ON -141

-101 ELEMENT ASSY OF

-141 ELEMENT ASSY OF

F i g u r e 83. I n j e c t o Er l e m e n t
t o a c t as f i l t e r s t o p r o t e c t t h e minimum i n t e r n a l f u e l f l o w area f r o mb e i n g
r e s t r i c t e d b yc o n t a m i n a t i o n . Theelement material i s CRES 3 0 4 L .

The i n j e c t o r body i s a na l l - w e l d e da s s e m b l yf a b r i c a t e df r o m CRES 3 4 7 . Thein-

j e c t o re l e m e n t sa n d NARloy f a c e p l a t e are b r a z e di n t ot h ei n j e c t o rb o d y . GRAYLOC
f i t t i n g s are u s ed as p r o p e l l a n t i n l e t s t o i n t e r f a c e w i t h t h e t e s t f a c i l i t y . An
envelopehasbeenretainedinthecenteroftheinjectorforpotentialuse of
a spark igniter.

Thecombustor i s a na l l - w e l d e da s s e m b l yo ft h ec o m b u s t o rb o d y ,e l b o w ,a n dt r a n s -
i t i o ns e c t i o n . Added m a r g i nf o rc o m p l e t em i x i n ga n d a uniform e x i t temperature
h a sb e e np r o v i d e db yu s i n gt h ee l b o wt oi n d u c ec i r c u l a t i o n . Thecombustor is
c o o l e db yf i l mc o o l a n ti n j e c t e df r o mo r i f i c e s a t t h e p e r i p h e r y of t h e i n j e c t o r .
The f i l m c o o l a n t t e m p e r a t u r e i s shown i n F i g . 84 a s a f u n c t i o no ft h ed i s t a n c e
f r o mt h ei n j e c t o rf a c e .

A c o u s t i ca b s o r b e r s were p l a c e di nt h ec o m b u s t o rw a l l ,d i r e c t l yb e l o wt h ei n j e c -
t o rf a c e ,t op r o v i d ea d d e ds t a b i l i t ym a r g i n b yd a m p i n ga c o u s t i c modes i n t h e
combus tor. A summary o fa c o u s t i ca b s o r b e re x p e r i e n c e( F i g . 85) shows t h a tt h e
d e s i g no p e na r e a of t h e g a s g e n e r a t o r a c o u s t i c a b s o r b e r lies i n a favorable
p o s i t i o nr e l a t i v et op r e v i o u se x p e r i e n c e .

A welded t r a n s i t i o n s e c t i o n was u s e d b e t w e e nt h eg a sg e n e r a t o ra n dt u r b i n em a n i -
f o l db e c a u s ea n a l y s i s showed t h a tt h eh i g ht e m p e r a t u r ei nt h i sa r e a wouldpro-
h i b i t e f f e c t i n g a p o s i t i v e s e a l w i t h a f l a n g e dj o i n t . The j o i n t i s f a b r i c a t e d
by w e l d i n gt h eI n c o n e l6 2 5t r a n s i t i o np i e c et ot h eR e n e ' 4 1 t u r b i n em a n i f o l d
(Fig. 86). T h i s w e l d i s t h e nh e a tt r e a t e d . A f t e r t h eI n c o n e l6 2 5g a sg e n e r a t o r
t r a n s i t i o n p i e c e i s w e l d e d t o t h ec o m b u s t o re l b o w ,t h e two t r a n s i t i o n p i e c e s a r e
j o i n e dw i t ha n EB w e l d . The g a sg e n e r a t o rt r a n s i t i o np i e c eh a s a l i n e rs e c t i o n
w h i c he x t e n d so v e rt h et r a n s i t i o np i e c ew e l d e dt ot h et u r b i n em a n i f o l d .T h i s
f or ms a t h e r m a lb a r r i e rw h i c he n s u r e st h a tt h el i f eo ft h ep r o t e c t e dt r a n s i t i o n
p i e c e i s c o n s i s t e n tw i t ht h a t o f t h et u r b i n em a n i f o l d . The d e s i g n of t h et r a n s -
i t i o ns e c t i o na l l o w st h eg a sg e n e r a t o rt ob e removedandrewelded t ot h et u r b i n e
m a n i f o l dw i . t h o u th a r m i n gt h eh e a tt r e a to r w e l d betweenRene' 41 and I n c o n e l6 2 5
s i n c et h er e w o r kc a nb e made i nt h ep r o t e c t e dI n c o n e l6 2 5t r a n s i t i o np i e c e s .

I g n i t i o no ft h eg a sg e n e r a t o r was t o b e a c c o m p l i s h e du s i n gp y r o t e c h n i ci g n i t e r s
s i m i l a rt ot h eR o c k e t d y n e P/N 651876 i g n i t e r e x t e n s i v e l y u s e d f o r 5-2 g a s gen-
e r a t o r andturbopumpdevelopmenttesting. Two p y r o t e c h n i ci g n i t e rp o r t s were
p r o v i d e di nt h ec o m b u s t o r . T h e subsequentdevelopmentof a s p a r kt o r c hi g n i t e r
under company f u n d i n gb a s e d on p r i o r workconductedunder NASA-LeRC d i r e c t i o n
p r e c l u d e dt h en e c e s s i t y of u t i l i z i n g t h e p y r o t e c h n i c i g n i t e r s .

FABRICATION

Component F a b r i c a t i o n

The methodsemployed i nf a b r i c a t i n gt h em a j o rc o m p o n e n t so ft h e LH2 turbopump

a r e d i s c u s s e di nt h ef o l l o w i n gp a r a g r a p h s .

123
 1600 HOT GAS 8

( 1 144)

I
I /
/
/

400
FUEL T/P MAX CONDITIONS
(477) F l L f l COOLANT (0.17 Ib/sec)
0
n (0.077 kg/sec)
E

-400 1 I 1 I I I I I
(33) 0 1 2 3 4 5 6 7
(C.025) (0.05l) (0.076) (0.102) (0.127) (0.152) (0.178)
D i s t a n c e from I n j e c t o r Face, inches (m)

F i g u r e 84. Gas GeneratorFilmCoolantTemperature

 -

.40 - UILIKE
UML I KE

.m - TRIPLET

NASA LEWIS
0 EFFECTIVE -LM ROCKETDYNE
a MRG I WAL
.15 IINEFFECTIVE

.IO 1
.a-
.06 - I HTSV C - l
.05- F- I
I SPARTAN
.04- J-2 (FAST
BURNING)
.03- L M ROCKETDINE
c-
.02 -
(DUAL ABSORBER)
LIU (BELL)=
XRL BOOSTER
(WAL M S O R S E R ) 0
.Q1 I I I 1 1 1 1 1 I I 1 1 I I 1 1 1
.2 .3 .4 .5 .6.7.8 1 2 3 4 567810 MER)

F i g u r e '85. Absorber Experience

\ -GAS GE?!ERATOR

tip T/P (IEICONEL E251 \ CLOSEOUT WELD

(REHE 41) (ELECTRON BEN41

Figure 86. Turbopump to Gas Generator Transition Joint

125
 Pump I n l e t . The pump i n l e th o u s i n g , shown i nF i g .8 7 , w a s a w e l d e da s s e m bl y
of componentsmachined o r f o r m e df r o m . I n c o n e 1 718 wrought material. The i n l e t
g u i d ev a n e s were g e n e r a t e db yp a n t o g r a p h i n g , as i l l u s t r a t e d i n F i g . 88. F i g u r e
89shows t h eh o u s i n gi n a s t a g eo fp a r t i a lc o m p l e t i o n ,w i t ht h e componentcon-
t a i n i n gt h eg u i d ev a n e sw e l d e dt ot h e dome, b u t b e f o r e t h e i n l e t t o r u s was
attached . The c o m p l e t e di n l e th o u s i n g are shown i nF i g . 90.

An a l t e r n a t e d e s i g n a p p r o a c h f o r t h e pump i n l e t w a s i n v e s t i g a t e d f o r p o t e n t i a l
c o s tr e d u c t i o n .I nt h i sa p p r o a c h ,t h er a d i a ls c r o l l - s h a p e di n l e t( F i g .9 0 )
was r e p l a c e d by a na x i a le n t r y , a s i l l u s t r a t e di nF i g .9 1 .B i d sr e c e i v e df r o m
t h r e ev e n d o r sb a s e do nt h ec o n c e p t u a ls k e t c h shown i nF i g .9 1r e v e a l e dt h a tt h e
a x i a l i n l e t w o u l db es l i g h t l y more e x p e n s i v e . A s a r e s u l t , t h e o r i g i n a l d e s i g n
concept w a s r e t a i n e d .

Pump C r o s s o v e r s .
"
The c r o s s o v e r s were f a b r i c a t e di nt h r e es e c t i o n sf r o mI n c o n e l
7 1 8 , a s i l l u s t r a t e di nF i g .9 2 . The i n t e r n a h l y d r o d y n a m i cp a s s a g e s i, n c l u d i n g
t h er a d i a ld i f f u s e ra n dt h e rows o f c r o s s o v e rg u i d ev a n e s , were g e n e r a t e db y
EDM. One o ft h es e t u p sf o rf o r m i n gt h ed i f f u s e rv a n e s i s shown i nF i g .9 3 .
The t h r e ec o m p o n e n t sp r i o rt oa s s e m b l y a r e shown i n F i g . 9 4 .

After a l l theinternalpassages were e s t a b l i s h e d ,t h ec o m p o n e n t s were j o i n e db y

EB w e l d i n g ,a n dt h ea s s e m b l y w a s h e a tt r e a t e da n df i n i s hm a c h i n e d . A 0.254 mm
(0.010 i n c h ) t h i c k s i l v e r p l a t i n g w a s a p p l i e dt ot h ei m p e l l e rl a b y r i n t hl a n d s .

Impellers.
-__I The i m p e l l e r s were f a b r i c a t e d f r o m s i n g l e p i e c e s o5.OA1-2.5Sn f
t i t a n i u mf o r g i n g s .E x t e r n a lf e a t u r e s ,h u b s ,a n d s p l i n e s were machined bycon-
v e n t i o n a lm e t h o d s . The i n t e r n a l f l o w p a s s a g e s were g e n e r a t e db y EDM f r o mt h e
i n l e ta n dd i s c h a r g es i d e . A t y p i c a l EDM s e t u pi nw h i c ht h ev a n el e a d i n ge d g e s
were formed i s i l l u s t r a t e di nF i g .9 5 .

C o n s i d e r a b l e d i f f i c u l t y was e x p e r i e n c e d i n o b t a i n i n g a satisfactorypassage
s h a p ei nt h et r a n s i t i o nz o n eb e t w e e nt h ei n l e ta n dd i s c h a r g eb e c a u s eo ft h e
l a c ko fa c c e s s i b i l i t yw i t ha ni n t e g r a lf r o n ts h r o u d .S e v e r a lr e w o r k s were made
i nt h a ta r e at oe l i m i n a t ed i s c o n t i n u i t i e sa n dp r o t r u s i o n si nt h ef l o wc h a n n e l .
The d e l i v e r e d i m p e l l e r s d e v i a t e d somewhatfrom t h ed r a w i n gi nt h a tt h ev a n e sd i d
nothave a continuous t w i s t f r o mi n l e tt od i s c h a r g e ,a n di nc e r t a i na r e a st h e
v a n e s were u n d e r s i z e . A s a r e s u l t o ft h ed i f f i c u l t i e se n c o u n t e r e di np r o d u c i n g
t h e i m p e l l e r s t o p r i n t , a d e s i g n m o d i f i c a t i o n was made i n w h i c ht h e impeller i s
f a b r i c a t e d i n two p i e c e sa n dj o i n e d by EB w e l d i n g . The d e t a i l s of t h i sa p p r o a c h
a r e d e s c r i b e de l s e w h e r ei nt h i sr e p o r t .

Each of t h ec o m p l e t e di n t e g r a li m p e l l e r s w a ss u b m i t t e dt op r o o fs p i n n i n g ,i n
whichthey were s p u n up t o a s p e e do f8 3 7 6r a d / s( 8 0 , 0 0 0 rpm) a t ambient t e m p e r -
a t u r e . No f a i l u r e so rp e r m a n e n td e f o r m a t i o n s were e n c o u n t e r e d .

A f i n i s h e ds e c o n d - s t a g ei m p e l l e r i s shown i nF i g . 96. The t h r e ei m p e l l e r s

s t a c k e d on the r o t o ra r ei l l u s t r a t e di nF i g .9 7 .

TurbineWheels. The t u r b i n ew h e e l s were machinedfrom i n t e g r a lA s t r o l o yf o r g -

i n g s .B e c a u s eo ft h ei n t e g r a ls h r o u d a t t h eo u t e rd i a m e t e ro ft h ew h e e l ,t h e
b l a d e s u r f a c e s were g e n e r a t e d by t h e EDM fromtheupstreamanddownstream side,

126
 Figure 87. Pump I n l eHt o u s i n g

127

L
 lXY52-10/2/74-ClL*

Figure 88. Mark 48-F I n l e t Housing Guide Vane Pantographing

128
I

Figure 89. Partially Completed Mark 48-F Inlet Housing

129
Y
w
0

F i g u r e 90. Mark 48-F I n l e tH o u s i n g s

 10 VANES
4 VANES (CONCEPTUAL)
(CONCEPTUAL) Y/A

Figure 91. Mark 48-F Turbopump Axial E n t r y Pump Inlet

Figure 92. Crossover Fabrication

131
 lXY52-8/19/74-C1 1*

Figure 9 3 . Mark 48-F Diffuser EDM Setup

 1xY52-11/21/74-c1c*
F i g u r e 94. LH Pump Crossover Details Before Welding
2
 lXY52-10/2/74-ClH*
Figure 95. Impeller EDM-ing Set-Up

134
 lXY25-5/15/75-ClD*
Figure 96. Second Stage Impeller

Figure 97. LH2 Turbopump Rotor

 respectively. All b l a d e s u r f a c e s were f o r m e dc o n c u r r e n t l yw i t h a one-piece
e l e c t r o d e , shown i n F i g .9 8 .T h el i g h t e n i n gh o l e s a t t h ec e n t e ro ft h eb l a d e s
were a l s o formedby EDM. T h ec o m p l e t e df i r s t -a n ds e c o n d - s t a g ew h e e l s are shown
i n F i g .9 9w i t ht h ec e n t e r tie bolt.

Housing.Themostcomplexcomponentoftheturbopump t o f a b r i c a t e w a s t h eh o u s -
ing. It i n c o r p o r a t e d ,i n a s i n g l ew e l d e ds t r u c t u r e ,t h e pump t h i r d - s t a g ed i f -
f u s e ra n dd i s c h a r g ev o l u t ea n d ,o nt h et u r b i n ee n d ,t h ei n l e tm a n i f o l da n df i r s t -
s t a g en o z z l e( F i g . 100). I n i t s i n i t i a l s t a g e so fm a n u f a c t u r e ,t h eh o u s i n g was
f a b r i c a t e d i n two s e p a r a t eg r o u p s . The c o n s t r u c t i o no ft h eh o u s i n g is illus-
t r a t e di nF i g . 100.Thechronologyofprocessing i s d e p i c t e di nF i g . 101.

The pump endof t h eh o u s i n g w a s machinedfrom two m a j o rf o r g i n g s . The-003

c o m p o n e n t ,w h i c hc o n t a i n e dt h et h i r d - s t a g ed i f f u s e r , w a s machinedfroman
I n c o n e l 718 f o r g i n g ,w i t ht h ed i f f u s e rv a n e sf o r m e db y EDM ( F i g . 101, s t e p 1).
The c o n t o u r so ft h e -005 v o l u t ec a p( F i g .1 0 1 , s t e p 2 ) were machinedbypanto-
g r a p h i n g( F i g .1 0 1 ,s t e p 3 ) fro mIn c o n e l7 1 8 ,a n dt h e two pieces were j o i n e d
by EB w e l d i n g( F i g .1 0 1 ,s t e p 4 ) . T r a n s i t i o nr i n g s (-027and-029)ofHaynes
188 material were a t t a c h e d ,b y EB w e l d i n g , i n t h e area w h e r et h et u r b i n em a n i -
f o l d w a s t ob ej o i n e dt ot h e pump h o u s i n g . A t t h i s s t a g e , t h e pump e n do ft h e
~ h o u s i n g was h e a t r e a t e dt oI n c o n e l 7 1 8 s p e c i f i c a t i o n s( F i g . 101, s t e p 5 ) .
~

i The f a b r i c a t i o n o f t h e t u r b i n e m a n i f o l d p r o g r e s s e d i n a paralleleffortwith
t h ea b o v e , as shown i n F i g . 1 0 1 . The t u r b i n ef i r s t - s t a g en o z z l e was made from
Haynes 188 a l l o y by EDM o ft h ef l a wp a s s a g e s( F i g . 1 0 1 , s t e p 1). A 1 . 5 2 mm
( 0 . 0 6 0i n c h )t h i c kl i n e was c o n s t r u c t e df r o mI n c o l o y9 0 3s h e e t metal t or e d u c e
t h e r m a lg r a d i e n t sa c r o s st h em a i np r e s s u r e w a l l s . The c o n t a c t i n gs i d eo ft h e
~

l i n e r was e t c h e dt op r o d u c el o c a lh i g hs p o t sa n dt h e r e b yr e d u c et h es u r f a c e
area i n c o n t a c t . The l i n e r was i n s t a l l e d" l o o s e 1 'b e t w e e nt h e two m a n i f o l dh a l v e s ,
i . e . , w i t h o u tw e l da t t a c h m e n tt oa l l o w i t t o e x p a n da n dc o n t r a c tw i t h o u tc o n -
s t r a i n t s( F i g .1 0 1 ,s t e p 11).

Thetwo m a n i f o l dh a l v e s were machinedfromRene' 4 1 a n da s s e m b l e db yt u n g s t e n

i n e r tg a s (TIG) w e l d i n g( F i g . 101, s t e p1 1 1 ) .P a r t so ft h em a n i f o l d ,w h i c h were
a n a l y t i c a l l yp r e d i c t e dt ob es u b j e c tt oh i g hs t r a i n , were p l a t e d ( F i g . 1 0 1 ,
s t e p I V ) 0 . 0 7 6t o0 . 2 5 mm ( 0 . 0 0 3t o0 . 0 1 0i n c h )t h i c kw i t hc o p p e rt op r o v i d e
hydrogen-environment-embrittlement p r o t e c t i o n H . aynes 188 t r a n s i t i o nr i n g s
were w e l d e d t o t h e t u r b i n e m a n i f o l d i n two a r e a sw h e r e i t was t o b e a t t a c h e d
t o t h e pump v o l u t e h o u s i n g .

A t t h i ss t a g e( F i g .1 0 1 , step V), t h e w e l d e d m a n i f o l da s s e m b l y was h e a t t r e a t e d

t o Rene' 4 1 s p e c i f i c a t i o n .

The w e l d e da n dh e a t - t r e a t e d pump h o u s i n ga n dt u r b i n em a n i f o l d were j o i n e d ( F i g .

101, s t e p 6 ) by EB w e l d i n g a t t h e Haynes188 t r a n s i t i o nr i n g s . The r i n g s were
of s u f f i c i e n t l e n g t h t o leave t h eh e a t - t r e a t e dI n c o n e l7 1 8a n dR e n e ' 4 1 on t h e
pump a n dt u r b i n ee n du n a f f e c t e db yt h ew e l dh e a t i n g .A f t e rt h ef i n a lw e l d i n g
was a c c o m p l i s h e d , t h e h o u s i n g i n t e r n a l f e a t u r e s a n d f l a n g e s were f i n i s h machined
t op r i n tr e q u i r e m e n t s( F i g . 101, s t e p7 ) .

136
 1XY52-8/19/74-C1L*
Figure 98. Turbine Wheel MachiningSet-up & Electrode
 !

lXY25-5/15/75-ClC*
F i g u r e 99. T u r b i n e Wheels ti C e n t e r Tie B o l t
t
 Turb opump As semb l y

R o t o rB a l a n c e .B e c a u s eo ft h eh i g ho p e r a t i n gs p e e d si n v o l v e d and t h es t a c k e d
rotorconfiguration,thebalancingprocedurehadtoeliminateinternal moments
r e s u l t i n g f r o m componentimbalance, as w e l l as moment a n d f o r c e v e c t o r i m b a l a n c e
oftherotor as a u n i t . To a c c o m p l i s h t h i s , b a l a n c i n g was performed as f o l l o w s :

1. The f i r s t - a n dt h i r d - s t a g ei m p e l l e r sw e r ea s s e m b l e d on t h e s h a f t w i t h
a s h o r ts p a c e rb e t w e e nt h e m . Two turbopump b e a r i n g s ,a x i a l l yp r e l o a d e d
i n t h e b e a r i n g sleeves as i n t h e turbopump i n s t a l l a t i o n , were u s e d t o
s u p p o r tt h er o t o ro ne i t h e re n d . Temporary wax c o r r e c t i o n s were made
i nt h e - p l a n e so ft h e two i m p e l l e rs h r o u d s . To e n s u r et h a tt h es p a c e r
betweentheimpellers w a s notaffectingthemeasuredimbalance, its
a n g u l a r p o s i t i o n w a s r o t a t e d1 . 5 7r a d (180 d e g r e e s ) r e l a t i v e t o t h e
o t h e r p a r t s , and dimensionalmeasurements were r e p e a t e da n dt h ea m o u n t
ofimbalancecompared. N o s i g n i f i c a n td i f f e r e n c e w a s n o t e d .

2. The s ec o n d -s t a g e i m p e l l e r w a s i n s t a l l e d i n p l a c e o ft h eb a l a n c es p a c e r
and i t s imbalance w a s d e t e r m i n e d , m a i n t a i n i n g c o n s t a n t t h e wax c o r r e c -
t i o n s on t h e f i r s t - a n dt h i r d - s t a g ei m p e l l e r s . Wax c o r r e c t i o n was
a p p l i e dt ot h es h r o u do ft h es e c o n d - s t a g e impeller.
3. The t u r b i n ew h e e l s were a d d e dt ot h er o t o ra s s e m b l y ,a n dt h e i ri m b a l a n c e
w a s t e m p o r a r i l yc o r r e c t e dw i t h wax.The b a l a n c ea s s e m b l y i s shown i n
theGisholtcradleinFig. 102.
4. R e p e a t a b i l i t yc h e c k s were p e r f o r m e dt oe n s u r et h a tt h ei m b a l a n c e re-
m a i n e dw i t h i na na c c e p t a b l et o l e r a n c eb a n d on r e p e a t e d d i s a s s e m b l i e s
an drea s s em b l i e s .
5. F i n a lb a l a n c ec o r r e c t i o n sw e r e made by g r i n d i n g material fromeach
impeller s h r o u d ,t h et u r b i n ed i s k s , and t h ei n s t r u m e n t a t i o nn u t .

The f i n a l r u n o u t m e a s u r e m e n t s o f t h e c r i t i c a l surfaces a r e n o t e d i n F i g . 103.

The G i s h o l t b a l a n c i n g m a c h i n e u s e d i s c a p a b l e of d e t e c t i n g a d i s p l a c e m e n t of
0.0006 mm ( 2 5p ' i n c h e s ) . With t h ew e i g h t of 3.746kg ( 8 . 2 5p o u n d s )o ft h e Mark
48-F r o t o r , t h i s t r a n s l a t e s i n t o a r a d i a l l o a d of227 N ( 5 1p o u n d s ) a t 9946
r a d / s (95,000 rpm) s h a r e db yt h ef o u rt u r b o p u m pb e a r i n g s . The f o r e g o i n gc o r r e s -
ponds t o an i n b a l a n c e of0.22g c m (0.09 g i n c h ) ; t h e r e p e a t a b i l i t y c h e c k i n d i -
cated a variationinthemeasuredinbalance of0.127 g cm ( 0 . 0 5 g i n c h ) , w h i c h
would r e s u l t i n a r a d i a ll o a do f 1 2 5 N ( 2 8p o u n d s ) .E i t h e ri n b a l a n c e level i s
c o m p a t i b l ew i t ht h ec a p a b i l i t yo ft h eb e a r i n g s .

TurbopunpAssemblyProcedure.Thebuildupoftheturbopump w a s accomplished i n
t h ef o l l o w i n gs e q u e n c e : I-
..
1. P a r t s were c l e a n e df o r LH2 s e r v i c e .
2. F r o n ta n d rear b e a r i n gi n n e r - r a c es p a c e rt h i c k n e s s e s were e s t a b l i s h e d
toprovidetheproperbearingpreloads.
3. The t h i c k n e s s of t h et u r b i n ew h e e l spacer w a s e s t a b l i s h e d t o p r o v i d e
thepropernozzle-to-rotoraxialclearance.

140
 L

L
, . .i . I .. I

. .. . .

?
 . .
. . .

.. '

... . .
'L
,
...
.
- i.1. .
. . 6

. . ... .
, .

..
1

Figure 101. Mark 48-F Housing

Fabrication Process

I 141
Figure102. Mark 48-F Balancing Setup
 0
0
0
.. .. ..
0 0
7
0
m . - b
I-
a
Ia- +a
hl
0
0
0
0
a - m a m
0 0 0 0
hl
0
“03UI
0 0 0 0
cv
0
C Q ~ 0 3 mM
0000 0
-
0
c
0
rnN
0 -
-ai
- 0
0 0 0 0 0 0 0 0000 0 0 0 0 0 0 0
. . . .
0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0000 0 0 0 0 0 0 0
0 0 0 0

I
t-
. . . . . ”-. ..

oooc)
In
.. mu3....
M O O 0
Ln .. ....
\D mm ‘.. \o
kt-++ t- I-
a a a a I- ai-+ I- a
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0 0 0 0
0 0 0 0
-
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000
03
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0 0 0 0
dddd
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000
000
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0

Fi g u re 103. Mark
48-F Balance Assembly R a d i a l Runouts(TIR, inch)
 4. The t h i c k n e s s o f t h e b a l a n c e p i s t o n l o w - p r e s s u r e o r i f i c e r i n g was
established to obtainthedesiredbalancepiston travel.
5. Dimensions were t a k e n t o e s t a b l i s h t h e a x i a l p o s i t i o n of t h e i m p e l l e r s
when b o t t o m e d o n t h e a d j a c e n t p a r t s t o p e r m i t c a l c u l a t i o n o f minimum
clearances later i n t h e b u i l d .
6. B e a r i n g ,s h a f t s e a l , a n di m p e l l e rr a d i a lc l e a r a n c e s were measured.
7. The r o t o r a s s e m b l y was b a l a n c e d .
8. The b a l a n c e p i s t o n l o w - p r e s s u r e o r i f i c e r i n g was installed.
9. The r e a r b e a r i n g c a r t r i d g e f r o n t a n d rear s h i m t h i c k n e s s e s were e s t a b -
l i s h e db yp e r f o r m i n g a rotorpush-pull test w i t h a p a r t i a l l y a s s e m b l e d
turbopump a t a m b i e n tt e m p e r a t u r e .
10. A " co l d "c h ec k w a s performed a t LN2 t e m p e r a t u r e t o d e t e r m i n e a n d a d j u s t
t h eb e a r i n gl o a d a t z e r op i s t o nl o w - p r e s s u r eo r i f i c ec l e a r a n c e .
11. The p a r t i a l a s s e m b l y u s e d f o r r o t o r p u s h - p u l l t e s t s was d i s a s s e m b l e d ,
l e a v i n gi nt h eh o u s i n gt h eb a l a n c ep i s t o nl o w - p r e s s u r e seal, s h a f t ,
rear b e a r i n gp a c k a g e ,s h a f t s e a l , a n dt h et h i r d - s t a g ei m p e l l e r .
12. S u c c e s s i v e l y ,t h es e c o n d - s t a g ec r o s s o v e r ,s e c o n d - s t a g e impeller, f i r s t -
s t a g ec r o s s o v e r ,f i r s t - s t a g ei m p e l l e r ,a n dt h ei n l e th o u s i n g were
a s s e m b l e d ,m e a s u r i n gf o re a c hs t a g et h e minimum a x i a l c l e a r a n c e s .
13. The f r o n t b e a r i n g p a c k a g e w a sa d d e da n dt h es h a f t was p r e l o a d e db y
s t r e t c h i n go na nI n s t r o nt e n s i l e t e s t e r t o 5 4 , 7 0 0 N (12,300pound)
l o a d ,t o r q u i n gt h er e t a i n i n gn u tw h i l et h es h a f t was u n d e rt e n s i l e
l o a d . A t o t a l s t r e t c h of0.686 mm ( 0 . 0 2 7i n c h ) was o b t a i n e d on t h e
shaftinthis manner.
14. The b e a r i n g p r e l o a d s were v e r i f i e d a t a m b i e n ta n d LN2 t e m p e r a t u r e s .
15. The t u r b i n e w a s a s s e m b l e d b y i n s t a l l i n g t h e w h e e l s p a c e r , r e t a i n i n g
s t u d s ,f i r s t - s t a g ew h e e l ,s e c o n d - s t a g en o z z l e ,s e c o n d - s t a g ew h e e l ,
r e t a i n i n gn u t s ,a n dw h e e lc o v e r .A x i a l minimum a n db l a d e - t o - b l a d e
c l e a r a n c e s were e s t a b l i s h e d a t e a c h s t e p .
16. On t h e pump i n l e t e n d , t h e i n s t r u m e n t a t i o n n u t a n d f r o n t c o v e r were
i n s t a l l e d a n dt h es p e e dp i c k u p ,t e m p e r a t u r et r a n s d u c e r s ,a n dB e n t l y
p r o x i m i t y t r a n s d u c e r s were a d d e d .
17. E l e c t r i c a l c h e c k s were p e r f o r m e d , :i:1d t h e pump was l e a k - c h e c k e dw i t h
g a s e o u sh e l i u m (GHe) a t 2 1 N/cm2 (30 p s i g ) .

The c l e a r a n c e s m e a s u r e d r e l a t i v e t o t h e f r o n t b e a r i n g a n d i n s t r u m e n t a t i o n p r o b e s
a r e shown i nF i g .1 0 4 .F i g u r e1 0 5 s h o w st h ei m p e l l e rl a b y r i n t hr a d i a lc l e a r -
a n c e s .I nF i g .1 0 6 ,t h ec l e a r a n c e sr e l a t i n gt ot h er e a rb e a r i n g s and s h a f t
s e a l are p r e s e n t e d . The a x i a lc l e a r a n c e sb e t w e e nt u r b i n ec o m p o n e n t s are n o t e d
i nF i g .1 0 7 . The r a d i a l c l e a r a n c e si nt h et u r b i n e ,a se s t a b l i s h e dd u r i n gt h e
c a l i b r a t i o nb u i l d ,a r ei n c l u d e di nF i g . 108.

1 44
 .oog mm (.0003 i n )
Speed Pickup 1.067 mn
.061 mm ( .0024 in)
( . 0 4i n2 ) 1“
in)

Bently
1 . 4 4 8 mm
(.OS7 in)

R a d i a lB e n t l y s
oo
90’
= .914 mm (.036 i n )
= - 9 4 0 mm (.037 in)
1-1 - I 1 I .004 mm (.00015 i n )

Figure 104. Mark 48-F S/N 01-0 Assembly Instrumentation

and Front Bearing Clearances
 .196 mm (.0077 i n ) .180 mm (.0071 i n )
.213 mm (.0084 in) .185 mm (.0073 i n )
.196 mm (.0077 i n ) ,170 mm (.0067 in) .206 mm (.0081 i n )

.185 mm (.0073 i n ) .193 mm (.0076 i n ) .203 nun (.008 i.n)

,132 mm (.0052 i n )
.172 mm (.0068 i n ) .157 mm (.0062 in)

.168 mm (.0066 i n ) .132 mm (.0052 i n )

F i g u r e 105. Plark 48-F S/N 01-0 A s s e m b l yI m p e l l e r Labyrinth C l e a r a n c e s

 .008 mm (.0003 in)

- .010 mm (.0004 in)

..084 mm (.0033 in)

.079 mm (.0031 in)

--- //
F i g u r e 106.
--.015

-.020
mm (-,0006 in)

mm (- .0008 in)

Mark 48-F T u r b i n e S/N 01-0 Axial C l e a r a n c e s

147
 2.997 mm (.118 in)

3.226 mm (.127 in)

I 3.302 mm (.130 in)

-
1.626 mm (.064 in) L, 7 in)

.610 mm (.024 in) 1.346 nun (.OS3 in)

F i g u r e 107. Mark 48-F T u r b i n e S/N 01-0 A x i a lC l e a r a n c e s

148
 1.575 rnrn dia.
(.062
/- in)

.711 rnmdia.
(.028 in)

. 1 2 7 mm dia.
( . 0 0 5 in)

I
I .165 rnm dia
I ! (.0065 in)

.193 mm dia
( ~ 0 7 6in)

. 1 2 7 mm dia
(.005 i n )

I
.660 mm dia.
(.(I26 i n )

1.
.E13 m l ~ :dia.
(.032 in)

F i g u r e 108. Mark 48-F T u r b i n e S/N 01-0 R a d i a lC l e a r a n c e s

149
 Each of t h e two p a i r s o f b e a r i n g s i s p r e l o a d e d i n t e r n a l l y bytwo Belville s p r i n g s
l o c a t e d a t t h e o u t e r races. A minimum a x i a l l o a d o f 431 N ( 9 7 pounds) i s r e q u i r e d
t o p r e v e n t t h e b a l l s f r o m s k i d d i n g on t h e races a t t h e d e s i g n s p e e d o f 9946 r a d / s
(95,000 rpm). The a c t u a l p r e l o a d o n t h e b e a r i n g s i s m e a s u r e db yb u i l d i n g a pre-
l i m i n a r ya s s e m b l yc o n s i s t i n go f t h e two b e a r i n g s , t h e b e a r i n g c a r t r i d g e , two
B e l v i l l e s p r i n g sa n dt h ei n n e r race s p a c e r . With the i n n e r race s t a c kc l a m p e d
a x i a l l y t i g h t w i t h a t o o l , t h e a x i a l m o t i o no ft h eo u t e r races as a f u n c t i o n o f
a p p l i e dl o a d i s measured. The inner race s p a c e r thickness i s a d j u s t e d u n t i l
the r e q u i r e dp r e l o a d i s o b t a i n e d . The a c t u a ll o a dc u r v e ,o b t a i n e df o rt h e pump
a n dt u r b i n ee n db e a r i n g s i s shown i n F i g . 1 0 9 a n d 110, r e s p e c t i v e l y .

The pump e n d b e a r i n g c a r t r i d g e i s f r e e t o move i n s i d e t h e i n l e t h o u s i n g b o r e ;

t h e r e f o r e ,t h e .s p r i n gp r e l o a d s a r e t h eo n l ya x i a ll o a d se x p e r i e n c e db yt h o s e
b e a r i n g s .I nc o n t r a s t ,t h et u r b i n e e n db e a r i n gc a r t r i d g e i s r e s t r a i n e da x i a l l y
s o t h a tt h o s eb e a r i n g s w i l l restraintherotorpositionwithincertain limits.
The p l a n n e d r o t o r p o s i t i o n / a x i a l l o a d r e l a t i o n s h i p is i l l u s t r a t e d i n F i g . l l l .
The o b j e c t i v e i s t oh a v et h eb e a r i n g sa b s o r b1 7 9 3 N ( 4 0 3 pounds) of r o t o r a x i a l
l o a dt o w a r dt h et u r b i n es i d e a t t h ep o i n tw h e r et h eb a l a n c ep i s t o nl o w - p r e s s u r e
o r i f i c e s f a c e s come i nc o n t a c t ,a n ds i m i l a r l ya b s o r b1 7 7 9 N (400 pounds)ofload
t o w a r dt h ed i r e c t i o no ft h e pump when t h e b a l a n c e p i s t o n h i g h - p r e s s u r e o r i f i c e s
a r e a x i a l l ya l i g n e d .T h i s w i l l h o l dt h er o t o ri nt h ed e s i r e dp o s i t i o n static-
a l l y and d u r i n gt h el o w - s p e e dt r a n s i e n tp h a s e .

To o b t a i n t h e a c t u a l b e a r i n g l o a d s v e r s u s r o t o r a x i a l p o s i t i o n c h a r a c t e r i s t i c s ,
a p u s h - p u l l t e s t i s made, i n w h i c ha x i a ll o a d i s a p p l i e dt ot h er o t o rt h r o u g h
a f o r c eg a g e ,a n dr o t o rm o t i o n i s m o n i t o r e dw i t hd i a lg a g e s . The s e t u p i s
i l l u s t r a t e di nF i g . 1 1 2 . Ad j u s t m e n t s a r e made i nt h et h i c k n e s so ft h es h i m s
l o c a t e do ne i t h e re n d of t h e b e a r i n g c a r t r i d g e u n t i l t h e d e s i r e d l o a d - t r a v e l
r e l a t i o n s h i p i s o b t a i n e d . The r e s u l t s o ft h ep u s h - p u l l tests obtained a t
a m b i e n tt e m p e r a t u r e a r e shown i n F i g . 1 1 3 . The t e s t i s r e p e a t e dw i t ht h e pump
c h i l l e dw i t h LN2 t os i m u l a t ec r y o g e n i cc o n d i t i o n s . The r e s u l t so b t a i n e d on t h e
c o l dp u s h - p u l l t e s t a r e p r e s e n t e di nF i g . 114.

The LN2 loadcheck was p e r f o r m e do n l yt o w a r dt h el o w - p r e s s u r es i d eb e c a u s e , at

z e r os p e e da n dp r e s s u r e , a f o r w a r dl o a d of 1780 N (401) pounds) i s a c h i e v e d a t
a n e g a t i v eh i g h - p r e s s u r eo r i f i c ea x i a lc l e a r a n c e .T h i s , combined w i t ht h ef a c t
t h a t a t c r y o g e n i ct e m p e r a t u r e st h e r e i s a r a d i a l o v e r l a p o ft h eo r i f i c e s ,c o u l d
damage t h e o r i f i c e s i f a s i g n i f i c a n tl o a dt o w a r d the. pump s i d e were imposed.

Turbopump Weights

D u r i n ga s s e m b l y ,t h ep r i n c i p a lc o m p o n e n t so ft h et u r b o p u m p a s w e l l a s t h e com-
p l e t e du n i t was weighed. A breakdownofthemeasuredweights i s i n c l u d e di n
T a b l e 15.

150
 240

1 OO( -

200

8oc -

v) 600
z
0
t-
2
z
a
-
a
0
-1
400

200

0
0 0.002 0.004 0.006 0.008
/ D E F L E C T I O N , INCH
L I I I I
0 0.05 0.10 0.15 0.20
DEFLECTION, mm

F i g u r e1 0 9 . Mark
48-F F r o n tB e a r i n gP r e l o a d

151
 1-

I-

l -

I -

1 -

0
0 0.002 0.004 0.006 0.008
DEFLECTION, INCH
I I I I
0.15 0.10
0 0.05 0.20

DEFLECTION, mrn

F i g u r e 110. Mark 48-F R e a rB e a r i n gP r e l o a d

152
 I
1- NO. 3 BEARING
1, LOAD

1.

POSITION AT 21 K
0 A N D 3144 N l c d

ROTOR LOAD

Kg BOTTOMS

N U L L P O I N T A T21 K

I-
“HOUSING LOW PRESSURE
ORIFICE POSITION AT 294 K

- -1 K‘3 BOTTOMS
FRONT ORIFICE ALIGNED
294 K, 0 NlcrnZ

“
I
-- 1

K1BOTTOMS
OPERATING POSITION AT 21K, 3144 N/crn2

-
I
I fi”--

I
FRONT ORIFICE ALIGNED, 21 K,

I I
3144 N/crn2

I I
0.25 0.20 0.15 0.10 0.05 0

15 3
 500 -
I -492
1- NO. 3 BEARING
I LOAD

400 -

z
300 -
u
w
HOUSING LOW-
E PRESSUREORIFIC
0 POSITION AT 423f
w 0 A N D 4 5 6 0PSlG
z -
m
U
200
3 ROTOR LOAD
I-
I11-

1-
a
s 4
IWHOUSING Kg BOTTOMS

LOWPRESSURE
ORIFICE POSITION AT70'
NULL P O I N T A T 4 2 3 F

-CARTRIDGE BOTTOMS

I -1 F R O N T O R I F I C E S A L I G N E D 4 2 3F , 0 PSlG

-1 K'3 BOTTOMS

-
I- f-" FRONT ORIFICE ALIGNED
-70 F, 0 PSlG

-
I-, OPERATING POSITION AT 423 F, 4560 PSlA

-500 I
- I
K, BOTTOMS

F R O N T O R I F I C E A L I G N E D , 4 2 3F, 4560 PSlA

I I I
0.010 0.008 0.006 0.004 0.002 0

h2 (INCH)

F i g u r e 111. Mark48-F Turbopump BearingLoads vs P i s t o n Position

(English Units

154
 lHS54-2/19/76-C2*
Figure 112. Mark 48-F Turbopump Assembly Push/Pull Setup
 I 600
't
5OC

40C

DRAG-
30C
1200
2 o o l
h
z
0
-
l-
800 -
V
W
-
cz
n
w 400-
-
z
m
cz
3
I-
0-
z
-
+
v

vr
z -400
0
-
I-
5z
2 -800 -
u
e
0
LL

-1200 -

- 1600 -

TRAVEL, INCH
I I I 1
0.30 0.20 .25 0.15 0.10 0.05 0
TRAVEL, rnm

F i g u r e 113. M a r k 48-F B e a r i n gP r e l o a d , Ambient T e m p e r a t u r e

156
-- lI600
zo0L -3001
TRAVEL, I NCH

0.30 0.25 0.20 0.15 0.10 0.05 0

TRAVEL, mm

F i g u r e 3.14. Mark48-F B e a r i n gP r e l o a d , LN2 Temperature

157
 TABLE 15. MARK 48-F TURBOPUMP WEIGHTS

-~

r"
~

Weight
kg pounds
Pump In1 et
5.0 1 1 .o
Housing (including GG) 22.7 50.0
First-Stage Crossover 4.5 10.0
Second-Stage Crossover 4.0 9.0
Turbine Second-Stage Nozzle 0.2 0.5
Turbine First-Stage Wheel 0.54 1.2
Turbine Second-Stage Wheel 0.54 1.2
Shaft 0.45 1 .o
First-Stage Impeller 0.45 1 .o
Second-Stage Impeller 0.4 0.9
Third-Stage Impeller 0.4 0.9
Miscellaneous 4.42 9.3
Tota 1 Weight 43.6 96.0
Rotor Weight 3.7 8.25

158
TESTING

G a s Generator Testing

To o p e r a t i o n a l l y c h a r a c t e r i z e t h e LH2 Mark 48-Fturbopumpassembly prior to

actualenginetesting, a g a sg e n e r a t o r. a s s e m b l y (P/NRs005024) w a s developed
a n dh o t - f i r et e s t e d . The g a sg e n e r a t o ra s s e m b l y w a s t e s t e di nt h eP r o p u l s i o n
Research Area (PRA) a t R o c k e t d y n e ' sS a n t aS u s a n aF i e l dL a b o r a t o r y( S S F L ) . The
3447 N/cm2 ( 5 0 0 0 - p s i ) p r o p e l l a n t t a n k r a t i n g s p r o v i d e d s u f f i c i e n t o p e r a t i n g
m a r g i nf o rt h er e q u i r e dg a sg e n e r a t o rr a t e dc h a m b e rp r e s s u r eo f 2344 N/cm2
( 3 4 0 0p s i a ) .F i g u r e s 115 and116 show t h eg a sg e n e r a t o ri n s t a l l a t i o n i n the
L i m a s t a n d o f PRA.

The LH2 tu rb o p u m pg a sg en e ra t o r test program w a s c o n c l u d e d s u c c e s s f u l l y a f t e r

a t o t a lo f1 5h o t - f i r e t e s t s . N i n eo ft h e s e tests were c o n d u c t e do ni n j e c t o r
u n i t No. 2 , w h i l e t h e r e m a i n i n g tests were conducted on i n j e c t o r u n i t No. 3 .
T a b l e s 1GA and 16B are p erfo rm a n c es u m m a r i e so ft h o s e tests c o n d u c t e dd u r i n g
t h ed e v e l o p m e n th o t - f i r ep r o g r a m .

Thr eeanoma l i e s were u n c o v e r e dd u r i n gt h et e s t i n ge f f o r t : (1) i g n i t e r ceramic

c r a c k i n g ,( 2 )f a i l u r et oa c h i e v ei g n i t i o n on s e v e r a l tests a n d , ( 3 ) h o ts t r e a k s
and a moderateamountoferosion a t t h ec o m b u s t o rb o d yi n t e r n a l wall. The
i g n i t e r ceramic c r a c k i n g p r o b l e m w a s r e s o l v e d by r e d u c i n g t h e c h a m b e r p r e s s u r e
b u i l d u p r a t e b ys l o wi n g down t h e o p e n i n g r a t e o ft h em a i n LO2 v a l v e .

I n t h e case o f t h e f a i l u r e o f t h e i g n i t e r t o a c h i e v e i g n i t i o n , t h e c a u s e h a s
beenattributedtothelack of a s p a r k a t d e s i g n e d a i r gap l o c a t i o n ( e l e c t r o d e /
i g n i t e ra d a p t e rm a n i f o l d ) .A c t u a ls p a r kc u r r e n tf l o w w a s r e c o r d e df o rt h e s e
tests (016-022, -023, a n d - 0 2 4 ) , b u t t h e p r e f e r e n t i a l c u r r e n t p a t h was deter-
mined t o b e a c r o s s t h e s p a r k p l u g c e r a m i c t o s p a r k p l u g o u t e r s h e l l , a n area
s h i e l d e d by t h eb o r o nn i t r i d ec a p . Any o x y g e ng a si o n i z e d by t h e s p a r k i n
t h i sl o c a t i o nw o u l dh a v e little chancetoreachtheigniterinjection area
due t o t h e t o r t u r o u s p a t h l e n g t h . The b o r o nn i t r i d ec a p w a s removed p r i o r t o
test 016-025, b u t t h e f o r w a r d e n d p i e c e o f b o r o n n i t r i d e was retained in the
as s embly. Each s u b s e q u e n t t e s t a c h i e v e di g n i t i o nw i t h o u ti n c i d e n t .

F i v eh o ts t r e a k s were o b s erv ed i n t h e c o m b u s t o r d u r i n g t h e t e s t i n g o f t h e two

LH2 t u r b o p u m pg a sg e n e r a t o ri n j e c t o r s .I nt h ec a s eo fi n j e c t o ru n i t No. 2 ,
t h eh o ts t r e a k sa p p e a r e do n l y as s u r f a c e d i s c o l o r a t i o n s a f t e r t h e 7 . 3 - s e c o n d
mains tage t e s t , a n dn oe r o s i o n w a s n o t e d .I nt h e case of i n j e c t o r u n i t No. 3 ,
o n eh o ts t r e a k( d o w n s t r e a mo fi n j e c t o re l e m e n t1 - 5 )p r o g r e s s e dt o a moderate
amountofcombustor w a l l e r o s i o n d u r i n g a 24-secondmainstage t e s t (016-029).
The e r o s i o n i s shown i n p h o t o g r a p h s o f F i g . 1 1 7 t h r o u g h 119.

Also d u r i n g t h e t e s t i n g e f f o r t , a n a s s o c i a t e d p r o b l e m was identified in that

a l a r g et e m p e r a t u r eg r a d i e n t w a s o b s e r v e d a t t h e e x i t o ft h ec o m b u s t o r . The
g r a d i e n t 2 4 4 K (440 R) f r o mt h e w a l l t o t h e c e n t e r o f t h e e x i t e l b o w was
r e c o r d e do na ne i g h t - t h e r m o c o u p l et e m p e r a t u r er a k e as shown i n F i g . 1 2 0 . The
g r a d i e n tv e r s u sd i s t a n c ef r o mt h e w a l l i s shown i nF i g .1 2 1 . A l s o , as shown,
thehotcore i s w e l l centeredwithintheflowstream,indicatingthatthesmooth

159
Figure 115. Gas Generator Installation
 lSM63-7/24/75-SlB
Figure 116. Gas Generator Installation
 TABLE 16A. LH2 TURBOPUMP GAS GENERATOR TEST SUMMARY (SI UNITS)

Test No. T e s t Type

Duration
sect
P
.c
N/cm
21I Combustion
Temperature, K
Oxidizer
Flowrate,
kg/s
Fue 1
Flowrate,
kg/s MR
Flow, Flow, Ignition

lgni t ion 2.0 96.5 708 0.0224 0.89 0.0252

016-019 1 8/15 Ignition 2.0 100 766 0.93 0.0245 0.0229
01 6-0208/20 Ma ins t a g e 1.5 2176 634 0.0184 0.0215 0.86
01 6-0218/20 Ma ins t a g e 5.0 21 96 729 0.0179 0.0213 0.84
01 6-0228/25 No I g n i t i o n
01 6-023 8/25 No I g n i t i o n
016-024 , 8/26 No I g n i t i o n
Ma ins t a g e 1.2 21 25 498 0.0181 0.0236 0.77
Ma i n s t a g e 7.3 2267 939 0.0131 0.0210 0.62
Ma in s t a g e 2.2 2267 746 0.0175 0.0234 0.75
Ma in s t a g e 3.5 221 8 70 1 0.0176 0.0225 0.78
Ma in s t a g e 24.0 21 91 898 0.0191 0.0225 0.85
Ma i n s t a g e 10.0 2375 82 1 0.0167 0.0195 0.85
Ma in s t a g e 22.0 2370 883 0.0173 0.0200 0.87
Ma in s t a g e 20.0 2374 98 8 0.0172 0.0212 0.81
" M a i n s t a g ed u r a t i o nd e t e r m i n e df r o mm a i np r o p e l l a n ti g n i t i o nt oc u t o f f
**LH turbopump i n j e c t o ru n i t No. 3
2
NOTE: Tests016-045, 046,and047wereconducted w i t ht h e9 0 - d e g r e em i t e r bend c o m b u s t o rc o n f i g u r a t i o n .
 TABLE 16B . L
H, TURBOPUMP GAS GENERATOR TEST SLJMMARY
L
(ENGLISH UNITS)

1
,I
I

.!
Test No.

016-018
016-019
I Test
, Date
1 1975

815
8/15
I
” !
Test Type

Ignition
Ignition
Duration
sec*

2.0
2.0
‘c’
psia

140
145
Cornbus t i o n
Temperature, R

1274
I379
Oxidizer
Flowrate,
1 b/sec

-
Fuel
Flowrate,
1 b/sec MR

-
Ox i d iz e r
Ignition
Flow
1 b/sec

0.0494
0.0505
Fuel
Ignition
F1ow
1 b/sec

0.0556
0.541
Ignition ’
MR

0.89
0.93
!

‘
~

i
’ 016-020 8/20 Ma ins tage 1.5 31 57 1141 2.543 0.61 0.0405 0.0473 0.86
1 016-021 8/20 Mainstage 5.0 3185 1312 2.747 0.72 0.0394 0.0469 0.84
i
~ 016-022 8/25 I No I g n i t i o n

~: 016-023 8/25 I
I No I g n i t i o n !’
01 6-024 8/26 I No I g n i t i o n I
01 6-025 8/26 Mains
89 tage
3083 1.2 7 1.726 4.445 0.61 0.0399 0.0521 0.77
01 6-026 8/26 Ma ins tage 7.3
1691 3289 2.071 3.267 0.94 0.0289 0.0464 0.62
,
““01 6-027 8/26 Ma ins3289
tage 2.2 1343 3.121 4.094 0.76 0.0385 0.0516 0.75
**016-028 8/26 3.5
Ma ins tage 1262 8 321 3.023 4.176 0.72 0.0388 0.0496 0.78
*%I
6-029 8/26 Ma ins tage 24.0 31 78 1617 -
3 052 3.286 0.93 0.0422 0.0497 0.85
**016-045 11/18 Ma ins tage 10.0 3445 1477 3.051 3.791 0.806 0.0368 0.0430 0.85
**016-046 11/18 Ma instage 22.0 3438 1590 3.123 3.553 0.879 0.0382 0.0441 0.87
**016-047 1 1 /26 Ma ins tage 20.0 3444 1778 3.187 3.273 0.972 0.0380 0.0468
i L

W a i n s t a g ed u r a t i o nd e t e r m i n e df r o mm a i np r o p e l l a n ti g n i t i o nt oc u t o f f
**LH2 turbopump i n j e c t o r u n i t No. 3
NOTE: Tests 016-045,046,and047were conductedwiththe90-degreemiter bend combustor c o n f i g u r a t i o n
Figure 117. Combustor I n t e r n a l E r o s i o n
 lHS35-9/9/75-C1C*
Figure 1 1 8 . Combustor I n t e r n a l Heat Marks
 lHS35-9/9/75-ClA*

Figure 119. Combustor Heat Penetration

166
NOTE: VIEW INTO DUCT TOWARD INJECTOR
TIC 1 TIC 1
1502 R 833 K

TIC 3 TIC 3
1680 R 933 K

TIC 5 TIC 5
1443 R 802 K
INSERTION DEPTHS SHOWN ARE APPROXIMATELY
3x SCALE-INDICATED DEPTHS (X.XXX")

F i g u r e 120. Thermocouple Rake I n s t a l l a t i o n and

TypicalTemperature"leasurements

THERMOCOUPLE INSERTION DEPTH, INCH

THERMOCOUPLE INSERTION DEPTH, cm

Fi g u re1 2 1 .C o m b u s t i o nT e m p e r a t u r e vs T h e r m o c o u p l eI n s e r t i o nD e p t h

167
 e l b o wc o u l db e a contributingfactorbyimposing some t y p e o f c e n t r i f u g e e f f e c t
o nt h ee x i tg a s e s . However, i t i s more l i k e l yt h a ti n j e c t o re l e m e n tf l o w s t r e a m
d e f l e c t i o n i s more l i k e l y a n d , t h e r e f o r e , p o s e s a more s i g n i f i c a n t p r o b l e m .

T h ec o m b u s t o ra n di n j e c t o r were s h i p p e d t o Canoga P a r k , C a l i f o r n i a f o r d e t a i l e d
a n a l y s i s .I n j e c t o ru n i t s 2 a n d 3 were water f l o w e d i n t h e l a b o r a t o r y i n t h e
a s - t e s t e dc o n d i t i o nt oe v a l u a t ea n yp o s s i b l ef l o wm a l d i s t r i b u t i o n .F i g u r e 1 2 2
shows t h e r e s u l t s o f t h e o x i d i z e r - s i d e f l o w d i s t r i b u t i o n tests o n i n j e c t o r
u n i t No. 3 ( p r o d u c e dc o m b u s t o re r o s i o n ) .N o t et h a tt h e two streams d i r e c t e d
t o w a r dt h eo u t s i d e( t o w a r dt h ec o m b u s t o rw a l l ) are t h e exact e l e m e n t sw h i c h
p r o d u c e dt h eh o ts t r e a k si nt h ec o m b u s t o r . The e l e m e n to nt h el e f t (1-5)
e r o d e dt h ec o m b u s t o r wall. T h esew a t e r - f l o w t e s t s were r u n a t low f l o w r a t e s .
andpressureswithnobackpressure;thefuelsideoftheinjector was
s i m i l a r l y water f l o wt e s t e dw i t h no g r o s sa b n o r m a l i t yn o t e d .I n j e c t o ru n i t
No. 2 was a l s o f l o w t e s t e d , a n d r e v e a l e d t h a t two LO2 stream e l e m e n t s ,w h i c h
were known t o p r o d u c e h o t s t r e a k s , were d i v e r t e do u t w a r dt o w a r dt h ec o m b u s t i o n
w a l l . The f l o w stream i m p i n g e m e n tp a t t e r nn o t e df o rt h e s ei n j e c t o r s was
r e p e a t e do v e r s e v e r a l fl o w t e s t s . T a b l e s 1 7 A and 1 7 B show t h ed a t ac o l l e c t e d
d u r i n g t h e water f l o w t e s t i n g o f i n j e c t o r u n i t No. 3.

F o l l o w i n gt h ew a t e r - f l o w t e s t s , t h e i n j e c t o r s were i n s p e c t e d d i m e n s i o n a l l y .
F i g u r e 1 2 3 i s a s c h e m a t i co ft h e LH2 i n j e c t o r u n i t 3 f a c e ,s h o w i n gt h e relative
l o c a t i o n sa n dt h ei d e n t i f i c a t i o n so ft h ee l e m e n t s . The a r r o w sn e x tt ot h e
element show t h e p o s t o f f s e t d i r e c t i o n as w e l l as t h e amountof o f f s e ti nr a d i a n s
( d e g r e e s ,m i n u t e s ) .F i g u r e1 2 3a l s ot a b u l a t e st h ea c t u a la n g u l a rm i s a l i g n -
ments . A similar i n s p e c t i o n w a s made on i n j e c t o r u n i t No. 2 ; a l l p o s t s were
w i t h i n 0.009 r a d i a n( 3 2m i n u t e s )o fn o r m a l i t y .T a b l e s 1 8 A a n d 1 8 B show t h e
r e s u l t so fi n j e c t o r u n i t 3 d i m e n s i o n a li n s p e c t i o n s .S i n c ei n j e c t o ru n i t 3 had
p r o d u c e dt h ee r o s i o no ft h ec o m b u s t o r , a m o r et h o r o u g ha n a l y s i so ft h es u s p e c t e d
e l e m e n t s (1-5 a n d 1-8) p l u so n ew h i c ha p p e a r e dt ob ew i t h i na c c e p t a b l et o l e r a n -
ces (2-3) w a s a c c o m p l i s h e d .F i g u r e 1 2 4 t h r o u g h 1 2 6 p r e s e n t st h er e s u l t so f
t h e c u pd i m e n s i o n so ft h o s ee l e m e n t s .G e n e r a l l y ,e l e m e n t s 1-8 a n d 2-3 a p p e a r e d
t oh a v et h e l e a s t amount o f a n n u l a r ( s l e e v e t o LO2 p o s t )d i m e n s i o n a ld i s c r e -
p a n c i e s ,w h i l ee l e m e n t 1-5 ( e r o d e d area o fc o m b u s t o r )h a st h em o s tp r o n o u n c e d
d i f f e r e n c e .E v a l u a t i o no fd i m e n s i o n LO2 d l( F i g .1 2 6 1 ,w i t hr e s p e c tt ot h e
g e o m e t r yo ft h ec o m b u s t o r , shows t h e LO2 p o s t s t o b e p o i n t i n gt o w a r dt h e wall
ofthecombus tor.T h i sa l i g n m en two u l dp ro du c e a h i g h - m i x t u r e - r a t i o ,h i g h -
t e m p e r a t u r er e g i o n ,a n dp r o b a b l yc a u s e dt h eo b s e r v e de r o s i o n .

A s a r e s u l to ft h ea n a l y s i so ft h ec o m b u s t o rh o ts t r e a ka n dh i g he x i tg a s tem-
p e r a t u r eg r a d i e n t ,t h ef o l l o w i n gd e s i g nc h a n g e s were made t o t h e n e x t h o t - f i r e
test series (016-045-047) :

1. The f i l mc o o l a n tf l o w was i n c r e a s e df r o ma b o u t 4 . 5 t o 9.5% b y machin-

i n gf i l mc o o l a n to r i f i c e sa d j a c e n tt oe a c ho u t e rc o a x i a le l e m e n tf r o m
0.051 t o 0.086 mm ( 0 . 0 2 0t o 0 . 0 3 4 i n c h ) t o p r o v i d e b e t t e r p r o t e c t i o n
forthewall.
2. The f i l mc o o l a n ti m p i n g e m e n tp a t t e r n was moved f u r t h e ri n t oc o m b u s t o r
s e c t i o nb yr e m o v i n g 0 . 0 7 6 mm (0.030 i n c h ) m a t e r i a l f r o m i n j e c t o r t o
c o m b u s t o rm a t i n gf l a n g et op r e v e n tp o s s i b l ei m p i n g e m e n to na c o u s t i c
c a v i t yo p e n i n g .

168
 lHS49-9/5/75-C1B

F i g u r e 122, I n j e c t o r Water Flow T e s t

169
 TABLE 17A. LH2 INJECTORUNIT NO. 3 WATER FLOW TEST RESULTS (SI UNITS)

LO2 Post
F u eS
l leeve Film F i l mC o o l a n t
E 1 emen t Flowrate, Flowrate, Coolant Flowrate,
No. kg/s kg /.s No. kg/s
~ ~~ ~ ~~

1-1 0.01 52 0.031 7 FC- 1 0.00125

1-2 0.01 5 2 0.031 6 -2 0.001 1 1
1-3 0.0147 0.0305 -3 0.001 1 1
1-4 0.0147 0.0320 -4 0.001 1 1
1-5 0.01 52 0.031 0 -5 0.00125
1-6 0.01 49 0.0303 -6 0.00125
1-7 0.01 18 0.0307 -7 0.00125
1-8 0.0149 0.0321 -8 0.00125
1-9 0.0145 0.031 2 -9 0.001 25
1-10 0.0149 0.0307 -10 0.00125
2- 1 0.0150 0.031 6 -1 1 0.001 1 1
2-2 "
0.0295 -12 0.00097
2- 3 0.0149 0.0312 -13 0.00125
2- 4 0.01 50 0.031 7 -14 0.001 1 1
2- 5 0.01 39 0.0299 -1 5 0.001 1 1
-1 6 0.001 39
-1 7 0.001 39
-1 8 0.001 1 1
-19 0.001 53
FC-20 0.001 1 1

Qt = 0.2196 Qt = 0.4657 Qt = 0.0242

= 0.0146
-Q = 0.0310 Q = 0.0012
5 = 20.0008 o = 2 0.00076 0 ~0.0001

NOTE: 1. F i l m c o o l a npt e r c e n t = 5.2

2. These d a t as h o u l db er e v i e w e do ni n d i v i d u a l LO2 o r
LH2 s y s t e m r e l a t i o n s f o r v a r i a t i o n s o n l y w i t h i n
t h a ts y s t e m .
3. U p s t r e a mp r e s s u r e sl i m i t e dt o 0.69 t o 9.7 N/cm2 due
t ol a b o r a t o r ys e t u pc o n d i t i o n s .

170
TABLE 17B. LH,L INJECTOR UNIT NO. 3 WATER
FLOW TEST RESULTS (ENGLISH UNITS)

7-

LO2 Post FuelSleeve Film FilmCoolant

E 1 ement Flowrate, Flowrate, Coolant Flowrate,
No. 9Pm 9Pm No. 9Pm
"

1-1 0.109 0.228 FC- 1 0.009

1-2- 0. l o g 0.227 -2 0.008
1-3 0.106 0.21 9 -3 0.008
1-4 0.106 0.230 -4 0.008
1-5 0.1 og 0.223 -5 0.009
1-6 0.107 0.218 -6 0.009
1-7 0.085 0.221 -7 0.009
1-8 0.107 0.231 -8 0.009
1-9 0.104 0. a24 -9 0.009
1-10 0.107 0.221 -10 0.009
2- 1 0.108 0.227 -1 1 0.008
2-2 "
0.21 2 -12 0.007
2- 3 0.107 0.224 -13 0.009
2-4 0.108 0.228 -14 0.008
2- 5 0.100 0.215 -15 0.008
-16 0.010
-17 0.01 0
-18 0.008
-19 0.01 1
FC-20 0.008

Qt = 1
-
- 579 -
Qt = 3.348 Qt = 0.174
-
Q = 0.1052 Q = 0.223 Q = 0.0087
a = +0.006 a = 20.0055 0 = +_0.0009

NOTE: 1. F i l m c o o l a npt e r c e n t = 5.2

2. These d a t as h o u l d be r e v i e w e do ni n d i v i d u a l LO2 o r
LH2 s y s t e m r e l a t i o n s f o r v a r i a t i o n s o n l y w i t h i n
t h a ts y s t e m .
3. U p s t r e a mp r e s s u r e sl i m i t e dt o 1 t o 4 p s i gd u et o
l a b o r a t o r ys e t u pc o n d i t i o n s .

171
 PROPELLANT INLETS

NOTE 1 . LN2 TURBOPUMP

INJECTORFACESHOWN
2. LO2 TURBOPUMPFACE HAS ELEMENT ROW 1 BLANK
3. FC-I = FUEL COOLANT DESIGNATION

Coaxial Element
LO;
Misal
'OSt

lnmen t T
J Film Coolant
T Radial
Misal I Clnments
I
Identification rad i ans minutes "
Identificatiov radians minutes
1-1 0.0087 30 FC- I 0.0023 8
1-2 0.0032 11 -2 0 0
1-3 0.0018s 65 -3 0.0029 IO
1-4 0.0087 30 -4 0.0076 26
1-5 0.0137 47 -5 0 0
1-6 0.0044 15 -6 0.0044 15
1-7 0.0125 43 -7 0.0070 24
1-8 0.0102 35 -8 0.0108 37
1-9 0.0087 30 -9 0 0
1-10 0.0189 65 -10 0.0015 5
2- 1 0.0102 35 -1 1 0 0
2-2 0.0244 84 -12 0.0108 37
2-3 0.0058 20 -1 3 0.0105 36
2-4 0.0224 77 -14 0.0058 20
2-5 0.0087 30 -15 0.0157 54
-16 0 0
-17 0 0
-18 0.0067 23
-19 0.0049 17
FC-20 0.01 I6 40
L

Figure123. Unit No. 3 LH Turbopump Injector Face Dimensional

2
Inspection Results

172
 TABLE 18A. INJECTOR INSPECTION RESULTS, LH2 TURBOPUMP INJECTOR UNIT NO. 3
( S I UNITS)

LO2 Post
LO Post Fuel S1 eeve T F i I m Coolant

Element
No.
(0.221
U/N 2
I D , cm
-,3.0000’
+O. 0076,

U/N 3 U/N 2
2
O r i f i c e , cm
(0.1143 +0.0013)
U/N 3
ID, cm

U/N 2 U/N 2
Post
Depth, cm
I (0.254+0.0127)
U/N 3
ID
No.
t
O r i f i c e Size, crn
(0.0508 fi0.00508)
U/N 2 U/N 2
-” “
Angle,
(0.087
U/N 2
radian
t o . 0087)
U/N 3
1-1 0.2184 0.2243 0.0853 0.1 I56 0.261 6 0.2718 -c- 1 0.0508 0.0521 0.1076 0.0960
1-2 0.2184 0.2235 0.1133 0.1130 0.2667 0.2692 -2 0.0508 0.0521 0.1059 0.0998
1-3 0.2210 0.2210 0.0965 0.1133 0.2692 0.2591 -3 0.0521 0.0516 0 0995 0.1056
1-4 0.2184 0.2184 0.1118 0.1 I30 0.2667 0.2642 -4 0.0508 0.0526 0.1018 0.0989
I
1-5 0.2184 0.2235 0.1 I38 0.1135 0.2642 0.2616 -5 0.0521 0.0526 0.1070 0.0989
1-6 0.2159 0.2210 0.1118 0.1156 I 0.2718 0.2667 -6 0.0508 0.0526 0.0995 0.1091
1-7 0.2527 0.2210 0.1166 0.0960 0.2718 0.2667 -7 0.0508 0.0521 0.1033 0.0989
1-8 0.2184 0.2235 0.1 I38 0.1130 0.2718 0.2642 -8 0.0508 0.0513 0.1062 0.1111
1-9 0.2184 0.2210 0.1156 0.1143 0.261 6 0.2642 -9 0.0508 0.0521 0.0989 0.1076
1-10 0.2210 0.221 0 0.1072 0.1158 I 0.2667 0.2718 -10 0.0483 0.0521 0.1036 0.1018
2- 1 0.2159 0.2240 0.1 I48 0.1 I30 0.2591 0.2642 -1 1 0.0483 0.052 1 0.1047 0.0890
2-2 0.2123 0.2235 0.1158 0.1130 0.2591 0.2616 -12 0.0483 0.0523 0.1004 0:0995
2-3 0.21 23 0.2210 0.1161 0.1 I48 0.2565 0.2591 -1 3 0.0508 0.0521 0.0989 0.0989
2-4 0.2123 0.2210 0.1168 0.1151 0.2591 0.2642 -14 0.0508 0.0518 0.0989 0.1076
2-5 0.2121 0.221 0 0.1 I56 0.1 I23 0.2642 0.2642 -15 0.0508 0.0518 0.1021 0.0998
-16 0.0483 0.0526 0.0992 0.1og1
(1) Varied 0.3927 to 0.3962 (5) Varied 0.3912 to 0.3927 -1 7 0.0508 0.0518 0.1006 0.0960
(2) Varied 0.3912 to 0.3945 (6) Varied 0.3917 to 0.3950 -1 8 0.0483 0.0526 0.1047 0.1085
(3) Varied 0.3929 to 0.3942 (7) Varied 0.3917 to 0.3955 -1 9 0.0508 0.0521 0.10g1 0.0983
(4) Vareid 0.3894 to 0.3929 (8) Varied 0.3891 to 0.3932 x-20 0.0508 0.051 6 0.0966 0.1062
-
 TABLE 18B. INJECTOR
INSPECTION R E S a T S , LH2 TURBOPUMP INJECTOR UNIT NO. 3
(ENGLISH UNITS)

Element
_" No.
1-1
1-2
1-3
U/N 2
0.086
0.086
0.087
L O 2 Post
IO, i n c h

U/N
0.0883
0.0880
0.0870
3
r
"
LO Post

U/N 2
0.0336
0.0446
0.0380
2
O r i f i c ei,n c h
(0.04520.005)

U/N
0.0455
0.0445
0.0446
3
F u l 1 Sleeve
ID, i n c h

(0.153 +i:iiA)
0.1544
0.103
0.107
I 0.105
0.
Post
Depth,
inch
(0.100 t 0 . 0 0 5 )

0.106
IO6 ! 0.102
"
IO
No.
FC- 1
-2
-3
r i f i c eS i z e ,i n c h
(0.020 20. 002)
U/N 2
0.020
0.020
0.0205
U/N
0.0205
0.0205
0.0203
3
r
F i l mC o o l a n t

7 U/N 2

6" 0 4 '
5" 42'
Angle,
(5" t 0 . 5 )

6" 1 0 ' 5"

5"
6"
30'
43'
03'
1-4 0.086 0.0860 0.0440 0.0445 0.105 ! 0.104 -4 0.020 0.0207 5" 50' 5" 40'
1-5 0.086 0.0880 0.0448 0.0447 I 0.104 10.103 -5 0.0205 0.0207 6" 08' 5" 40'
1-6 0.085 0.0870 0.0440 0.0455 -6 0.020 0.0207 5" 42' 6" 15'

I
0.107 j 0.105
1-7 0.0995 0.0870 0.0459 0.0378 0. I O 7 i 0.105 -7 0.020 0.0205 5" 55' 5" 40'
1-8 0.086 0.0880 0.0448 0.0445 0.107 j 0.104 -8 0.020 0.0202 6" 05' 6" 20'
1-9 0.086 0.0870 0.0455 0.0450 0.103 ' 0.104 -9 0.020 0.0205 5" 40' 6" IO'
1-10 0.087 0.0870 0.0422 0.0456 0. I O 5 I O . 107 -10 0.019 0.0205 50 56' 50 50'
2- 1 0.085 0.0882 0.0452 0.0445 0.102 0.104 -1 I 0.019 0.0205 6" 00' 5" 06'
2-2 0.0836 I 0.0880 0.0456 0.0445 0.102 ! 0.103 -1 2 0.019 0.0206 5" 45' 5" 42'
2- 3
2-4
2-5

(I)
(2)
0.0836
0.0836
0.0835

Varied
Varied
0.0870
0.0870
0.0870

0.1542 t o 0.156
0.154 t o 0.1553
"-
0.0457
0.0460
0.0455
0.0452
0.0453
0.0442

(5)
(6)
Varied
Varied
I
0.154 t o 0.155
0.101
0.102
0.104

0.1542 to 0.1555
0.102
0. I O 4
0.104
-13
-14
-15
-16
-17
-18
-19
0.020
0.020
0.020
0.019
0.020
0.019
0.020
0.0205
0.0204
0.0204
0.0207
0.0204
0.0207
0.0205
5"
5"
5"
5"
5"
6"
6"
40'
40'
51 '
41 I
46' 5" 30'
00' 6" 13'
15' 5" 38'
5" 40'
6" 10'
5" 43'
5" 15'
I

I
i

(3) Varied 0.1547 t o 0.1552 (7) Varied 0.1542 t o 0.1557 FC-20 0.020 0.0203 5" 32' 6" 05.'
(4) Varied 0.1533 t o 0.1547 (8) Varied 0.1532 t o 0.1548
F i g u r e 124. C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e r I n j e c t o r ,
U n i t 3 , Element 1-5 ( S I U n i t s )

175
 TYPE I NJECTOR _- LH2
.

TOCENTER OF INJECTOR
U N I T NO. " 3
ELEMENT NO. "5

POST

"N/M = NOT MEASURED-

F i g u r e1 2 4 .C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e r I n j e c t o r ,
U n i t 3 , E l e m e n t1 - 5( E n g l i s hU n i t s )

176
 TYPEINJECTOR -LH2
- TOCENTEROFINJECTOR
U N I T NO.
3

t
"

ELEMENT NO. 1-8

FUELSLEEVE

,LOX POST

All dimensions in millimeters

Figure 125. Coaxial Element Evaluation ASE Preburner I n j e c t o r ,

Unit 3 . Element 1-8 (SI Units)

177

n
 .LH2
TYPE I NJECTOR -~ TO CENTER OF INJECTOR
UNIT NO. 3
t
"

ELEMENT NO. -5-

FUEL S L E E V E

LOX POST

A l l d i m e n s i o n s i n inches

d, = 0.0168,
d5
= 0.0164 d
7
= 0.0904 AT' 0.1548
d2 = 0.0162 d6
= 0.0174
diO
=: 0.0923 KF=
0. I555

d3 -
- 0.0164
d7
= 0.0168 dl, = 0.0905 c<= 0.1556

d4
= 0.0161
de = 0.0161 d,2 = 0.0924 fi" 0.1562

F i g u r e1 2 5 .C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e r I n j e c t o r ,
U n i t 3 , Element 1-8 ( E n g l i s hU n i t s )

178
 . LH2
TYPE INJECTOR
TO CENTER OF INJECTOR
UNIT NO. 3 ~

ELEMENT
NO. 2-3

Figure 126. Coaxial Element Evaluation ASE Preburner Injector,

Unit 3, Element 2-3 ( S I Units)

179
F i g u r e 1 2 6 . C o a x i a lE l e m e n tE v a l u a t i o n ASE P r e b u r n e r I n j e c t o r ,
U n i t 3 , Element 2-3 ( E n g l i s hU n i t s )
 3. S i n c et h ea c o u s t i c c a v i t i e s h a v eb e e no b s e r v e d t o c o l l e c tm o i s t u r e
following a test, drainholes0.762 mm (0.030 inch) i n d i a m e t e r were
machined i n t oa c o u s t i cc a v i t y .T h i sd e s i g nc h a n g e w i l l n o tn e g a t e
the effectiveness of the acoustic cavities.

4. T h r e eb o s s e s were p r o v i d e d t o d e t e r m i n et h et e m p e r a t u r ep r o f i l ei n
t h e l a r g e s e c t i o n of t h ec o m b u s t o ru p s t r e a m of t h e c o n v e r g i n g s e c t i o n .
The t h r e et e m p e r a t u r em e a s u r e m e n t sm o n i t o r( a ) w a l l t e m p e r a t u r eb e l o w -
t h e p r e v i o u s e r o d e d area i n - l i n e w i t h t h e l a r g e r f i l m c o o l a n t o r i f i c e
0.864 mm (0.034 i n c h ) , (b) the c e n t e r c o r e t e m p e r a t u r e , a n d (c) w a l l
t e m p e r a t u r eb e l o wt h e smaller f i l m c o o l a n t o r i f i c e 0 . 5 0 8 mm (0.020
i n c h )a b o u t2 . 0 9r a d i a n s( 1 2 0d e g r e e s )f r o mm e a s u r e m e n t( b )a b o v e .

5. The LO2 p o s t so fi n j e c t o ru n i t No. 3 were s t r a i g h t e n e dm e c h a n i c a l l y

p r i o rt on e x t t e s t . R e c o r d so fa n yp o s t movements w i l l b em a i n t a i n e d .

6. The q u a r t e rt o r u ss e c t i o n w a s changed t o a 1 . 5 7r a d i a n( 9 0d e g r e e )
miter b e n d .T h i sd e s i g nc h a n g e w a s made t oe n s u r ea d e q u a t em i x i n go f
theexhaustgasestomaintain a more u n i f o r m t e m p e r a t u r e f r o m t h e
c o r et ot h eo u t e rw a l l .F i g u r e 1 2 7 i s a s k e t c ho ft h ec h a n g e st o
t h ec o m b u s t o rb o d y .

Thr ee t e s t s c o m p r i s e dt h ef i n a lg a sg e n e r a t o rc a l i b r a t i o n test series f o r

m a i n s t a g ed u r a t i o n s of 1 0 , 2 2 ,a n d2 0s e c o n d s ,r e s p e c t i v e l y .R e s u l t so ft h e
test e f f o r t d e m o n s t r a t e d t h a t t h e c u r r e n t f a c i l i t y LH2 tankvolumewould
s a f e l y p e r m i t LH2 t u rb o p u m pg a sg e n e r a t o rn o m i n a lm a i n s t a g e tests of20
s e c o n d sd u r a t i o n ,i n c l u d i n ga l l o w a n c e sf o rf u e ll e a da n dc u t o f fl a gf l o w
volumes.

The o v e r a l l o b j e c t i v e o f t h e s e f i n a l t e s t s was t o e v a l u a t e t h e e f f e c t s o f
c h a n g i n gt h eq u a r t e r - t o r u ss e c t i o no ft h ec o m b u s t o rt o a 1 . 5 7r a d i a n (90 d e g r e e )
miter be n d(Fi g . 127). The miter bendwas i n s t a l l e dt oe n h a n c ep r o p e l l a n t
m i x i n ga n dt h e r e b yr e d u c et h ep r e v i o u s l yo b s e r v e dt h e r m a lg r a d i e n tb e t w e e n
t h ec o r ea n d wall g a s t e m p e r a t u r e s .

F i g u r e 1 2 8 shows t h e L i m a t e s t f a c i l i t y i n s t a l l a t i o n o f t h e LH2 turbopumpgas

g e n e r a t o rw i t ht h e1 . 5 7r a d i a n (90 d e g r e e ) miter b e n d . The r e s u l t so ft h e
t e s t i n g show t h a tt h e1 . 5 7r a d i a n ( 9 0 d e g r e e ) miter b e n da c h i e v e dt h ed e s i r e d
e f f e c t ,i nt h a t ,t h et h e r m a lg r a d i e n t was reducedfromabout244 K (440 R)
b e f o r et h ec o m b u s t o rm o d i f i c a t i o nt oa b o u t 81 K (145 R) a f t e r t h e c o m b u s t o r
m o d i f i c a t i o n .F i g u r e 1 2 9 shows t h ec o m p a r i s o n of t h ec o m b u s t o re x i tp l a n e
( i . e . ,t u r b i n ei n l e t )g a st e m p e r a t u r ev e r s u st h e r m o c o u p l ei m m e r s i o nd e p t h
b o t hb e f o r ea n da f t e rt h ec o m b u s t o rm o d i f i c a t i o n .I na d d i t i o nt ot h ee i g h t
e x i tp l a n et h e r m o c o u p l e s ,t h r e ea d d i t i o n a lt h e r m o c o u p l e s were i n s t a l l e d i n
t h eu p p e rc o m b u s t i o nz o n ea b o u t1 5 . 2 4 cm (6 i n c h e s )b e l o wt h ei n j e c t o rf a c e .
Thes ethe rm o c o u p l es were i n s e r t e d2 . 5 4 ,1 5 . 2 4 ,a n d2 9 . 2 1 mm (0.1, 0 . 6 , and
1 . 1 5i n c h e s )i n t ot h ec o m b u s t o rg a s flow.

181
 LH2 INLET

Figure 127. Small, High-pressure Gas Generator Combustor Modifications

182
 5AJ33-12/1/75-S1A
F i g u r e 128. LH2 Turbopump Gas Generator Installation
(Lima Stand, PRA)

183
 - 2000
0 16-029
110c (PRE-HOD),

1 goo

#/ (go MITER BEND)

1 ooc - 1800
i
z
W
cz
3
-
2cz 1700

/”
W
a a
r r
W
W
/
I-
90(
1600

150c

301
- 1401
0.1 0.2 0.3’ 0.4 0.5 0.6 0.7
THERMOCOUPLE I N S E R T I O N DEPTH, INCH

I I U
0 1 .o 2.0
THERMOCOUPLE INSERTION DEPTH, cm

Figure 129. LH Turbopump Gas G e n e r a t o r E x i t P l a n eT e m p e r a t u r eP r o f i l e

2
F i g u r e 131 shows t h e t e m p e r a t u r e p r o f i l e i n t h e u p p e r c o m b u s t i o n z o n e f o r test
016-047. Thesethermocouples were n o ti n s t a l l e db e f o r et h ec o m b u s t o rm o d i f i -
c a t i o n ;t h e r e f o r e ,n od i r e c tc o m p a r i s o no ft h eu p p e rc o m b u s t i o nz o n et e m p e r a -
t u r ep r o f i l e w a s p o s s i b l e . From t h e r e s u l t s o f t h e s e tests, i t i s recommended
t h a t t h e 1 . 5 7 r a d i a n (90 d e g r e e ) miter b e n d b e i n c o r p o r a t e d i n t o t h e c o m b u s t o r
body f o r t e s t i n g w i t h t h e LH2 turbopump.

The h a r d w a r e c o n d i t i o n f o l l o w i n g t h e s e series of tests w a s s a t i s f a c t o r y w i t h

nodamage n o t e d .F i g u r e1 3 2 shows t h ec o n d i t i o no ft h ei n j e c t o r( u n i t 3M)
face.

Figure133is.aninjectorperformancepredication map f o r i n j e c t o r u n i t 3M
s h o w i n gt h er e l a t i o n s h i po f LO2 i n j e c t i o n p r e s s u r e v e r s u s f u e l i n j e c t i o n
p r e s s u r ev e r s u st h ep e r f o r m a n c et a r g e to fP C , MR, a n dt e m p e r a t u r e .

The i n j e c t o re l e m e n td e s i g n i s shown i nF i g .1 3 0 .M e a s u r e m e n t so ft h e 0.381mm

(0.015 i n c h ) f u e l s l e e v e a n n u l u s i n d i c a t e d some o x i d i z e r p o s t b i a s a n d , t h e r e -
f o r e ,t h es t r a i g h t e n i n go fp o s t sa n dt h ei m p o s i n go fs o m e . m e c h a n i c a 1 method
f o rm a i n t a i n i n g them s t r a i g h t , may b e s u f f i c i e n t . The r e s u l t s o f t h e test
e f f o r ti n d i c a t et h a t ,f o rc o n c e n t r i c - e l e m e n ti n j e c t o r sd e s i g n e dt ou s e LH2
as t h e f u e l , small a n n u l l i c a n r e s u l t i n f l o w stream d e f l e c t i o n , a n d a hot
c o r eo rp o s s i b l e w a l l s t r e a k i n gc a nr e s u l t .A l t e r n a t i v e s ,s u c h as d e c r e a s i n g
t h e number o f e l e m e n t s , h a v e p o s s i b l e p e r f o r m a n c e a n d w e i g h t i m p l i c a t i o n s a n d ,
t h e r e f o r e ,t h em a i n t a i n i n g of s t r a i g h t e l e m e n t s ( w i t h o u t d i s t u r b i n g t h e f u e l
f l o w )i na n area t o be i n v e s t i g a t e d .

LH2 0.394 m
1 (0.0155-INCH) F U E L ANNULUS-,

2.54 mn
(0.100 I N. )

Figure 130. M E LH2 Turbopump Gas G e n e r a t o rI n j e c t o r

E l e m e n t( C r o s sS e c t i o n )

185
 220c

120[

2 1 oc

2000l -
110c

* e
W
. w
- 1 goo l -

e az
3 3
I- I-
Q
CL
W
s
w
a a
5 1 ooc 4 1800 I -
I" I-

900
1700 -

1600
/, D l FFERENCE
(CORE TO WALL) = 273 K (492 R)

1500 -
0 0.1 0.2 0.3 0.4 0.6 0.7 0.8 0 . 9 1.0 1.1
d

1.2
THERMOCOUPLE I N S E R T I O N DEPTH, I N C H
I I I
0 1 .o 2.0 3.0
THERMOCOUPLE I N S E R T I O N DEPTH, crn

Figure 131. LH2 Turbopump Gas Generator Combustion Zone

Temperature Profile

186
 lSE135-11/17/75-S2A
F i g u r e 132. I n j e c t o rU n i t 3M Following Test
280C

240

FUEL INJECTION, PSlA

I I I
2400 2600 2800
FUEL INJECTION PRESSURE,N/cmZ

F i g u r e 133. I n j e c t o r Performance Map

Turbine
-~ Calibration Testing

Calibration of the Mark48-F turbine to establish its aerothemdynamic per-

formance w a s ac co m p l i s h e dwi t ha m b i e n t - t e m p e r a t u r e GN2 as t h e p r o p e l l a n t . The
r o t o r s p e e d s were m a i n t a i n e d i n t h e r a n g e o f 1 0 5 0 r a d / s ( 1 0 , 0 0 0 rpm) t o 2600
r a d / s( 2 5 , 0 0 0 rpm) t o s i m u l a t e t h e o p e r a t i o n a l ' w h e e l t i p s p e e d / g a s s p o u t i n g
v e l o c i t yr a t i o s (U/Co).

The t e s t i n g w a s performed a t Wyle L a b o r a t o r y i n E l S e g u n d o ,C a l i f o r n i a .T h e

b a s i c test s e t u p i s i l l u s t r a t e d i n F i g . 1 3 4 a n d 135.Powerdevelopedbythe
t u r b i n e w a s a b s o r b e d b y a Mark 4 pump w h i c h r e c i r c u l a t e d water from a reser-
v o i r . A Lebow i n - l i n e t o r q u e m e t e r w a s i n s t a l l e d b e t w e e n t h e t u r b i n e a n d
thepow er-a b s o rb i n g pump t o i n d i c a t e t h e t o r q u e d e v e l o p e d b y t h e t u r b i n e .
The t e s t u n i t i n s t a l l e d i n t h e Wyle f a c i l i t y i s shown i nF i g . 1 3 6a n d1 3 7 .

The tests were s t a r t e d o n 1 2 A u g u s t 1 9 7 6 , a n d were c o n d u c t e d i n e s s e n t i a l l y

two series. The f i r s t series (Table19) w a s c o n d u c t e d a t t u r b i n es p e e d s up
t o 2200 r a d / s( 2 1 , 0 0 0 rpm) and U/Co r a n g ef r o m0 . 1 6t o0 . 3 9 .T h i s test series
w a s i n t e r r u p t e d when a suddenchange i n t h e r o t o r t o r q u e c h a r a c t e r i s t i c s was
obs er ved . The t u r b i n e w a s removedfrom t h e t e s t s t a n dd i s a s s e m b l e df o ri n s p e c -
tion. I t w a s f o u n dt h a tt h e slave t h r u s tb e a r i n go nt h et u r b i n es i d eo ft h e
r o t o rh a df a i l e d . The f a i l u r e w a s d i a g n o s e d as o r i g i n a t i n g i n t h e p h e n o l i c
c a g ef r o mt h r e ep o t e n t i a lc a u s e s : (1.) i n s u f f i c i e n tl u b r i c i t yo ft h eF r e o n
1 3c o o l a n tu s e d ,( 2 )r e s i d u a l stresses i n t h e c a g e f r o m f l a i r i n g t h e e n d s o f
t h e t u b u l a r r i v e t s , (3) c o r r o s i o n o f t h e races and b a l l due t o water conden-
s a t i o n b e t w e e n tests.

The t u r b i n e w a s r e b u i l t , u s i n g a t h r u s t b e a r i n g w i t h s o l i d c a g e rivets, and

t e s t i n g w a s re s u m ed wi t h o i l as t h e b e a r i n g l u b r i c a t i n g f l u i d i n s t e a d o f
Freon. No f u r t h e rm e c h a n i c a lp r o b l e m s were e n c o u n t e r e d .

Testing w a s concludedbyobtainingtherequireddatapoints at thehigher

v e l o c i t yr a t i o s( T a b l e2 0 ) .T h e s e tests were p e r f o r m e dp r i m a r i l y at rotor
s peedsof 2100 and2600rad/s(20,000and25,000rpm). Two d a t a p o i n t s a t
low-velocityratioswhich were c o v e r e d d u r i n g e a r l i e r tests were r e p e a t e d
t ov a l i d a t et h ec o n t i n u i t yo ft h ed a t a . The r e p e a t e d p o i n t s f e l l w i t h i n t h e
b a n do fe x p e c t e dd a t a scatter. A n a l y s i so f t e s t d a t a shows p r e d i c t e dt u r b i n e
performance w a s a c h i e v e d t h r o u g h t h e f u l l r a n g e o f test v e l o c i t y r a t i o s .
Tests 006through014 were c o n d u c t e d d u r i n g t h e s e c o n d test p h a s e f o r v e l o c i t y
r a t i o sr a n g i n gf r o m0 . 1 9 7t o0 . 5 5 2 ,a n ds p e e d sf r o m 2110 t o 2640 r a d / s( 1 9 , 2 2 0
t o 25,247rpm).Three tests were made a t v e l o c i t y r a t i o s (U/Co (T-T) = 0.197,
0 . 2 2 7 ,0 . 3 1 1 )e q u i v a l e n tt ot h o s er u nd u r i n gt h ef i r s t - p h a s et u r b i n e tests
0 0 1t h r o u g h0 0 5 ;t u r b i n ep e r f o r m a n c e w a s r e p e a t e d as shownby t h e v e l o c i t y
r a t i o / t u r b i n ee f f i c i e n c yd a t ap l o ti nF i g . 138. T u r b i n ee f f i c i e n c i e s were
calculated with developed horsepowers calculcated with Lebow t o r q u e m e t e r
data,andisentropicavailableenergyand GN2 w o r k i n g f l u i d m a s s - f l o w c a l c u l a t e d
a t t h er e s p e c t i v eo p e r a t i n gp o i n t s .T u r b i n ee f f i c i e n c i e s were a l s o c a l c u l a t e d
using an alternate methodwhichusedmeasured totaltemperaturedrop (AT(T-T)
acrosstheturbine; g o o da g r e e m e n te x i s t sb e t w e e nt u r b i n ee f f i c i e n c yd a t a
c a l c u l a t e d w i t h Lebow t o r q u e d a t a a n d m e a s u r e d t u r b i n e t e m p e r a t u r e d r o p .

189
 T U R B I N IEN L E T

TORQUEMETER

MAR I(- 4 PUMP

TURB I NE
EXHAUST

F i g u r e 134. Mark 48-F T u r b i n eC a l i b r a t i o n Test S e t u p

190
 lS.01

I"r
. . . . .
.,
..

"
 -. .
......_.. ..
,

' , 8.
. .
 .. .
.

191
Figure 136. Small, High-pressure Turbine Calibration
Installation (View A)

193
 'TABLE 19. MARK 48-F TEST DATA FRO1

_____
" ~~~
LC

Sonic Flow Sonic Flow

-
Nozz 1 e Nozzle Turbine Turbine Turb
larometric InletTotal n l e tS t a t i c Inlet Total ExitStatic nlet .
Run Pressure, remperature, Pressure. remperature, Temperature, Press1
-
Run -
51 i c e Date H9 K . N/cm2 K (T2). K N/cl
- ~
-~ ~

1 8-1 1-75 760.9 256.1 54 ' 267.8 253.4 9

. . 265.6 247.2 6
. - .
I 3-12-75 7633 255.5. 34 -
3 763 i 3 259.2 45 267.8 255.8 IO
-~
4 . 259-0 43 268.2 255-0 9
5 256.7 61 268.1 252.8 13
6 257.2 68 268.9 . 257.8 16
I 5- 13-75 764.8 .L
65 253-9 * 12
2 764.8 L
.
80 253-9 * 30
3 763. a *
94 254.4 * 18
4 254.4 * 24
763.8 .A
103
5 763.8 I 36 255.6 33
I 6-15-75 253.6 90 266.9 241.7 15
I 8-22-75 761.7 249.7 IO3 261. I 244.4 21
2 761.7 243.3 1 IO 257.8 235.0 23
3 761.7 240.6 1 IO 256.1 232.2 21
4 761.7 238.9 109 255.0 22

- -
Sonic Flow Sonic Flow
Nozzle Nozzle Turbine Turbine Turb
Barometric I n l e tT o t a l I n l e tS t a t i c I n l e tT o t a l :xi t S t a t i c nlet
Hun Run Pressure. remperature, Pressure. 'emperature. remperature Press
SI i c e Date i n . Hg F psia F 02). F ps i
- -
I 8-11-75 29.96 1 .o 79 22 -3.8 . 13
002 I 8-12- 75 30.06 0 49 18 -15 9
3 30.05 6.5 65 22 0.5 14
I ' I

1 5
6
4
r
6.2
2
3
63
88
98
22.8
22.5
24
-I
-5
4
13
19
24
I
i >.
003 I 8- i3-:75 30. I I 94 -3 t 18

i 2
3
30.1 I
30.07
I I6
137
-3 t
.,.
44
26
6-2
4 30.07 149 -2 36
5 30.07 I97 0 48
004 1 8- 15-75 30. I -3.5 130 20.5 -25 23
00 5 I 8-22-75 29.99 -10.5 150 IO -20 30
2 29.99 -22 160 4 -37 33.
3 29 -99 -27 160 1 -42 33'
4 29 99 -30 158 -1 33.
- -
"No temperature datarecorded.
 ... ).'
.,

:: ., . . . . . .

. .
IATA FROM WYLE LABORATORIES, EL SEGUNDO, CALIFO@?M

~
. . .
I
I UNITS
Turbine
- :
. ..
r ) .
L .

le Turblne Turbine . Turblne Turbine '' ' Inlet , .

atic nlet Total InletStatic Ex1t Total ExitStatlc Manifold furb I ne lrbine u/c nt
.ure, Pressure. Pressure. Pressure, Pressure, 'ressure, rorque peed. Ah OR u/co
-K N/cm2 N/cd
,, 8 c ..- ...
.';y>
I.
N/cm2
~~
N/cm2
""
N/crnZ
.
Nm :ad/s .
-
j.94 7i, 14.3
K J/kg 0-7)
- - R

t . 94 .. .I
.
- 55 . 55 ' 9 :;I823 ,
0.047 o:I6$ ..
3.53
.
! 62 60. . . 34. . 36 59 ' 11.3 ' i178. 18; 3 0.054 0 : 205 5. I I
1 ' 103 100 " ' 76 76 98 10.2 'I 047 11.9 0.030 0.246 . 5.07
1 93 90 64 63 87 11.1 1035 13.2 0.034 0.225 3.14
8 134 I 30 * -... 92 92 I26 12.5 1381 15.3 0.036 0 * 293 2.61
1 I68 163 130 130 162 12.4 I I61 FI.1 0.026 0.289 2.77
126 I25 82 81 I24 14.1 I698
304 165 118 1 I7 I63 14.2 1576
182 181 i 26 125 179 13.9 1763
248 246 195 195 245 13.6 I586
334 330 270 269 332 14.0 1633
7 159 I59 97 97 I60 1995 25.3 0.060
4 212 204 123 120 193 23.2 I773 16.7 0.051 0.316 2.49
I 23 I 220 139 142 214 21.1 1978 22.8 0.049 0.362 2.17
2 228 220 132 137 210 20.3 2153 23.9 0.052 0.382 2.01
229 220 I32 137 210 19.8 2199 0.051 0.391 "'I .98
- -

ISH UNIT!
Turbine
le Turbine Turbine Turbine Turbine Inlet
atic InletTotal InletStatic E x i tT o t a l E x i tS t a t i c Manifold Turbine T nt
ture Pressure, Pressure, Pressure, Pressure, 'ressure. Torque, C
nt u/c
F PS i g PS i g PS i g PS i g PS i g in.-lb (T-T) OR

" 125, 80 79 :5 13. I 0. I648 0.5815 3.5258

! 87 50 52 85 0.2052 0.6387 5.1 I26
I45 I10 I10 142 1 0.2460 0.7564' 5.0748
130 :,. 93 91 I26 0.2251 0 - 7077 3. I439
!
188 134 133 183 111 i 0.2925 0.7627 2.6075

I
237 189 189 235 1 IO II 1 0.2886 0.7984 2.7665
i 182 1 I9 1 17- 180 125
239 171 237 126 i -4
169 !
263 183 182 260 123 I
357 283 283 356 . I20 I
I
479 391 390 482 124
230 I40 I40 232 45.5 i 15.711
296 1 78 174 280 205 13.329 D.3163 0.7878 2.4906
,320 20 1 206 310 187 ,888 12.6631 D.3619 0.7852 2.1697
3 20 191 198 305 180 13.488 D.3818 0.7687 2.0134
. .. 320 191 I 98 305 175 ,000 13.421 D . 3908 0.7734 1 .9790
21I

195
 Son I c Sonlc
Flow
Nozzle
Flow -..
Nozzle
- Turblne Turbine
Turbine
Inlet Turblne .
Inlet Inlet Inlet Ex1t Manifold Ex1t
Test Barometric To t a 1 S t a t IC Total Total Pressure Total .
Test Test - Date Pressure, Temperature, Pressu e,- :.Temperature,
5 . . K Temperature, (Statlg) , Pressure,
-
-NO.
-. ~
Slice 1975 .' I Hg
IIITI K N/cm
...
..- .~K N/cm N/cm2 .'

006 2 11/11 761 .O 252 65 268' 247 159 110

007 1 11/11 761.0 248 83 261 245 138 100
008 1 11/11 761 .O 255 48 268 253 83 56
009 2 11/12 762.5 247 I12 27 1 239 203 I I4
oio 1 11112 761 .O 258 172 '_. 276 254 345 234
2 11/12 761 .O 253 145 275 249 274 174
0.11 1 11/13 761 .O 253 148 27 I 248 283 193
2 11/13 761 .O 252 148 271 248 283 I93
01 2 2 11/13 759.5 253 224 269 252 455 338 C
11/13 3 759.5 251 163 267 250 33 1 243 C
Dl 3 1 11/14 762.0 243 176 262 24 1 337 214 C
01 4 1 11/17 756.9 242 228 258 24 1 427
0 *Lebow Torquemeter d a t a
e
0 C -
Working f l u l d : CN2
(PressureStatic,Test) + (Pressure DynamIc, Calculated)

(ENGLISH UNITS)
"

Son I c I
Flow Turbine
Nozzle Turbine Turb I ne Inlet Turbine Turbine
Inlet Inlet Ex1t Manifold Ex1t Exit
Test Barometric To t a 1 Total To t a 1 Pressure Tota 1 Static
Test Test Date Pressure, Tempera t u re, Temperature, Temperature, (Static), Pressure, Pressure,
No. S1 i c e 1975 . in. Hg - F. F F PS i g PS lg PS i g
.'' 006. 11/11 29.96 - 6.0 ,22.0
.
-14.5
.
230 160 150
007 I 1j,11:, 29.. ?.! . .-13.0
. ' 9.0 .-19.0 200 145 135
-008 1'1/1lr ..:,.29.96: ',
* O '. 22.0 - 4.0 120 82 75
009 tlill 30.02 " -16.0 27.5 -30.0 295 165 165
010 11/12 29.96 5.0 37.0
11/12
.,;
,29.96 - 4.0 34.5
2.0
-12.0
500
398""
340
252
340
240
--
01 1 11/13 29.97 5.0 28.0 -14.0 410 280 275
11/13 29.97 6.0 27.0 -14.0 410 280 275
012 11/13
11/13
29 90
29 90
- 4.0
- 9.0 24.0
21 .o
- 6.0 660 491 C 485
-10.0 480 353-2 C 350
013 11/14 30.00 -23.0 , 11.0 -26.5 490 310 C 305
. 4
. 01 11/17 29.80 -23 * 5 4.0 -26.0 620 450 C 440
~. ~~

e *I
0 1

196
 . .
1TA FROM WYLE LABORATORIES, EL SEGUNDO, CALIFORNIA

( S I UNITS)
- -7

I Turblne
Temperature
Irb lne
inlet
~nlfold
'essure
;tatls),
Turblne
Ex1t
Total
Pressure,
Turblne
Ex1 t
Static
Pressure,
Turblne
Speed
'(Nt) 9
Dro Isentropic
(ATP
(Total-to-
,Tots 1 .) ,
En tha 1 py
. Drop

(Ahs
hy,
Velocity

( r e TU 827)
Turbine
Efficiency
(nt 1
(T-T) (T-T) .. .
N/cm . . N/cm* NE cm.._.
2 rad/s K. J/kg -
159 1 IO . 103 1 14.0 201 2
1081
276
271
0.042 .
0.227
?. .

70.8
..

138 100 93 2
0
:
1 0.037
83 56 52. 14.4 1004 270 0.042 0.197 66.3
203 1 I4 114 29.4 1990 0.067 287 0.31 1 79.1
345 234 234 23.4 2529 .277 0.048 0.467 76.8
274 174 165 23.1 2592 28 I 0.055 0.445 78.7
283 193 190 25.4 2077 279 0.046 0.390 80.9
283 193 190 25.4 2092 278 0.046 0.394 81.6
455 338 C 334 26.0 2264 272 0.036 0.481 77.8
33 1 243 C 24 1 23 .O I979 273 0.037 0.414 78.4
337 214 C 210 22.6 2491 276
427 310 C 303 2643 272 0.037 0.552

I
I
I
ENGLISH UNITS)
;1 Turbine
Temperature
Drop Isentropic Velocity
(AT) Enthalpy Rat i o Turbine
(Total-to- Drop (u, co) Efficiency
Total), (Ah,) , ( r e TU 827) (nt 1
R Btu/lb (T-TI (T-T)
36.5 ..10.99
28.0 9.59 0.227 70.8
26.0 11.00 0.197 66.3
57.5 17.40 0.31 1 79.1
39.0 12.42 0.467 76.8
46.5 14.38 0.445 . 78.7
42.0 12.01 0.390 80.9
41 .O 11.99 0.394 81.6
30.0 9.39 0.481 77.8
31O. 9.67 0.414 78.4
37.5
30.0 9.71 0.552
0.9

0.8 -

0.7 -

PERFORMANCE

0.6 - TEST 14-1

/
0.5

0.4 -

0.3 -

TWO REACTION STAGES

0.2 -
0 TESTS 006 THROUGH 014, NOVEMBER 1975
TESTS 001 THROUGH 005, AUGUST 1975
AOoOoO TURBINETESTDATA,
0.1 -

0 I I i I I
0 0.1 0.2 0.3 0.4 0.5 0.6

VELOCITY RATIO, U/C T-T

OR

Figure138. Mark 48-F Turbine P e r f o r m a n c e

197
 A compar is o n of t h e m e a s u r e d p e r f o r m a n c e of t h e t u r b i n e w i t h p r e d i c t e d v a l u e s
, shows t h a t ,i ng e n e r a l ,t h ep r e d i c t e dp e r f o r m a n c e w a s e x c e e d e dS
. pecifically,
at t h e d e s i g n v e l o c i t y r a t i o of 0 . 3 4 , t h e m e a s u r e d e f f i c i e n c y w a s 79%, 4 per-
centagepointshigherthanpredicted.

Turbopump T e s t i n g

T e s t Discussion. The f a c i l i t y ,p r o c e d u r e s ,a n di n s t r u m e n t a t i o nu s e di nt e s t i n g
t h e Mark 48-F turbopump are d e s c r i b e d i n t h e f o l l o w i n g .

F a c i l i t y .T e s t i n go ft h e Mark48-F turbopump w a s c o n d u c t e do n Lima S t a n d

i n R o c k e t d y n e ' sP r o p u l s i o nR e s e a r c h Area a t t h e S a n t a S u s a n a F i e l d L a b o r a t o r y .
Schematics of t h ef a c i l i t yf o rt e s t i n gw i t ha m b i e n t - t e m p e r a t u r e GH2 as t h e
t u r b i n ep r o p e l l a n t ,a n dw i t h a hot-firinggasgenerator are i n c l u d e d i n F i g .
139 and 1 4 0 , r e s p e c t i v e l y .

Countdown Summary. P r o c e d u r e sf o rc o n d u c t i n gs p e c i f i cp r o g r a mt a s k sf o r
a ni n d i v i d u a l t e s t h a v eb e e nd e v e l o p e df o rt h e Lima test f a c i l i t y . The p r o -
c e d u r e s are m o n i t o r e d c o n t i n u o u s l y d u r i n g t h e t e s t p r o g r a m ,a n dr e v i s e d when
n e c e s s a r yt oa c h i e v e a h i g h l yr e l i a b l e t e s t f a c i l i t yo p e r a t i o n a ls y s t e m . The
proceduresandcountdown a r e d i v i d e db e t w e e nm a n u a la n da u t o m a t i co p e r a t i o n s .
Generally,thepretestprocedures are c o n t r o l l e dm a n u a l l y , w h i l e t h e a c t u a l
t e s t i s c o n t r o l l e da u t o m a t i c a l l y .T a b l e 2 1 below l i s t s t h o s ep r e t e s to p e r a -
t i o n a lp r o c e d u r e su t i l i z e dd u r i n gt h et e s t i n g of t h e LH2 turbopump.AppendixC
p r e s e n t s t h e Test C o n t r o lL o g i cB l o c kD i a g r a mu s e dd u r i n gt h e GH2 t u r b i n e
d r i v e t e s t i n g of t h e LH2 turbopump. A r e v i e wo ft h el o g i cd i a g r a m reveals
some i n s t a n c e s o f m a n u a l o v e r r i d e o p e r a t i o n s .

T e s t i n go ft h e LH2 turbopump w a s a c c o m p l i s h e d p e r t h e e s t a b l i s h e d p r o c e d u r e s
a n dc o n t r o ll o g i cs y s t e mw i t h o u ti n c i d e n t . A s t h e t e s t series p r o g r e s s e d ,t h e
p r o f i c i e n c yo ft h e test c o u n t d o w ni n c r e a s e d as a f u n c t i o n o f t h e i n d i v i d u a l
s y s t e m sc h a r a c t e r i z a t i o n s .

I nt h e case o ft h et u r b o p u m pc h i l l - TABLE 21. LII2- TURBOPUMP TEST PROCEDURES

down a n d t h r o t t l e v a l v e s e t t i n g ,
LIST LIMA STAND - ROCKETDYNE PRA
p r e c i s ec o n t r o lo ft h e s ef u n c t i o n s
w a s p o s s i b l et h r o u g hd i r e c t test
e x p e r i e n c e ,a n dp r o v e dt ob eq u i t e
repeatable, t e s t t o test. Inthe I 1. Pretest S e t u p
case oftheturb o p u m pch i l l d o wn ,
i t was o b s e r v e d t h a t good q u a l i t y
1 2. Test Data S h e e t
LH? p r o p e l l a ni tn l ecto n d i t i o n s I 3. Sequence Test S a f e t y C i r c u i t Checks
( 2 5 K , 45 R ) was o b t a i n e d a t
4. LH2 Turbopump Drying Procedure
( 21 X/cm2) ( 3 0 - p s i g )t a n k
p r e s s u r e a n d by m o d u l a t i n g t h e 5. Test Conductors C o u n t d o w n
turbopump LH2 f l o w w i t h t h e
6. C r i t i c aPl a r a m e t eV
r erifications
o u t l etth r o t t l ev a l v eI. n
t h e case of t h e t e s t t h r o t t l e 7. Comparator S e t u p S h e e t
v a l v ep o s i t i o n ,t h e pretest 8. S e q u e n c e Times S e t u p S h e e t
GI12 blowdown t e s t s which
~~~

c h a r a c t e r i z e dt h et h r o t t l e
v a l v e a n d GH2 s p i n v a l v e

198
 602. SCF
VENT
STACK 5000 PSI

n
LH2
t LH2 THROTTLE
VALVE
REG

VENTURI

GH2 SPIN
VALVE
EXHA'UST
STAlCK

I
TANK
LH2 T/P OUTLET
15,000 BLEEDVALVE INJECTOR
GALLONS REPLACEMENT
F I XTURE
GG BODY
100 P S I

VENTURI

Figure 139. Gaseous HydrogenTurbineDrive

N
0 VENT
0
STACK GH2 SUPPLY
220 GAL. 602 SCF 133 GAL.

"I I
VALVE

R E G F )

I I VALVE

LH2 T/POUTLET
BLEED VALVE

GC FUEL

4,
TMFV
I FV

HLV

CC ASSEMBLY *

-
LH2 T / P INLET BLEEDVALVE

F i g u r e1 4 0 . Gas Generator T u r b i n e Drive

 o p e r a t i o n sp r o v e dt ob ea n asset i n t h e p r e l i m i n a r y s e t t i n g s o f t h e t h r o t t l e
valve t o m a i n t a i n t a r g e t e d h e a d - f l o w v a l u e s .

The c o u n t d o w n , o p e r a t i o n a l , a n d c o n t r o l f u n c t i o n s o f t h e test program were w e l l

d e f i n e d ,m e e t i n g , i n all r e s p e c t s , t h e r e q u i r e m e n t s s e t f o r t h i n t h e test p l a n .
F i g u r e 1 4 1 i s an ab b rev i a t edc o u n t d o w n summary a p p l i c a b l e f o r t h e t e s t i n g o f
t h e Mark 48-F LH2 turbopump.

- LH2 Turbopump C h i l l d o w nR e s u l t s . The LH2 t u r b o p u m pc h i l l d o w np r o c e d u r e s

f o l l o w e dt h en o r m a lp r e t e s tc o u n t d o w no p e r a t i o n s . The c h i l lp r o c e d u r e sr e q u i r e d
a f a c i l i t y line prechillfromthe LH2 o f f - s t a n d s t o r a g e t a n k t o t h e t u r b o p u m p
i n l e t l i n e p r e v a l v ep r i o rt oi n t r o d u c i n g LH2 i n t o t h e turbopump. The m a j o r i t y
of the f a c i l i t y l i n e w a s vacuum j a c k e t e d ( - 2 / 3 t o t a l l e n g t h ) , while the re-
m a i n i n gs e c t i o n w a s foamand t a p ei n s u l a t e d .W i t ht h e LH2 o f f - s t a n d tank
p r e s s u r i z e dt oa b o u t2 1 N/cm2 (30 p s i g ) , a LH2 r u n l i n e t e m p e r a t u r e ( b l e e d
f lowups tr ea mo f the t u rb o p u m pi n l e t : valve) o fa b o u t 33 K (-400 F) r e q u i r e d
about 30 m i n u t e s of countdown time. When t h e f a c i l i t y l i n e w a s p r e c h i l l e dt o
33 K a t 2 1 N/cm2 (-400 and 300 p s i g ) , t h e t u r b o p u m p o u t l e t t h r o t t l e valve w a s
opened t o a b o u t lo%, t h e n t h e turbopump i n l e t v a l v e w a s opened. LH2 f l o w
thr oughthet u rb o p u m p as w e l l as turbopumpspeed w a s c o n t r o l l e d by t h e o u t l e t
throttlevalveuntiltherequired LH2 p r o p e l l a n t q u a l i t y o f 25 K a t 2 1 N/cm2
( 4 5 R a t 30 p s i g ) w a s a c h i e v e d . Theturbopump c h i l lo p e r a t i o nr e q u i r e da b o u t
a na d d i t i o n a lc o u n t d o w n t i m e o fa p p r o x i m a t e l y 30 m i n u t e s .T o t a lc h i l l d o w n
t i m e f o r t h e LH2 s y s t e m w a s a b o u t 1 hourofcountdown time. As t h et e s t i n g
c o n t i n u e d ,t h ec h i l l d o w nt e c h n i q u e s w e r e i m p r o v e du n t i l a t o t a l c h i l l d o w n ’
time of o n l ya b o u t 20 t o 30 m i n u t e s was r e q u i r e d .B a s i c a l l y ,t h ef a c i l i t y
lineprechilloperation was e l i m i n a t e d , s i n c e i t w a s f o u n dt h a ta d e q u a t e
c h i l l d o w nc o n t r o lc o u l db ea c h i e v e dw i t ht h et u r b o p u m po u t l e tt h r o t t l e valve
and,inaddition, a c o n s i d e r a b l e volumeof LH2 was s a v e d i n t h e p r o c e s s .
( i . e . ,F o rt h ef i r s t t e s t , a p p r o x i m a t e l y 26.5 m3 (7000 g a l l o n s )o f LH2 were
r e q u i r e d ,w h i l ed u r i n gt h e l a t t e r t e s t s a t o t a lo fa b o u t3 . 8 m3 (1000 g a l l o n s )
p e r t e s t were r e q u i r e d . )D u r i n gt h ee n t i r e test p r o g r a m ,a c c e p t a b l e LH2 i n l e t
q u a l i t y w a s a c h i e v e df o re a c h t e s t t o meet t h e turbopump n e t p o s i t i v e s u c t i o n
e headrequirements.

I n s t r u m e n t a t i o na n dR e d l i n e r . A l l p r e s s u r e s ,t e m p e r a t u r e s ,a n df l o w
measurements were r e c o r d e d o n t a p e bymeansof t h e BeckmanModel210 Data
A c q u i s i t i o na n dR e c o r d i n g System. This s y s t e ma c q u i r e sa n a l o gd a t af r o m
thetransducers,andconvertsthedatatodigitalforminbinary-coded
d e c i m a lf o r m a t . The l a t t e r i s r e c o r d e do nt a p e sw h i c h are t h e nu s e df o r
c o m p u t e rp r o c e s s i n g .

T a b l e 2 2 p r e s e n t st h ei n s t r u m e n t a t i o nr e c b r d e dd u r i n gt h e Mark 48-F t u r b o -
pump t e s t i n g .F i g u r e 1 4 2 i s a c r o s s - s e c t i o n a ls c h e m a t i c of t h e LH2 turbopump
a s s e m b l ys h o w i n g. t h et u r b o p u m pp a r a m e t e r si d e n t i f i c a t i o na s s o c i a t e dw i t ht h e
p a r t i c u l a rc a v i t yl o c a t i o n . Not l i s t e d ,h o w e v e r , i s t h eh i g h - s p e e di n s t r u -
m e n t a t i o n wh5ch w a s r e c o r d e d o n FM tape f o r h i g h - s p e e d a n a l y s i s o f t h e t u r b o -
pump r o t o r d y n a m i c s .I n c l u d e d i n t h e FM i n s t r u m e n t a t i o n were B e n t l yt r a n s d u c e r s
f o r turbopump s h a f t movement dynamicsand triaxialaccelerometersforoverall
t u r b o p u m pg - l e v e ld e t e r m i n a t i o n .

201
 I I 7-
7
i F A C I L I T Y PREPS L H 2T I P
COMPLETE
VACUUM DRY I H G
i i

SECURE FOR
F A C I L I T YS U P P L Y
LINE PRE-CH I LL
(INSTRUMENTATION,
i BLOCKHOUSE,
ETC.) I ; PROCEDURES TEST
- -. OPERATIONS
"_I . ".

-
. . " . "" _. - .. . . - .I..
_" ...
I

CHILLDOWN

-
I T/P
PRESSURE
CONTROL

CONTROL
-

VALVE

.. .
..1

-*
I
I
SYSTEMS
PRESSURlZATlON
THROTTLE! OUTLET
TEST
SEQUENCE START
(REDLINES ACTIVE)
1
1
4I T/P
PRE-TEST
VALVE
TO
POSITION
(MANUAL)
" -
'

TEST
'
I

'7
[TI;

I
I
GH

TO
SPIN V A L VOEP E C ]
SPEEQ
ADJUSTED

(MANUAL)
. .-
1-7
I
1 H-Q
._
EXCURSION
THROTTLEVALVE
CONTROL
(MANUAL)
BY
-

-_-" I (MANUAL) .___

.. . .-,

I
i

~ ~
I

T
"

(THROTTLE
F E F ~

(MANUAL)
s VALVE
~ ~ ~ 1 4
F ~ ~
I

~ ~ !POST-TEST
s T
OPERATIONS
.-

SECURING
 TABLE 2 2 . ADVANCED SPACE ENGINE MARK 48-F HYDROGEN TURBOPUMP TEST INSTRUMENTATION

Range Range Range Range

- Parameter (51 Units) (EnglishUnits) Parameter (SI Units) (EnglishUnits)

Turbine
Discharge
Temperature '
I
1366 K 2000 F
CH
2
Venturi Upstream Pressure No. I 3480 N/cm2 5000 p s i
T u r bI innl e t Temperature No. 2 I366 K 2000 F
GH Venturi
Throat
Pressure 3480 N/cm2 5000 p s i
Turbine
Bearing
Coolant Temperature I 2 0 K -425 F 2
SpinValveServoControlPressure 3480 N/cm2 5000 p s i
Pump Bearing
Coolant Temperature I 2 0 K -425 F
Turbine Seal Pressure 3480 N/cm2 5000 p s i
NAN Power Supply
L I M PowerSuppi:'
I - First-Stage NozzlePressure 3480 N/cm2 5000 p s i
TurbineTotalDischargePressure 3480 N/cm2 5000 p s i
Temperature Reference Junction
TurbineInletTotalPressure 3480 N/cm2 5000 p s l
LH
Pump I n l e t Temperature No. I 8.0 nv
2 Fi rst-Stage Crossover Discharge Pressure 1380 N/cm2 2000 p s i
LH Pump I n l e t Temperature No. 2 8.0 nv
2 CH SpinLinePressure 3480 N/cm2 5000 p s i
2
LH
Pump I n l e t Run Line Temperature 8.0 nw
2 Third-StageImpellerDischargePressure 3480 N/cm2 5000 p s i
LH Pump Discharge Temperature No. i 8.0 nv
2 CH RegulatorOutletPressure 3480 N/cm2 5000 p s i
8.0 nv 2
LH
Pump DischargeTemperature No. 2
2 Balance Piston Sump Pressure 3480 N/crn2 5000 PSI
CH Venturi Temperature No. I 16.0 IC
2 LH
Pump Venturi Upstream Pressure 3480 N/cm2 5000 p s i
16.0 IC 2
GH Venturi Temperature No. 2
2 LH Pump Discharge
Pressure 3480 N/cm2 5000 p s i
GH VenturiDifferentialPressure No. I 241
N/crn2 2
2
350 psi
Hydraulic SupplyPressure 2068 Y/cm2 3000 p s i
CH VenturiDifferentialPressure No. 2 207N/cm2 300 p s i
2 First-StageImpellerDischargePressure I380 N/cm2 2000 p s i
GH2 SpinValvePosition
First-Stage Crossover I n l e t Pressure 1380 N/cm2 2000 p s i
SpinServo Command
First-Stage CrossoverMid-Pressure 1380 N/cm2 2000 p s i
LH2
Pump T h r o t t l e Valve P o s i t i o n
Second-Stage ImpellerFront Shroud 3480 N/cm2 5000 p s i
GH VenturiOifferentialPressure No. I 348 N/cm2 500 p s i
2 Second-Stage D i FfuserDischargePressure 3480 N/cm2 5000 psi
GH 2 Regulator Ups.tream Pressure 3480 N/cmZ 5000 p s i
Balance PistonCavityPressure 3480 N/cm2 5000 p s i
Pump DischargeVenturiThroatPressure 3480 N/cmZ 5000 psi
LH2
Pump I n l e t Pressure No. 1 100 p s i
Low-Pressure LH2Tank Pressure 138 N/cm2 200 p s i , 69
LH
Pump I n l e t Pressure No. 2 241 N/cm2 350 p s i
3480 N/cm2 5000 p s i 2
Turbine I n l e t S t a t i c Pressure
LH
Pump O u t l e tT h r o t t l e ValvePressure 3480 N/cm2 5000 p s i
5000 p s i 2
TurbineManifoldPressure 3480 N/cm2
Throttle Valve ServoControlPressure 3480 Nlcrn2 5000 PSI
Faci I it y Exhaust Duct Pressure 348 N/cm2 500 psi
Pump Speed 12,560 r a d l s 120,000rpm
T u r b i n eS t a t i c DischargePressure 3480 N/cm2 5000 p s i

w
0
W
 1 s t STAGE CROSSOVER BALANCEPISTON
I H L E TP R E S S U R E SUMPPRESSURE
-\
DIFFUSER IMP_ELLER 1 s t STAGE .
DlSCtlARGEPRESSURE

PUMP
BEARING

TEMPERATURE

- TURBINE
OUTLET

TURBINE
, MAN I FOLD

PRESSURE
1 s t STAGETURBINE
NOZZLEPRESSURE
1 s t STAGE CROSSOVER
TURBINE H I D-PRESSURE
COOLANTTEMPERATURE
BALANCE CROSSOVER Is, t STAGE
PRESSURE D l SCHARGE

2nd STAGE
IMPELLER
FRONT SHROUD PRESS^
’ 3 r d STAGE IMPELLER
DISCHARGE PRESSURE

Figure 142. LH2 Turbopump

D u r i n gt h et e s t i n g ,r e d l i n e s were a s s i g n e dt o c e r t a i n k e yp a r a m e t e r s . These
r e d l i n e s i n some i n s t a n c e s were a d j u s t e d f o r t h e p a r t i c u l a r turbopumpspeed
r a n g eb e i n ge v a l u a t e d T
. a b l e s2 3t h r o u g h 26 p r e s e n t h o s er e d l i n e sa p p l i -
c a b l ef o rt u r b o p u m ps p e e d so f1 9 9 0 ,4 7 1 0 ,6 2 8 0 ,a n d9 9 4 7r a d / s( 1 9 , 0 0 0 ,4 5 , 0 0 0 ,
60,000, a n d9 5 , 0 0 0r p m ) ,r e s p e c t i v e l y .

T e s t D i s c u s s i o n .T e s t i n go ft h e Mark 48-F turbopumpassemblybeganon 31 March

1976 a t t h eR o c k e t d y n eP r o p u l s i o nR e s e a r c h Area (PRA). A t o t a lo f 10turbo-
pump tests f o r a n a c c u m u l a t e d r u n d u r a t i o n of 884 s e c o n d s were s a t i s f a c t o r i l y
conducted on LH2 turbopump, S / N 01-0. T a b l e 2 7 p r e s e n t s a summary o ft h o s e
tests c o n d u c t e d , w h i l e a more d e t a i l e d d i s c u s s i o n o f t h e tests i s p r e s e n t e d
be low.

Test No. 1 (016-001)

T e s t Date: 3-31-76
Dur ation:
s155
eco n d s
Objectives: 1. O b t a i n LH2 t u r b o p u m pc h i l l d o w nc h a r a c t e r i s t i c sw i t ht h et u r b o -
pump LH2 i n l e t p r e s s u r i z e d t o 2 1 N/cm2 (30 p s i a ) .
2 .D e t e r m i n et h ei n t e g r i t yo ft h et u r b o p u m p a t theidle-mode
s p e e d of 1 9 90r a d / s( 1 9 , 0 0 0r p m ) . Map t h eh e a d - f l o wc h a r a c -
t e r i s t i c s by m a n u a l l ya d j u s t i n gt h et u r b o p u m ps p e e da n df l o w .
E v a l u a t et h et u r b i n ed i s c h a r g eb a c k - p r e s s u r eo r i f i c i n g .

Results : Countdown p ro c ee d ew d i t h o uatnpyr o b l e m sA. f t esre q u e n c e start,

t h et u r b o p u m po u t l e tt h r o t t l ev a l v e w a s a d j u s t e d t o 55% t o e n s u r e
a s a f e pump o u t l e tb a c k - p r e s s u r el e v e lf o rt h ef i r s t t e s t . The
GH2 s p i n v a l v e w a s s l o w l yo p e n e dm a n u a l l yu n t i l a head rise and
f l o w was i n d i c a t e d on t h e c o n t r o l l e r o p e r a t o r ' s X-Y p l o t t e r .
The turbopumpspeed w a s i n c r e a s e d m a n u a l l y by f u r t h e r o p e n i n g
o f t h e GH2 s p i n v a l v e w h i l e a d j u s t i n g t h e t u r b o p u m p o u t l e t
t h r o t t l ev a l v et oo b t a i nt h en o m i n a lt a r g e t e dc o n d i t i o n s . The
t e s t was t e r m i n a t e dp r e m a t u r e l yd u et o a low i n d i c a t e dt u r b o p u m p
d i s c h a r g ep r e s s u r ef o rt h ei n d i c a t e ds p e e da n df l o wv a l v e s . Tur-
bopump shutdown was s m o o t h ,w i t h no i n d i c a t i o n o f e r r a t i c s p e e d
behavior.

A n a l y s i sP
: o s t t e s at n a l y s i sr e v e a l e dt h a t h et u r b o p u m ps h a f st p e e dd a t a
d i s p l a y was i n e r r o r by a f a c t o ro ff o u r . The a c t u a la v e r a g e
s p e e d w a s d e t e r m i n e d by o s c i l l o s c o p e t o b e a b o u t 5 2 3 r a d / s
(5000 r p m ) ,c o r r e s p o n d i n gt ot h er e c o r d e dl o wt u r b o p u m po u t l e t
pressure. A maximum s p e e do f1 0 4 7r a d / s( 1 0 , 0 0 0 rpm) w a s a c h i e v e d
( d i s p l a y = 4190 r a d / s , ( 4 0 , 0 0 0 r p m ) ,b u t w a s r e d u c e d by c o n t r o l
of t h e GH2 s p i nv a l v ed u et ot h ee r r o n e o u ss p e e dd i s p l a y . The
c a u s eo ft h es p e e dd i s p l a ym a l f u n c t i o n was tracedtothe Anadex
s y s t e m .F o rt h en e x t t e s t , t h e Anadex s y s t e m w a s a d j u s t e d t o
g i v et h ec o r r e c ts p e e di n d i c a t i o n .

205
 TABLE 2-3. MARK 48-F TURBOPUMJ? REDLINES
(1990 r a d / s ; 19,000. rpm)

Parameter ( S I Ur; i t;) Automatic

~ _ ~- _ ~
Pump I n l e tT e m p e r a t u r e (No. I), K 25.6 (Inax)
Pump I n l e tP r e s s u r e (No. 2) N/cm2 Blueline: 52 (rnin)
Redline: 38 (min)
Speed, r a d / s 2722 2722 (max)
Pump B e a r i n gC o o l a n tT e m p e r a t u r e , K AT = +6 d e g r e e s a f t e r
stabilization
T u r b i n eB e a r i n gC o o l a n tT e m p e r a t u r e , K AT = +6 d e g r e e s a f t e r
stabilization
Pump D i s c h a r g eP r e s s u r e , N/cm2 689
B a l a n c eP i s t o nC a v i t yP r e s s u r e , N/cm2 < 207
69 < 'cav
B e n t l yT r a n s d u c e r( R a d i a l ) , mm 0.25
B e n t l yT r a n s u d c e r( A x i a l ) , mm 0.25
Accelerometer, Pump ( R a d i a l " ) , g rms 20
A c c e l e r o m e t e r( A x i a l " ) , rms
g 20
A c c e l e r o m e t e rT
, u r b i n e( R a d i a l : ' : ) , rms
g 20
T u r b i n eI n l e tP r e s s u r e , N/crn2
~. -- .- .... - - .. - -- .- . "

<:2000 Hz Low-Pass F i 1 t e r Tar-get Speed = 1989 I.ad/s

-
P a r a m e t e r( E n g l i s hU n i t s-). - Automat ic Visual
"______
Pump I n l e T
t emperature (No. I ) , R 46 (rnax)

!
I
Pump I n l e tP r e s s u r e (No. 2 ) ,p s i g
I Blueline:
Red1 i n e :
75 (rnin)
55 (min)
Speed,
rpm 26,000 26,000
(max) I
Pump B e a r i n gC o o l a n tT e m p e r a t u r e , R AT = +IO d e g r e e s a f t e r
I
stabi 1 ization i
!
' T u r b i nB
e e a r i nC
g o o l a nTt e m p e r a t u r e , R I
1 AT = +IO d e g r e e s a f t e r
I stabi 1 ization I
I
Pump D i s c h a r gPer e s s u r ep,s i g
I !
1000

1
'

B a l a n c eP i s t o nC a v i t yP r e s s u r e ,p s i g
I 100 < Pcav < 300
I
I
I

j
B e n t l yT r a n s d u c e r( R a d i a l ) i, n c h 0.010
I
' B e n t lTyr a n s d u c e( rA x i a l i)n, c h 0.010
Accelerometer, Pump ( R a d i a l " ) , rms
g 20 !
, A c c e l e r o m e t e( A
r xial?:), rms
g 20 !
I
~ A c c e l e r o m e t eT
r ,u r b i n(eR a d i a l ? : ) rms
g 20
T u r b i nIen l ePt r e s s u r ep,s i g 150
~

__ .. - " . .-. -. . - -. .. --.. ..-.-..- .- " " __ - . -"" . "- " .

I
"I
"2000 Hz Low-Pass F i l t e r

206
 TABLE 24. MARK 48-F TURBOPUMP REDLINES
(4710 rad/s; 45,000 r p m )

Parameter (SI Units) Automatic Visual

Pump I n l e tT e m p e r a t u r e (No. 11, K 25.6 (max)

Pump I n l e tP r e s s u r e (No.
21, K Blueline: 52 (rnin)
Redline: 38 (min)
Speed, r a d / s 10,160 10,160
Pump BearingCoolantTemperature, K AT = 6 degrees a f t e r
stabilization
T u r b i n eB e a r i n gC o o l a n tT e m p e r a t u r e , K AT = 6 degrees a f t e r
stabilization
Pump D i s c h a r g eP r e s s u r e , N/cm2 2068
B a l a n c eP i s t o nC a v i t yP r e s s u r e N/cmZ 207 < PC, < 689
B e n t l yT r a n s d u c e r( r a d i a l ) , mm 0.25
B e n t l yT r a n s d u c e r( A x i a l ) , mm 0.25
Accelerometer, Pump ( R a d i a l " ) , g rms 20
Accelerometer(Axial;:), g rms 20
A c c e l e r o m e t e r ,T u r b i n e , Radial;':,
g rms 20
T u r b i n eI n l e tP r e s s u r e , N/cm2 517 (max)

*2000 Hz Low-Pass F i l t e r T a r g e t Speed = 4712 r a d / s

P a r a m e t e(rE n g l i s h

Pump I n l e tT e m p e r a t u r e
Pump I n l e tP r e s s u r e

Speed,
rpm
Pump BearingCoolantTemperature,
(No.
Units)

(No.
Z),

T u r b i n eB e a r i n gC o o l a n tT e m p e r a t u r e ,

Pump D i s c h a r g eP r e s s u r e ,p s i g
B a l a n c eP i s t o nC a v i t yP r e s s u r e ,p s i g
B e n t l yT r a n s d u c e r( R a d i a l ) ,i n c h
B e n t l yT r a n s d u c e r( A x i a l ) ,i n c h
Accelerometer, Pump (Radial:';),
I),
psig
R

g rms
R

R
I Automat ic
~ " _ _ _
46 (max)

97,000

3000
Visual

1 Redl i ne:
97,000
55 (min)

AT = + 0 degrees a f t e r
stabi 1 zat ion
AT = + 0 degrees a f t e r
stabi 1 zation

300 < Pcav

0.010
0.010
20
< 1000

A c c e l e r o m e t e r (, A x i a l " ) , g rms 20
A c c e l e r o m e t e r ,T u r b i n e( R a d i a l " ) , g rms 20
T u r b i n eI n l e tP r e s s u r e ,p s i g 750 (rnax)
"" - -. . .. . - .. . . -..
"" " .
-. """ -. .. ... - . "_
. . - --

"2000 Hz Low-?ass F i l t e r T a r g e t Speed = 45,000 rprn

207
 TABLE 25. MARK 48-F TTJFGOPUMP REDLINES
(62SO rad/s , 60,000 rpm)
Parameter (SI U ntis ) Automatic Visual

Pump I n l e t Temperature (No. I ) , K 25 (max)

Pump I n l e tP r e s s u r e (No. 2 ) , N/cm 2 Blueline: 59 (min)
Redline: 48 (min)
Speed, rad/s 10,160 IO, 160 (rnax)
Pump BearingCoolantTemperature, K AT = +6 degrees a f t e r
stabilization
TurbineBearingCoolantTemperature, K AT = +6 degrees a f t e r
stabilization
Pymp DischargePressure, N/cm 2 3447
2
B a l a n c eP i s t o nC a v i t yP r e s s u r e , N/cm 345 < Pcav < 1241
B e n t l yT r a n s d u c e r( R a d i a l ) , mm 0.25
B e n t l yT r a n s d u c e r( A x i a l ) , mm 0.25
Accelerometer, Pump (Radial::), g rms 20
A c c e l e r o m e t e r( A x i a l f i ) , rms
g 20
A c c e l e r o m e t e r ,T u r b i n e (Radial.:;), g rms 20
T u r b i n eI n l e tP r e s s u r e , N/cm2 1034 (rnax)

"2000 Hz Low-Pass F i l t e r T a r g e t Speed = 6282 r a d / s

Pump IPnrl e st s u r e (No.p s2i)g, 1

1
1 Blueline:
Redline:
85 (min)
70 ( r n i n ) I1
Speed, rprn 97,000 I 97,000 (max)
I
Pump Bearing
Coolant
Temperature, R ! AT = + I 0 d e g r e e s a f t e r 1
stabi 1 ization
!
Turbine
Bearing
Coolant
Temperature, R AT = +IO d e g r a
e fet se r
stabi 1 ization
i
Pump D i s c h a r g eP r e s s u r e ,p s i g I 5000
B a l a n c eP i s t o nC a v i t yP r e s s u r e ,p s i g i 500 < Pcav < 1800 I
I
I
BentlyTransducer(Radial),inch I ~ 0.010
TBr aenn(i snA
t ldcyxu
hi ac le) r, ! j 0.010
Accelerometer, Pump (Radial;':), g rms
I 20
I
A c c e l(eArxoim
a le) ,t e r , g rrns i 20
A c c e l e r o m e t e rT, u r b i n e(,R a d i a l " ) ,
g rms I i

c
2o
P r e s s u r eI n, l e t T u r b i n e I 1500 (max)
.. - ." " __ I ~ ...- "
. I
. .. . "

"2000 Hz Low-Pass TFai lrtgeer t Speed = 60,000 rpm

. " - -
. "- "

208
 TABLE 26. MARK 48-F TURBOPUMP REDLINES
( 9 9 4 7 rad/s; 95,000 rpm)

Parameter (SI U n i t s ) V i sua1

Pump I n l e tT e m p e r a t u r e (NO. l), K

Pump i n l e tP r e s s u r e (No.
2) N/cm2 Blueline: 59 (min)
Redline: 48 ( m i n )
S p e e dr,a d / s 10,160 10,160
Pump B e a r i n gC o o l a n tT e m p e r a t u r e , K AT = 6 d e g r e e s a f t e r
stabi 1i z a t i o n
T u r b i n eB e a r i n gC o o l a n tT e m p e r a t u r e , K AT = 6 d e g r e e s a f t e r
stabi 1 izat ion
Pump D i s c h a r g eP r e s s u r e , N/cm2 3447
B a l a n c eP i s t o nC a v i t yP r e s s u r e , N/cm 2 965 < P < 2895
cav
B e n t l yT r a n s h c e r( R a d i a l ) , mm 0.25 (max) .
B e n t l yT r a n s d u c e r( A x i a l ) , mm 0.25 (max)
Accelerometer, Pump ( R a d i a l " ) , g rms 20

I
A c c e l e r o m e t e (r A x i a l ; ' : ) , g rms
A c c e l e r o m e t e r ,T u r b i n e( R a d i a l " ) , g rms 20
- ~ _ - "-
__. 2o
22000 Hz Low-Pass F i l t e r T a r g e t Speed = 9947 r a d / s
- - .. ~"

..~~ .-.

I
"" "~

Parameter (Engl ish Units) Automatic Visual

-. -.--. " . .--- " .
Pump I n l e T
t emperature (No. l), R 45 (max) I
iI
,
Pump I n l e tP r e s s u r e

Speed,
rpm
(No. 2 ) ,p s i g

97,000
i1 i Blue1 ine:
Redline:
97,000
85
70
(min)
(min)

I I
Pump B e a r i n gC o o l a n tT e m p e r a t u r e , R ! I AT = + 1 0d e g r e e sa f t e r

T u r b i n eB e a r i n gC o o l a n tT e m p e r a t u r e , R
i I stabi 1ization
. AT = + 1 0d e g r e e sa f t e r
' stabi 1ization
Pump D i s c h a r g eP r e s s u r e ,p s i g 5000
i
B a l a n c eP i s t o nC a v i t yP r e s s u r e ,p s i g 1400 < Pcav < 4200
B e n t l yT r a n s d u c e r( R a d i a l ) i, n c h 0.010
(max)
B e n t l yT r a n s d u c e r( A x i a l ) ,i n c h 0.010
(max)
Accelerometer, Pump ( R a d i a l " ) , g rms I 20
A c c e l e r o m e t e(rA x i a l : : ) , g rms 20
A c c e l e r o m e t e rT
, u r b i n e( R a d i a l ? : ) , g rms 20
____ - - - - - -. .. .. . . "

;':2000 Hz Low-Pass F i l t e r T a r g e t Speeci = 95,000rpm

209
 TABLE 27. ADVANCED SPACE
ENGINE MARK 48-F HYDROGEN TURBOPUMP TEST
HISTORY
(TURBOPLJMP S / N 01-0)

!
Accumulated
Duration, Time,
Test No. Seconds Starts Seconds Rema r ks
"_
01 6-001 3-31 -76 155 1 155 1047 rad/s (10,000 rpm) maximum speed. Average speed
! o f 524 r a d / s (5000 rpm) .
S h a f t speed d i s p l a y e r r o r by
I f a c t o r o f 4. C u t o f f due t o lowind i c a t e dd i s c h a r g ep r e s s u r e .
!
01 6-002 3 - 3 1 -76 ! 33 2 188 Target N = I989 rad/s (19,000 rpm). Max imum ac t u a 1
I

i N = I619 rad/s (15,464 rpm).Shaft speed d i s p l a y h i g h by

f a c t o r o f 2. T e s tc u to f fe r r o n e o u s l y by pump d i s c h a r g e
! I p r e s s u r er e d l i n e .
i 016-003 4-7-76
!
90 3 264 Target N = 4712 rad/s (45,000rpm). Reached 1187 rad/s

j ( I 1 , 3 3 3 rpm)
T e s tc u t o f f
. Shaft speed c o u n t i n e r r o r
due t o f i r e i n f a c i l i t y
i n s t r u m e n t a t i o nf i t t i n g .
by f a c t o r o f 2.
pump i n l e t l i n e

016-004 ' 4-7-76 ! 133 4 397 Target N = 4712 rad/s(45,000rpm). Reached 3926 rad/s
(37,500rpm).Test c u t o f f by erroneousoverspeedindication.
01 6-005 73 5 470 Target N = 4712 rad/s(45,000rpm). Reached 4712 rad/s
(45,000rpm).Test c u t o f f by t u r b i n er a d i a a
l ccelerometer VSC.
01 6-006 1 68 6 638 Target N = 6282 rad/s(60,000rpm). H-Q e x c u r s i o na t 4712
and 6282 rad/s(45,000 and 60,000rpm). T e s tc u t o f f due t o
II i t u r b i n eb e a r i n gc o o l a n tt e m p e r a t u r ed r i f t i n g o f f s c a l e (-355 F ) .
!
I Reached 6837 rad/s
01 6-007
I
31 7 669 i Target N = 9423 rad/s (90,000rpm).
(65,300 rprn). C u t o f f by t u r b i n er a d i a l V S C (10 g rms).
I
i I S h i f t e dt u r b i n er a d i a la c c e lt oo b s e r v e ro s c i l l o s c o p e .
01 6-008 I 31 8 700 Target N = 9423 rad/s (90,000 rprn). Reached 7853 rad/s(75,000
\
I
I rprn). Speed 1 i m i t e d by a v a i l a b l e GH2 p r e s s u r e( s t a r t e dw i t h
! 2930 N/cm2 (4250-psig)tankpressure).
I
01 6-009 ! 36 9 736 Target N = 9423 - 9947 rad/s(90,000 - 95,000 rpm). Reached
I
9737 rad/s(93,000rpm).Shaft speed d i s p l a yc o u n tl o s t .
Pump bearingcoolanttemperature went o f f s c a l e (-355 F).
01 6-01 0

I "
148

. . "
10 884 Target N = 4712 rad/s(45,000
45,000 rpm.
rpm). Actual N = 4712 rad/s
T e s t No. 2
” (016-002)

Test Date : 3-31-76

Duration : 33 s e c o n d s

Objectives : 1. D e t e r m i n et h ei n t e g r i t yo ft h et u r b o p u m p a t t h ei d l e - m o d e
s p e e d of 1990 r a d / s( 1 9 , 0 0 0 rpm) . Map t h eh e a d - f l o w charac-
t e r i s t i c s b ym a n u a l l ya d j u s t i n gt h et u r b o p u m ps p e e da n df l o w .
Evaluatetheturbinedischargeback-pressureorificing.

Results : Countdown p r o c e e d e dw i t h o u ta n yp r o b l e m s .B a s e do nt h e first

test r e s u l t s , the t h r o t t l e valve t e s t p o s i t i o n w a s r e a d j u s t e d
t o a b o u t 35% open.The s t a r t s e q u e n c e w a s smoothwithnoprob-
lems, b u t t h e test w a s t e r m i n a t e dp r e m a t u r e l yb yt h et u r b o p u m p
dischargepressureredline 6 9 0 N/cm2 (1000 p s i g maximum).

Analysis : It w a s d e t e r m i n e d t h a t t h e c u t o f f w a s e r r o n e D u sa n d ,i nf a c t ,t h e
pump d i s c h a r g e p r e s s u r e was a b o u tn o m i n a l for t h e a c t u a l pump
s p e e d . The problem was t r a c e dt o a p r e t e s t pump d i s c h a r g et r a n s -
2
d u ce rc h an g e . On t h e f i r s t t e s t , 0 t o 3445 N / c m ( 0 t o 5 0 0 0 p s i g )
t r a n s d u c e r was u s e d b u t b e c a u s e of t h e r e s o l u t i o n o n t h e X-Y
p l o t t e r a 0 t o 345 N / c m 2 ( 0 t o 500 p s i g )t r a n s d u c e r was installed
t o e n a b l e a more p r e c i s e r e a l t i m e e v a l u a t i o n by t h e c o n t r o l l e r
operator. The f u l l - s c a l ev o l t a g eo u t p u t of t h e 3445 N/cm* ( 5 0 0 0
p s i g ) t r a n s d u c e r w a s t h e same as t h e f u l l - s c a l e c o u t p u t o f t h e
345 N / c m 2 (500 p s i g ) t r a n s d u c e r , b u t t h e c o m p a r a t o r c i r c u i t sen-
s i t i v i t y was n o ta d j u s t e d .T h e r e f o r e ,t h er e d l i n ec i r c u i t
erroneouslyobtained a highdischargepressureelectronicsignal
a n da u t o m a t i c a l l yi n i t i a t e dc u t o f f . The s p e e dm o n i t o rd i s p l a y
systemalsomalfunctionedand w a s i n e r r o r by a f a c t o r of two.
Ac t u alt u rb o p u m ps p e e do b t a i n e d w a s 1 6 1 9r a d / s ( 1 5 , 4 6 4 rpm). It
w a s d e t e r m i n e dt h a tt h ep r o b l e m w a s a s s o c i a t e dw i t ht h et y p e of
An a d exs y s t e mb ei n gu s e d .A n o t h e rt y p eo f Anadex s y s t e m was
i n s t a l l e d t o b e more c o m p a t i b l e w i t h t h e t u r b o p u m p s p e e d m o n i t o r -
ing system.

T e s t No. 3 (016-003)

T e s t Date: 4-7-76

Duration : 90 s e c o n d s

Objectives: 1. Map t h e turbopump performance a t 4 7 1 2r a d / s ( 4 5 , 0 0 0 rpm).

Mapping t o i n c l u d e a f l o w / s p e e d r a t i o r a n g e o f 0 . 7 t o 1.3
of nominal.

2. E v a l u a t et h et u r b i n ed i s c h a r g eb a c k p r e s s u r eo r i f i c i n g .

211
 Results: The t e s t w a s t e r m i n a t e dp r e m a t u r e l yb y an o b s e r v e rd u et o a fire
i n the v i c i n i t y o f t h e turbopump.

Analysis: The f i r e w a s c au s e db y a l o o s e B-nut o ni n s t r u m e n t a t i o n i n the

LI42 s y s t e m . Maximum rpm o b t a i n e d w a s 1 1 8 7r a d / s( 1 1 , 3 3 3r p m ) ;
however,thespeeddatadisplay was a g a i n o f f b y a factorof
t w o ,b u ti n d i c a t e d a real time d i s p l a y o f n e a r l y 240000 r a d / s
(23,000 rpm) . S i n c e t h e 11-Q-rpm v a l u e s for t h e s e tests were
f a l l i n g o n the X-Y p l o t t e r p r e c a l c u l a t e d m a p p i n g l i n e s , i t was
decidedtousethe X-Y p l o t t e r e x c l u s i v e l y t o c o n t r o l t h e t u r b o -
pump o p e r a t i o n .

Test No. 4 (016-004)

Test Date: 4- 7- 76

Duration : 1 3 3s e c o n d s

Objective : 1. O b t a i ns t a b i l i z e d turbopumpperformance a t 1 9 8 9r a d l s( 1 9 , 0 0 0
rpm) f o r r e a l t i m e m a n u a ld a t aa c q u i s i t i o n .

2. Map t h e turbopumpperformance a t 4712 r a d / s( 4 5 , 0 0 0r p m ) .

Mapping t o i n c l u d e a f l o w l s p e e d r a t i o r a n g e o f 0 . 7 t o 1 . 3 of
n o m i n al .

3 .E v a l u a t et h et u r b i n ed i s c h a r g eb a c k p r e s s u r eo r i f ic i n g .

Results : The turbopump r e a l time m a n u a l d a t a a c q u i s i t i o n a t 1 9 8 9r a d l s

(19,000 rpm) was s u c c e s s f u l l yo b t a i n e d .T h e test was terminated
p r e m a t u r e l y by t h et u r b o p u m po v e r s p e e dr e d l i n ed u r i n gt h es p e e d
i n c r e a s ef r o m1 9 8 9t o 4712 r a d / s( 1 9 , 0 0 0t o4 5 , 0 0 0 rpm) l e v e l .

Analysis : Maximum turbopump rpm a c h i e v e d was a b o u t 3926 r a d / s( 3 7 , 5 0 0r p m ) .

A c t u a ls p e e dr e d l i n e w a s s e t a t 4158 r a d / s( 4 0 , 0 0 0r p m ) T
. urbo-
pump o p e r a t i o na p p e a r e dn o r m a l ;t h e r e f o r e ,t h er e d l i n e was read-
j u s t e dt o1 0 , 5 1 6r a d / s( 9 7 , 0 0 0 rpm) maximum, a n da n o t h e r test
was a t t em p t e d .

Test No. 5 (01.6-005)

T e s t Date: 4-7-76

Duration : 7s ec
3 onds

Objectives: 1. Map t h e turbopump performance a t 4 7 1 2r a d / (s 4 5 , 0 0 0r p m ) .

Mapping t o i n c l u d e a f l o w t o s p e e d r a t i o r a n g e o f 0.7 t o 1 . 3
o fn o m i n a l .

2 .E v a l u a t et h et u r b i n ed i s c h a r g eb a c k - p r e s s u r eo r i f i c i n g .

212
 Results : The t a r g e t e d 4712 r a d / s ( 4 5 , 0 0 0 rpm) w a s a c h i e v e d b, u t the test
w a s t e r m i n a t e dp r e m a t u r e l yb yt h eV i b r a t i o nS a f e t yC u t o f f (VSC)
d e v i c e when t h e t u r b i n e r a d i a l a c c e l e r o m e t e r e x c e e d e d 10 g rms).

Analysis: A l l t u rb o p u m p erf o r m a n cve a l u easp p e a r e n dormal. The d a t a ob-

tained by the turbine radial accelerometer appeared to be in
errorB . e n t l yt r a n s d u c e r sa n dt h er e m a i n i n g twoturbopump
a c c e l e r o m e t e rd a t aa p p e a r e dn o r m a l . The t u r b i n er a d i a la c c e l e r o -
meter w a s r e p l a c e d p r i o r t o t h e n e x t test.

T e s t No. 6 (-0 1 6 - 0 0 6 )

T e s t Date: 4-7-76

Duration : 168 seconds

Objectives: 1. Map t h e turbopumpperformance a t 4712 r a d / s ( 4 5 , 0 0 0 rpm) .

Mapping t o i n c l u d e a f l o w t o s p e e d r a t i o r a n g e o f 0.7 t o 1.3
ofnominal.

2. Map t h e turbopumpperformance a t 6 2 8 2 r a d / s ( 6 0 , 0 0 0 rpm) .

Mapping t o i n c l u d e a f l o w l s p e e d r a t i o r a n g e o f 0.7 t o 1.3
o f nominal .
3. E v a l u a t et h et u r b i n eb a c k - p r e s s u r eo r i f i c i n g .

Results : O b j e c t i v e os b t a i n e d
satisfactorily. The b e s t w a s t e r m i n a t e n
de a r
t h ec o m p l e t i o no ft h e H-Q e x c u r s i o n a t 6 2 8 2 r a d / s ( 6 0 , 0 0 0 rpm) due
t ot h et u r b i n eb e a r i n gc o o l a n tt e m p e r a t u r es l o w l yd r i f t i n go f f
t h ec h a r ts c a l e 5 8 K , (-355 F ) .

Analysis: An a n a l y s i so ft h et u r b i n ep r e s s u r er a t i or e v e a l e d a v a l u eo f 1.44
p e rt h ep r e d i c t e dv a l u e .A c t u a lt u r b i n eb a c k - p r e s s u r eo r i f i c e
c o n s i s t e do fn i n eo r i f i c e so fa p p r o x i m a t e l ye q u a ld i m e n s i o n
i n s t a l l e d i n a f a c i l i t ya d a p t e r , PIN 99FS010280. The a c t u a l
g e o m e t r i c a l t o t a l area o f t h e t u r b i n e d i s c h a r g e o r i f i c e ( s ) is
4 . 1 cm2 ( 0 . 6 3 6 i n . 2 )w i t hw e l l - r o u n d e de n t r a n c e s . F o r t h en e x t
t e s t , t h et u r b i n eb e a r i n gc o o l a n tt e m p e r a t u r ec h a r t was rescaled,
s i n c en oa b r u p tt e m p e r a t u r e rise o r anomaly w a s i n d i c a t e d by t h e
d a t a .F o l l o w i n gt h e t e s t , t h e r a w d a t as i g n a lo ft h et u r b o p u m p
r p m w a s a n a l y z e df r o mt h eh i g h - s p e e d FM t a p e . From t h e a n a l y s i s ,
i t w a s e v i d e n tt h a tt h ew a v e f o r mp r o d u c e d by t h e c i r c u i t was
v a r y i n g as a fu nc t i o no ft u r b o p u m ps p e e d . A d e t a i l e de x p l a n a t i o n
of thespeedmonitoringproblemfollows.

F i g u r e 1 4 3 s c h e m a t i c a l l yr e p r e s e n t st h es p e e dm o n i t o r i n gd e v i c e
u s e df o rt h e Mark 48-F LH2 turbopump. A permanentmagnet (PM)
p i d k u po p e r a t e s by c o u p l i n g t h e f l u x (@)p r o d u c e d ( v i a a n i n t e r n a l
PM) a c r o s st h eg a p (G) b e i n gm o n i t o r e d( F i g . 1 4 3 ) . A s t h er o t a t i n g
b o d y(t u rb o p u m ps h a f t ) moves p a s t t h e s e n s i n g t i p o f t h ep e r m a n e n t

213

I
 PERMANENT blAGNET
AND C O I L

RCTAT I FIG
T II C
NAGN ET
MEIIBER

F i g u r e1 4 3 .O r i g i n a l Mark 48-F SpeedPickupSystem

m a g n etwi t h an a n g u l a r v e l o c i t y (w) , t h e f l u x a c r o s s t h e g a p
v a r i e s as a f u n c t i o no fb o t h U and G [$ = f (w, G ) ] . The
v o l t a g ei n d u c e di nt h ec o i lo ft h ep i c k u p i s e x p r e s s e db yt h e
followingequation:

(Lenz ' s law)

I f @ d o e sn o tv a r ys i n u s o i d a l l y( i r r e g u l a ro rd i s c o n t i n u o u sg a p
v a r i a t i o n s ) , IC d @ / d t = a w i l l n o t b e a p u r e s i n u s o i d b u t will
c o n t a i nm u l t i p l eh a r m o n i c sc o r r e s p o n d i n g to a(G)/t. The i n t e r -
a c t i o no ft h ep i c k u ps o u r c ei m p e d a n c ea n dt h et o t a ll o a di m p e d a n c e
( i n c l u d i n g l i n e e f f e c t s )c a u s e st h e s eh a r m o n i c st os h i f t i n ampli-
t u d ea n dp h as e as (11 v a r i e s .F i x e df r e q u e n c yf i l t e r s become i m -
p r a c t i c a lf o rf i l t e r i n go u tt h e s eh a r m o n i c so v e rw i d er a n g e so f
w. F i g u r e 144Ashows a low-frequencywaveformrecordedfrom the
Mark 48-F s p ee dp i ck up . The d i s t o r t i o nr e s u l t i n gf r o mt h en o t c h e d
s h a f tc o n f i g u r a t i o n i s r e a d i l ya p p a r e n t .F i g u r e 1 4 4 ~showsthe
same p i c k u pw a v e f a r md i s t o r t e d a t h i g h e rf r e q u e n c i e s . The e f f e c t s
o fh a r m o n i c ss h i f t i n gb e c o m e sr e a d i l ya p p a r e n t . A s t h ew a v e f o r m
becomesmoreandmore d i s t o r t e d ,w i t hi n c r e a s i n g w, d e s i g n i n g
c i r c u i t r yw i t hs e n s i n gt h r e s h o l d sa n da d e q u a t es e n s i t i v i t yb e c o m e s
d i f f i c u l t , t h a t i s , a v o i d i n gt h ed i s t o r t i o nw h i l es i m u l t a n e o u s l y
s e n s i n gt h ep u l s e , b e c o m e si m p r a c t i c a l .

214
 LOW-FREQUENCY
A. WAVEFORM

B. HIGH-FREQUENCY
WAVEFORM

Figure 144. High-speed FM Tape Analysis, Mark 48-F

LH2-Turbopump rpm Test 016-006

215
 F i g u r e s 14% t h r o u g h1 4 5 cr e p r e s e n ts p e c t r a lp l o t st h a t show
t h e relative h a r m o n i c c o n t e n t of t h e w a v e f o r m o f F i g . 144A a n d
144B ( f r e q u e n c y i s t h e a b c i s s a w h i l e a m p l i t u d e i s t h eo r d i n a t e )
a t d i f f e r e n tf r e q u e n c i e s .F i g u r e 145D ( I s o p l o t ) is a similar
p l o t , a t r e d u c e da m p l i t u d e ,a n ds h o w st h eh a r m o n i cs h i f t a t 4-
s e c o n d i n t e r v a l s as w i s i n c r e a s e d f r o m z e r o t o 6 2 8 2 r a d / s
(60,000 rprn).

Theanswer t o t h e s p e e d m o n i t o r i n g p r o b l e m a p p e a r s t o b e modi-
fyingthecontouroftherotatingsurface s o t h a t @ varies s i n u -
s o i d a l l yw i t ht h e minimum h a r m o n i cc o n t e n t .T h i s w a s a ni m p r a c -
tical modificationtothe Mark48-F turbopump a t t h i s time;
t h e r e f o r e , a t h r e s h o l dt r i g g e r i n gc i r c u i t w a s d e s i g n e d .F i g u r e
1 4 6r e p r e s e n t st h ew a v e f o r m a t a b o u t6 2 8 2r a d / s( 6 0 , 0 0 0 rpm)
t a k e nf r o mt h e E" t a p eo f t e s t 016-006.Peaks A and B are t h e
p u l s e sp r o d u c e db yt h e two n o t c h e d s u r f a c e s ( e v i d e n t l y a small
difference in geometry exists between slot A and s l o t B r e s u l t i n g
inthedifferenceinpulseheights)whilepeaks C y D, and E a r e
t h ed i s t o r t i o n sp r o d u c e db yt h eh a r m o n i c s . The t h r e s h o l dm o n i t o r
c i r c u i t w a s d e s i g n e dt oc o u n to n l yt h o s ew a v e f o r mv o l t a g ea m p l i -
t u d e sg r e a t e rt h a nt h ei n d i c a t e d l e v e l , H , o fF i g 1. 4 6 T. hus,
thedistortionproducedbythesystem was i g n o r e d f o r a l l v o l t a g e
levelsbelow, H.

-
Note: During the assembly and checkout of the Mark 48-0 turbo-
pump s p e e d m o n i t o r i n g d e v i c e , t h e i n f o r m a t i o n a n d r e c o m m e n d a t i o n s
derivedfromthe LH2 turbopump t e s t i n g was u s e d t o d e s i g n t h e
s p e e d - p i c k u p r, o t a t i n g - s h a f tg e o m e t r y shown i nF i g . 147A. F i g u r e
147B r e p r e s e n t st h eo u t p u to ft h e same p i c k u p( a t2 0 9 4r a d / s ,
20,000 rpm)when installed with the modified shaft design.
C o n s i s t e n t o u t p u t s were m o n i t o r e df r o m1 0 4 7t o3 1 4 1r a d / s( 1 0 , 0 0 0
t o 30,000 rpm). It a p p e a r st h a tt h er o t a t i n gc h o r d( r e p r e s e n t e d
b yt h ef l a ts u r f a c eo fF i g . 147A) c a u s e s t h e f l u x t o v a r y more
s m o o t h l yt h a nt h e LH2 t u r b o p u m pn o t c h e dc o n f i g u r a t i o n ,a l t h o u g h
thewaveform i s s t i l l n o t a p u r es i n u s o i d . However,enough
improvement i n t h e w a v e f o r m h a s b e e n a c h i e v e d t o p r o d u c e a usable
signal. The d i s t o r t i o n i s s u f f i c i e n t l y low s o t h a t e f f e c t i v e
thresholdsandsensitivityvaluescanbe set.

Test No. 7 : (016-007)

T e s t Date: 4-9-76

Duration : 31 s e c o n d s

Objective: 1. Ach i e v e9 4 2 3rad / (9

s 0,000 rpm) f o r a s t a b i l i z e dp e r i o dt o
e v a l u a t et h et u r b o p u m pi n t e g r i t ya n dp e r f o r m a n c e .

2. E v a l u a t et u r b o p u m ps p e e da n dm o n i t o rt h r e s h o l dc o u n t i n gc i r c u i t .

216
 A B

1 D
L

Figure 145. High-speed FM Tape Analysis, Mark 4 8 4 Turbopump

rpm Spectral Analysis, Test 016-006
 Peak A ( n o t c h 1)

"
1 Peak B ( N o t c h 2)

II n H

Figure 146. O r i g i n a l Mark 4 8 SpeedPickupSystems

Results : Maximum rpm a c h i e v e d w a s a b o u t 6837 r a d / s ( 6 5 , 0 0 0 rpm) when the

VitrattonSafetyCircuit (VSC) d e v i c e i n i t i a t e d c u t o f f d u e t o a n
indicatedgreaterthan 20 g m s v a l u e a t t h e t u r b i n e r a d i a l
a c c e l e r o m e t e rl o c a t i o n . Turbopump p e r f o r m a n c e w a s s a t i s f a c t o r y .

Analysis: Test r e s u l t si n d i c a t e dt h a t h e g l e v e (l 2 1 0 g rms) a s s i g n e d

w a s t o ol o w ,s i n c et h er e m a i n d e ro ft h eh i g h - s p e e dr o t o r d y n a m i c
i n s t r u m e n t a t i o nd i dn o ti n d i c a t e a p r o b l e m .F o rt h en e x t test,
theturbineradialaccelerometeroutput was moved t o a n o s c i l l o -
s c o p e ,m o n i t o r e db ya no b s e r v e r ,a n dt h er e d l i n e level was i n -
c r e a s e d t o 20 g rms. The r e m a i n d e ro ft h et u r b o p u m pp e r f o r m a n c e
was s a t i s f a c t o r y . The s p e e dm o n i t o rc i r c u i tf u n c t i o n e d
satisfactorily.

Test No. S : (016-008)

Test Date: 4-9-76

Duration : 3s 1
e co n d s

Objective: 1. .Achieve 9423 r a d / s ( 9 0 , 0 0 0 rpm) f o r a s t a b i l i z e dp e r i o d to

e v a l u a t et h et u r b o p u m pi n t e g r i t ya n dp e r f o r m a n c e .
2. E v a l u a t et u r b o p u m ps p e e dm o n i t o rt h r e s h o l dc o u n t i n gc i r c u i t .

218
 A.
MARK 48-0 L O 2 TURBOPUMPSPEEDPICKUPSHAFT
R E L A T I V E GEOMETRY(FOURPULSESPERREVOLUTION)

B.
LABORATORY TEST RESULTS OF M A R K . 4 8 - L0 O T2 U R B O P U M P
S P E E DM O N I T O RC I R C U I T( 3 1 4 1R A D / S , 30,000 RPM SHOWN)

Figure 147. Mark.48-0 LO2 Turbopump Speed MonitorCheckout

219
 Results : The test w a s t e r m i n a t e dd u et o a l a c ko fs u f f i c i e n t GH2 t u r b i n e
d r i v e - g a sp r e s s u r et oa c h i e v et h ed e s i r e d9 4 2 3r a d / s( 9 0 , 0 0 0r p m ) .
A c t u a l maximum t u r b o p u m p s p e e d o b t a i n e d w a s a b o u t7 8 5 3r a d / s
(75,000 rpm) . Turbopump o p e r a t i o n w a s s a t i s f a c t o r y .P r i o rt o
t h e n e x t t e s t , t h e GH2 s u p p l y l i n e a t t h e g a s g e n e r a t o r i n l e t
c o n n e c t i o n w a s changedfrom a 2.54 cm t o a 5.04 c m ( 1 . 0 i n c h t o
2 - i n c h )o dl i n et or e d u c et h el i n er e s i s t a n c eb e t w e e nt h e GH2
s p i n valve a n d t u r b i n e i n l e t .

T e s t No. 9 : (016-009)

T e s t Date: 4-15-Z6

Duration: 36 s e c o n d s

Objective: 1. Achieve9423 t o 9 9 4 7r a d / s( 9 0 , 0 0 0t o9 5 , 0 0 0 rpm) f o r a

stabilizedperiodtoevaluatethe turbopump i n t e g r i t y and
p erfo rm an c e.

2. E v a l u a t et u r b o p u m ps p e e dm o n i t o rt h r e s h o l dc o u n t i n gc i r c u i t .

Results : Turbopump p e r f o r m a n c ep a r a m e t e r si n c r e a s e ds m o o t h l yu n t i l , at
>8376 r a d / s( 8 0 , 0 0 0r p m ) ,t h es p e e dm o n i t o rd i s p l a yc i r c u i t mal-
f u n c t i o n e d ,e x h i b i t i n g e r r a t i c s p e e dc o u n t s . A p o s t t e s t manual
c o u n to ft h e r a w s i g n a l rpm showed t h a t a maximum o f9 7 3 7r a d / s
(93,000 rpm) h a db e e na c h i e v e d .A c t u a lc u t o f f w a s i n i t i a t e d by
t h e t u r b o p u m pb e a r i n gc o o l a n tt e m p e r a t u r er e d l i n eo b s e r v e r when
thevalueexceededthechart s c a l e o f 5 8 K (-355F).

Analysis : A reviewofthe r a w turbopump rpm d a t a o n h i g h - s p e e d i n s t r u m e n -

t a t i o n showed t h a t , a t i n c r e a s i n g v a l u e s o f s h a f t s p e e d , t h e
a b s o l u t em a g n i t u d eo ft h ew a v e f o r md e c r e a s e d .R e f e r r i n gt o
Fi g .1 4 6 : Peaks A a n d B d e c r e a s e dt ot h ep o i n tw h e r et h e
thresholdmonitorvalueexceededtheactua.1signaloutputfor
peak B y t h u sh a l v i n gt h es p e e dc o u n t .H o w e v e r ,t h em a g n i t u d e
ofpeaks A and B f l u c t u a t e d d u r i n g t h e t e s t , a c c o u n t i n gf o rt h e
e r r a t i c real time s p e e dd i s p l a y . No p r o b l e m so rh a r d w a r e damage
i s suspected due to the higher-than-normal turbopump bearing
c o o l a n tt e m p e r a t u r e . Some e l e v a t i o ni nb e a r i n gt e m p e r a t u r e is
t o b ee x p e c t e d a t h i g h e rt u r b o p u m ps h a f ts p e e d s .

Test N o . 1 0 : (016-010)

Test Date: 4-15-76

Duration : 143 seconds

Objective: 1. E v a l u a t et h ei n t e g r i t y of t h e turbopump a t c o n s t a n t 4712 r a d / s

(45,000 rpm) f o r 200 s e c o n d so r test s t a n d l i m i t a t i o n .
2 .E v a l u a t et u r b o p u m ps p e e dm o n i t o rt h r e s h o l dc o u n t i n gc i r c u i t
a t 4712 ra d / s(4 5 , 0 00r p m ) .

220
Results : A l l o b j e c t i v easc h i e v esdu c c e s s f u l l y . .

Analys isA
: ct u atlu rb o p u m ps p e ed w a s h e l dc o n s t a n t a t 4712 r a d / s ( 4 5 , 0 0 0
rpm) ' f o r t h e d u r a t i o n o f t h e test withmanualcontrolofthe GH2
spinvalve.Finalthrottlevalvesetting w a s 28% o p e n i n g t o
t a r g e tn o m i n a l pump p e r f o r m a n c e . The s p e e dc o u n t i n gd i s p l a y
circuitfunctionedflawlessly a t t h e l o w e r rpm 4712 r a d / s ( 4 5 , 0 0 0
rpm) a n d a g r e e d t o a c t u a l FM and IBM d a t a .

Pump Hydrodynamic Performance. A discussion of the pump h y d r o d y n a m i c t r e n d s

o b s e r v e d . i nt h et u r b o p u m p test d a t a i s p r e s e n t e d i n t h e f o l l o w i n g .

Head a n dE f f i c i e n c y .T h e pump p r e s s u r e rise i s shown as a f u n c t i o no f

t h ed i s c h a r g ef l o wi nF i g . 148. R e p r e s e n t a t i v ed a t ap o i n t s are shown a t
s p e e d so f 4 7 1 2 ,6 2 8 2 ,7 8 5 3 and 9947 r a d / s ( 4 5 , 0 0 0 ,6 0 , 0 0 0 ,7 5 , 0 0 0 , and 9 5 , 0 0 0
r p m ) .F o rp u r p o s e so fc o m p a r i s o n ,t h ep r e d i c t e dp r e s s u r e rise f o re a c ho f
t h e s es p e e d s i s a l s o shown o v e r a b r o a df l o wr a n g e . A s c a nb es e e nf r o mt h e
f i g u r e ,t h ea g r e e m e n ti ng e n e r a l is excellent. The h e a d rise a t t h e t h r e e
l o w e rs p e e d sg e n e r a l l ye x c e e d st h ep r e d i c t i o ns l i g h t l y ,a l t h o u g h i t a l s oi n d i -
cates a t r e n dt o w a r d a somewhat s t e e p e r h e a d - f l o w r e l a t i o n s h i p so that, at
h i g h e rf l o w s ,t h eh e a d i s b e l o wt h ep r e d i c t e d a t some p o i n t s .

The d a t a o b t a i n e d a t t h e h i g h e s t s p e e d l e v e l s , n e a r 9423 r a d l s ( 9 0 , 0 0 0 rpm)

f a l l b e l o wt h ep r e d i c t e dc u r v e .H o w e v e r ,t h ep r e d i c t e dc u r v e s were g e n e r a t e d
as a p r e s s u r e rise f r o m t h e f i r s t - s t a g e i m p e l l e r t o t h e pump d i s c h a r g e ,a n d
were b a s e do nc a l c u l a t e db e a r i n gf l o wa n dt e m p e r a t u r ev a l u e s . To a t t e m p t
t om a t c ht h ed a t a , a small a d d i t i o n a l p r e s s u r e l o s s m u s t b e a d d e d t o r e p r e s e n t
t h e pump i n l e t c o n f i g u r a t i o n , a n d t h e m e a s u r e d i n l e t b e a r i n g f l o w t e m p e r a t u r e
s h o u l db eu s e d . The f o r m e ro ft h e s ec o r r e c t i o n sh a s a v e r y small e f f e c t , a n d
i s a f u n c t i o no f the f l u i dv e l o c i t ys q u a r e d . The l a t t e r c o r r e c t i o n i s n o t
small b e c a u s et h em e a s u r e dt e m p e r a t u r eo ft h eb e a r i n gc o o l a n tf l o w w a s much
h i g h e rt h a ne x p e c t e d . A d i s c u s s i o no ft h i sa n o m a l y i s p r e s e n t e d i n a sub-
s e c t i o nb e l o w . I t s h o u l db en o t e dt h a tt h es c a t t e ri nt h ed a t as c a l e dt o
9947 r a d / s ( 9 5 , 0 0 0 rpm) i nF i g . 1 4 8 s h o u l dn o tb ei n t e r p r e t e d as a ni n d i c a -
t i o no f a p o s i t i v e H-Q s l o p e . Some o ft h eh i g h - s p e e dd a t a were o b t a i n e d
w i t h o u ts u f f i c i e n ts t e a d y - s t a t ei n t e r v a lf o rs a t i s f a c t o r yr e p e a t a b i l i t y .

The p r i m a r y f a c t o r p o s t u l a t e d as c o n t r i b u t i n gt o w a r dt h el o w e rp e r f o r m a n c e
i s i n c i p i e n t c a v i t a t i o n of t h e f i r s t - s t a g e i m p e l l e r . A t t h eh i g h e rs p e e d s ,
thesuctionspecificspeedofthefirst ' i m p e l l e r is increasing with a result-
i n gh i g h e rp o t e n t i a lf o rc a v i t a t i o n .T h i s i s compoundedby t h eh i g h e r t e m -
p e r a t u r eo ft h eb e a r i n gc o o l a n tf l o w .

U s i n gt h e pump i n l e ta n dd i s c h a r g ep r e s s u r ea n dt e m p e r a t u r e s ,t h e pump i s e n -
t r o p i ce f f i c i e n c yc a nb ec a l c u l a t e d . This i s e n t r o p i c e f f i c i e n c y is v e r ys e n -
sitivetothetemperaturedifferentialacrossthe pump; t h e r e f o r e , a t t h e
l a r g e rs p e e d sw i t hh i g h e rt e m p e r a t u r ed i f f e r e n t i a l s ,t h ea c c u r a c yo ft h e tem-
p e r a t u r em e a s u r e m e n t i s n o t as c r i t i c a l and a more a c c u r a t e e f f i c i e n c y c a n b e
d e t e r m i n e d .F o re x a m p l e ,n e a r 9423 r a d / s ( 9 0 , 0 0 0 rpm) , t h et e m p e r a t u r ed i f f e r -
e n t i a l a c r o s s t h e pump is 28 t o 33 K (50 t o 60 F) b u t , a t 4712 r a d / s ( 4 5 , 0 0 0
r p m ) , i t i s o n l y a b o u t 8 K (12 F) .

221
 D I SCHARGE FLOW, LB/SEC

G 1 .o 2.0 3.0
D l SCHARGEFLOW, kg/s

Figure 148. Mark 48-F Pump Performance

2 22
 The e f f i c i e n c y i s e x p e c t e d t o v a r y w i t h Q/N (where Q e q u a l s pump f l o w i n
gpm, and N i s pump s p e e d i n rpm) a n d ,d u et ot h et h e r m o d y n a m i cc h a r a c t e r -
istics o ft h eh y d r o g e n , w i l l v a r yw i t hs p e e d .T h e s ee f f e c t s are c l e a r l y
seen i n t h e d a t a i n F i g . 149. T h em e a s u r e de f f i c i e n c i e s a r e h i g h e rt h a n
predictedandconsideredtobevery good f o r the s i z e a n d c o m p l e x i t y of t h i s
pump. The f l o wr a n g ec o v e r e db yt h ed a t a i s minimal, s o t h a tt h es h a p e of
t h ee f f i c i e n c yc u r v e s as f u n c t i o n of Q / N i s somewhat s u b j e c t i v e . The d a t a
i n t h es p e e dr a n g eo f5 2 3 5t o 6282 r a d / s( 5 0 , 0 0 0t o6 5 , 0 0 0 rpm) c o v e r s t h e
l a r g e s tf l o wr a n g e ,a n d was usedtoestablish the g e n e r a l s h a p e of the test
d a t ac u r v e s .W i t ht h e s ec u r v e s ,t h ed a t ai n d i c a t et h a tt h ep e a ke f f i c i e n c y
p o i n t o c c u r s a t a somewhat smaller f l o w than p r e d i c t e d , b u t v e r y near t h e
d e s i g np o i n t Q/N. The c u r v e s a l s o i n d i c a t e t h a t t h e e f f i c i e n c y is d r o p p i n g
m o r eq u i c k l yt h a np r e d i c t e d a t b o t ht h eh i g h -a n dl o w - f l o wc o n d i t i o n s . With
small pumps, i t g e n e r a l l y i s more d i f f i c u l t t o a c h i e v e a b r o a df l o wr a n g e .

Numerous i n t e r n a l p r e s s u r e m e a s u r e m e n t s were made a t d i f f e r e n t p o i n t s t h r o u g h

t h e pump. T h e s ei n t e r n a lp r e s s u r e s a r e , o fc o u r s e ,m o s tu s e f u l as d i a g n o s t i c
i n f o r m a t i o nt ou n c o v e rt h es o u r c eo fp e r f o r m a n c ed e f i c i e n c i e s ,b u tn os i g n i -
f i c a n tp e r f o r m a n c ed e f i c i e n c i e sw e r eu n c o v e r e di nt h ep r e s e n t test e f f o r t .
W i t ht h e s ei n t e r n a lp r e s s u r e s , a c o m p a r i s o nw i t hp r e d i c t e di n t e r n a lp r e s s u r e s
i s p o s s i b l et oi n d i c a t et h ec o n s i s t e n c yo ft h ep r e d i c t i o n a t intermediate
s t e p s . Having m e t t h e o v e r a l l pump p e r f o r m a n c ep r e d i c t i o n , i t w a s expected
t h a tt h ei n t e r m e d i a t ep r e s s u r e sw o u l da l s ob e met. T h i s i s s e e nt ob et h e
cas ef r omF i g .1 5 0an d1 5 1 ,wh i chc o m p a r ep r e d i c t e da n d test pressures a t
s e v e r a ls t a t i o n sa n d a t two d i f f e r e n ts p e e d s . The a c t u a l t e s t v a l u e s a r e
shown bysymbolsand are a r b i t r a r i l y c o r r e c t e d b y s t r a i g h t l i n e s , n o t
n e c e s s a r i l yi m p l y i n gt h a tt h ep r e s s u r ev a r i e sl i n e a r l yw i t hd i s t a n c e .F o rt h e
predictedvalues,theactualmeasuredinletandbearingcoolanttemperatures
were used as a s t a r t i n g p o i n t .

A t t h es p e e do f 6125 r a d / s( 5 8 , 5 0 0 rpm) ( F i g .l 5 0 ) ,t h ep r e d i c t e da n dm e a s u r e d
v a l u e s are v e r y c l o s e a t e a c h p o i n t , t h e m e a s u r e d d a t a s h o w i n g somewhat b e t t e r
p r e s s u r er e c o v e r yt h r o u g ht h es e c o n d - s t a g er a d i a l l yo u t w a r dd i f f u s e rt h a n was
predicted. A t 9 4 2 3 r a d / s (90,000 rpm) ( F i g .1 5 1 )t h ef i r s t - s t a g ei m p e l l e ra n d
d i f f u s e r a p p e a r t o beshy i n pe r f o r m a n c e .T h i s i s compensatedsomewhatbythe
good p e r f o r m a n c eo ft h es e c o n dd i f f u s e r .H o w e v e r ,t h e loss ofperformance
inthefirststagecouldbeindicativeof a potentialcavitationproblem,
o r i t may i n d i c a t e s i m p l y t h a t t h e q u a l i t y o f t h e f i r s t i m p e l l e r , f r o m a
f a b r i c a t i o ns t a n d p o i n t , i t l e s s t h a nt h eo t h e r s ,a n dt h a tt h i s i s beginning
t o show d e t r i m e n t a le f f e c t s a t t h eh i g h e rf l o w sa n ds p e e d s . I t a l s os h o u l d
bekeptin mind t h a tt h e s em e a s u r e dp r e s s u r e s are l o c a l s t a t i c p r e s s u r e sa n d
may n o t b e t r u l y r e p r e s e n t a t i v e o f t h e a v e r a g e s t a t i c p r e s s u r e a c r o s s t h e
s t a t i o n ,a n dt h a tt h i sl o c a lv a l u ec o u l de a s i l yv a r yf r o m a t r u ea v e r a g e a t
c h a n g i n gs p e e d sa n df l o w s .I ng e n e r a l ,t h eo v e r a l la g r e e m e n tb e t w e e nm e a s u r e d
p r ve d
aalinuc dteesd g o ovde. r y ibse c o ntsoi d e r e d -
S u c t i o nP e r f o r m a n c e .T h e r e w a s no p l a nt or u n a t y p i c a l c a v i t a t i o n test
w i t h pump i n l e t p r e s s u r e d e c r e a s i n g u n t i l a d r o pi nh e a do c c u r sd u et o pump
c a v i t a t i o n .I ng e n e r a l ,t h e pump i n l e t p r e s s u r e w a s m a i n t a i n e d a t a p p r o x i -
m a t e l yt h ec o n s t a n tv a l u eo f 6 9 N/cm2 (100 p s i a ) .
T h e r e f o r e ,t h eo n l yc h a n g e s

223
 TEST SPEED RANGE
8376 < rad/s
6806 < rad/s < 8376
5235 < rad/s < 6806
3665 < rad/s < 5235

0 80,000 < RPM

0 65,000 < RPM < 80,000
0 50,000 < RPM < 65,000
35,000 < RPM < 50,000
8 PREDICTED
AT
(35,000 RPM)
9947 r a d / s

40 I I I I
0.4 0 .0.7
5 0.6 0.8 x

Q/N, GPH/RPM

5.0 4.0 3.0 X

Q/N (rn3/s)/ ( r a d / s )

Figure 149. Mark 48-F Pump Efficiency

 MEASURED
PREDICTED
I “1
1000

500

F i g u r e 150. Mark 48-F Pump Test Data: Run 6 , S l i c e 10; N = 6125 r a d / s

N 4800
N
o\

3000

4000 -0- MEASURED

PREDICTED

a
;3200
a
200a

v)
w 2400

-
V

s o ”
l-
a
160C
1 ooc ,““””” /

0’
/
80c
/’/
a

F i g u r e 151. Mark 48-F Pump Test Data; Run 9, Slice 7; N = 9 4 2 3 rad/s (90,000 rpm)
 in thesuctionspecificspeed are t h o s e r e s u l t i n g f r o m t h e i n c r e a s e i n flow
. ands peed. I f t h e pump i n l e t p r e s s u r ea n dt e m p e r a t u r e( u p s t r e a mo ft h e pump
i n l e t m a n i f o l d ) are u s e d t o c a l c u l a t e t h e net p o s i t i v e s u c t i o n h e a d ( W S H ) ,
theresultingsuctionspecificspeeds are l o w t h r o u h o u t t h e test e f f o r t ,
r e a c h i n g a maximum o f 2 . 0 9 ( r a d / s ) ( m 3 / s ) 1/21 (J/kg)3Y4 5700 rpm g p m 1 / 2 / f t 3 / 4
a t 9737ra d / s(9 3 , 0 0 0rp m ). However, t h e c r i t i c a l s u c t i o ns p e c i f i cs p e e d is
t h a to c c u r r i n g a t t h e f i r s t - s t a g e i m p e l l e r i n l e t . This r e q u i r e sm i x i n gt h e
estimatedfrontwear-ringleakageandthefrontbearingcoolantflowwiththe
pump i n l e t f l o w t o e s t a b l i s h t h e a v e r a g e t e m p e r a t u r e at thispoint.

Using a 9 4 2 3ra d / s(9 0 , 0 0 0 rpm) d a t a p o i n t as a ne x a m p l e ,t h es u c t i o n s e ific

speed, based on pump inlet: c o n d i t i o n s , w a s 2 . 0 4 ( r a d / s ) ( n ~ ~ / s ) ~ / ~ / ( J / k g )S/E
(5559 rpmgprn1l2/ ( f t ) 314) but, based on calculated impeller inlet conditions,
w a s 2 . 4 7 ( r a d / s ) ( 1 n ~ / s ) l / ~ / ( J / k g > 3 / 4 ( 6 7 4 1 rpm gpm l l 2 / f t 3 i 4 ) , a 21% i n c r e a s e .
T h i si n c r e a s e i s l a r g e ,p r i m a r i l yb e c a u s eo ft h eh i g ht e m p e r a t u r eo ft h e
b e a r i n gc o o l a n tf l o w . The n e c e s s a r yf l o w r a t et om a t c ht h em e a s u r e db e a r i n g
d i s c h a r g et e m p e r a t u r e i s c a l c u l a t e dt ob ea p p r o x i m a t e l y0 . 0 0 1 7 7k g / s( 0 . 0 0 3 9
lb/sec).

I na na t t e m p tt oa s s e s st h ei m p a c to ft h eb e a r i n gc o o l a n tf l o w r a t e ,w h i c h is
d e s c r i b e di nd e t a i lb e l o w , a r a n g eo fo r i f i c er e s i s t a n c ev a l u e s was s t u d i e d , t h e
I< v a l u e su s e db e i n gv a r i e df r o m1 . 0t o1 . 5 .T h r o u g ht h i sr a n g eo f K v a l u e s ,t h e
c o o l a n tf l o w r a t et h r o u g ht h eb e a r i n gc h a n g e d by a p p r o x i m a t e l y2 2 % . Even w i t h
t h eh i g h e rl o s s e s ,t h ef l o w r a t et h r o u g ht h eb e a r i n g was 0.048 k g / s (0.106 l b / s e c ) .
W i t hf l o w r a t eo ft h i sm a g n i t u d e , i t i s n o tp o s s i b l et oe x p l a i nt h eh i g ht e m p e r a -
turemeasuredatthebearingexit.

T h er e m a i n i n gp a r a m e t e r st h a tc a na f f e c tt h ec o o l a n tf l o w r a t e are t h e areas
o ft h eo r i f i c e s .O r i f i c e s 3 and 6 a r ed r i l l e dh o l e sw h i c hc a n n o tc h a n g e .
Area A5 i s c o n s i d e r a b l yh i g h e rt h a na n yo t h e ri nt h es y s t e m .T h e r e f o r e ,t h e
o n l yc r i t i c a la r e a sc o n c e r n i n gt h ef l o w r a t et h r o u g ht h eb e a r i n g AI, A 7 a , and
A7b. A p a r a m e t r i cs t u d yo ft h e s e areas was done t o e s t a b l i s h t h e areas a t
t h e s es t a t i o n st h a tw o u l dr e d u c et h ef l o wt h r o u g ht h eb e a r i n gt o a rate a t
w h i c ht h ee x i tt e m p e r a t u r ew o u l dr e a c ht h em e a s u r e d value.

R e d u c i n go n l ya r e a A 1 c a n n o tr e d u c et h ef l o w r a t et h r o u g ht h eb e a r i n gb e l o w a
minimum o fa p p r o x i m a t e l y0 . 0 2 7k g / s (0.06 l b / s e c ) .T h i s i s due t o t h e f a c t
t h a t , as t h ep r e s s u r ed r o pt h r o u g h A 1 i n c r e a s e s ,t h ef l o wi ns e g m e n t 2 through
t h e rear wear r i n g reverses a n df l o w st h r o u g ht h eb e a r i n g . I t w a s found i n
t h ea n a l y s i st h a to r i f i c e 7a i s t h e c o n t r o l l i n g o r i f i c e p a s t t h e b e a r i n g .
The o r i g i n a lc l e a r a n c e a t o r i f i c e 7a i s 0 . 1 5 2 mm (0.06 i n c h ) .R e d u c i n gt h e
gap a t o r i f i c e 7a t o 0.005 mm (0.0002 i n c h ) , w h i l e h o l d i n g A c o n s t a n t ,t h e
f l o w r a t et h r o u g ht h eb e a r i n g , i 3 , i s r e d u c e dt o 0.003 k g / s( 0 . 0 0 7l b / s e c ) .
T h i sf l o w r a t ew o u l dy i e l dt h em e a s u r e de x i tt e m p e r a t u r ei ft h eb e a r i n gh e a t
o u t p u t were a p p r o x i m a t e l y 1 . 8 times t h a t a n a l y t i c a l l y p r e d i c t e d , w h i c h is
q u i t er e a s o n a b l e . A f v r t h e rr e d u c t i o ni nt h e gap a t p o i n t7 at o 0.0002 mm
(0.0001 i n c h )r e d u c e s u3 t o a r a t e o f0 . 0 0 1 3 k g / s (0.0028 l b / s e c ) d e s i g n was
e x p e c t e dt oa c h i e v e a s u c t i o ns p e c i f i cs p e e do fa p p r o x i m a t e l y4 . 0 4( r a d / s )
( m 3 / ~ ) ~ / ’ / ( J / k g ) ~ / ~ ( 1 1 , 0 0rpm 0 gpm 1 / 2 / f t 3 / 4 .H o w e v e r ,w i t ht h e small s i z e
o ft h ei m p e l l e r sa n dt h ec o r r e s p o n d i n gd i f f i c u l t yo fm a i n t a i n i n gt h ed e s i r e d
inletthicknessandbladeangledistributions, a suctionspecificspeed of

227
 4.04 ( r ad/s ) (m 3 / ~ )' !~ / (J / k g ) 3/4 (11,000 rpm g ~ m L / 2 / f t 3 / ~ ) . c o u l d b e o p t i m i s t i c ,
s p e e d s o f 2.57
A t the d e s i g n f l o w
2/(J/kg)3/4 7000 rpm
rpm gpml 2 / f t 3 / 4 )
s p esepde sc ui fcitci o n is p r e s s ui rnel e t .)
Inexamining a l l o f t h e d a t a p o i n t s f r o m t e s t 9 which were n e a r 9 4 2 3 r a d / s
(90,000 rpm), there i s a r a t h e r c o n s i s t e n t c o r r e l a t i o n of h i g h e r r e a d r i s e
w i t hl o w e rs u c t i o ns p e c i f i cs p e e d sb a s e do n pump i n l e t c o n d i t i o n s . T h i s t o o
w o u l dt e n dt oi n d i c a t ec a v i t a t i o ne f f e c t s ;a l t h o u g h ,w i t hd a t ag r o u p e d so
closely,thisobservationcannotbeinterpreted as v e r y c o n c l u s i v e .

I nc o n c l u s i o n ,a l t h o u g h a p o t e n t i a l l yl o w e rs u c t i o np e r f o r m a n c e is indicated
t h a n was p r e d i c t e d , t h e a v a i l a b l e d a t a do n o t c l e a r l y e s t a b l i s h t h e pump
suction performance.

BearingCoolantFlow. A s k e t c ho ft h e pump-end b e a r i n g ,i n c l u d i n gt h e
f l o wp a t ho fc o o l a n t ,a p p e a r si nF i g . 152. The p a t ha n dd i r e c t i o n of t h e
c o o l a n tf l o w i s f r o m t h e i n l e t t o t h e s e c o n d - s t a g e i m p e l l e r t h r o u g h t h e s l o t
r e s i s t a n c e No. 1. The f l o wt h e ns p l i t s ,p a r tg o i n gt h r o u g ht h e r e a r wear
r i n gt ot h ef i r s t - s t a g e impeller d i s c h a r g e . The r e m a i n d e r o f t h ef l o wg o e s
t h r o u g ht h eb e a r i n g ,e v e n t u a l l yd i s c h a r g i n g at t h ef i r s t - s t a g ei m p e l l e ri n l e t .

A t e m p e r a t u r ep r o b e i s l o c a t e dj u s td o w n s t r e a mo ft h eb e a r i n g , as shown i n
F i g . 152. I t was f o u n dt h a t ,d u r i n g a 9 4 2 3r a d / s( 9 0 , 0 0 0 rpm) t e s t ( r u n9 ,
s l i c e 7 ) , t h et e m p e r a t u r eo ft h ec o o l a n te x i t i n gt h eb e a r i n g was 8 7 K ( 1 5 7 R ) .
T h i st e m p e r a t u r e i s c o n s i d e r a b l yh i g h e rt h a ne x p e c t e d . The f l o w r a t eo fc o o l a n t
t h r o u g ht h i sb e a r i n g w a s c a l c u l a t e dt ob ea p p r o x i m a t e l y 0.045 k g / s ( 0 . 1 l b / s e c ) .
A n a l y s i so ft h eb e a r i n gh e a to u t p u ty j . e l d s a t o t a lo fa p p r o x i m a t e l y 1118 J / s
( 1 . 0 6 B t u / s e c . )f o rt h ed u p l e xb e a r i n gp a c k a g e . An e s t i m a t eo ft h et e m p e r a t u r e
a t t h es e c o n d - s t a g ei m p e l l e ri n l e t i s 37 K ( 6 7 R ) . I fd e s i g nc o o l a n tf l o w r a t e
i s a c h i e v e d ,t h ec o o l a n tt e m p e r a t u r ee x i t i n gt h eb e a r i n gs h o u l di n c r e a s eb y ,
a t most 1 t o 1 . 5 I<, ( 2 t o 3 R ) .

Because o f t h i s d i s c r e p a n c y , a p a r a m e t r i cs t u d yo ft h eb e a r i n gc o o l a n t .f l o w
l o o p was made. A sc:hematic o f t h er e s i s t a n c e se n c o u n t e r e db yt h ec o o l a n tf l o w
i s shown i nF i g .1 5 3 .P r e s s u r ed r o p st h r o u g ho r i f i c e sa n dl i n e losses a r e
a c c o u n t e df o ri nt h e K v a l u e sa te a c hr e s i s t a n c e .T h ep r e s s u r ed r o pt h r o u g h a
r e s i s t a n c e i s d e f i n e d .a s :

Where <g. i s mass f l o w r a t e , p i s s p e c i f i cw e i g h t , h i s a r e a ,a n d g is gravita-

1
t i o n a la c c e l e r a t i o n . The f l o ws y s t e m was s o l v e df o rc o n t i n u i t ya n dp r e s s u r e
b a l a n c eb e t w e e ns t a t i o n s 1, 2 , and3.Thepressure r i s e b e t w e e ns t a t i o n s 1 and
2 due t o w h i r l on t h e b a c k s i d e o f t h e .i m p e l l e r was i n c o r p o r a t e d i n t o t h e solu-
t i o n . The a n a l y s i sa c c o u n t e df o rd e n s i t yc h a n g e sd u et oc h a n g e si np r e s s u r e
t h r o u g ht h es y s t e m .

228
 "I-

RES ISTANCE
SLOTS (K7a
RESISTANCE #2 - WEARING
%a, K 2 b ,K2c )

RESISTANCE #I - SLOT (K,)

RESISTANCE
HOLES (Kg)

R E S I S T A N C E i'3 - H O L E (SK 3 )

RESISTANCE #5 - ANNULUs(K5

N
N
W F i g u r e 152. FrontBearingCoolant Flow Path
 .
2
i.
+ \;12
-
1.

K2cpA2c
K2b,A2b
'i
B E A R I tiG
!
1\
3 K~a,A2a 5
z / 7

K 7b , A 7 b

K6 , A 6 ", 7

K A
5, 5
F i g u r e1 5 3 .F r o n tB e a r i n gC o o l a n tR e s i s t a n c e s

T h eh e a tt r a n s f e r rate ((1) f r o m t h e b e a r i n g s t o t h e f l u i d has t h e r e a l t i o n s h i p :

Q = C (T - Tin) ;d3
p out
Considering T = 87 I( (157 R ) and T i n = 37 K ( 6 7 R ) , a na v e r a g es p e c i f i ch e a t ,
out
C e , a t t h e p r e s s u r e a t t h eb e a r i n g i s a p p r o x i m a t e l y 0 . 0 2 J/kg-K ( 3 . 0B t u / l b- R ) .
W l t ht h eb e a r i n gh e a ti n p u to f 118 J/s ( 1 . 0 6E t u / s e c ) ,t h en e c e s s a r yf l o w r a t e
t o m a t c ht h em e a s u r e db e a r i n gd i s c h a r g et e m p e r a t u r e i s c a l c u l a t e dt ob ea p -
pr oximatel y0 . 0 0 1 8 k g / s ( 0 . 0 0 3 9 l b / s e c ) .T h i s i s a p p r o x i m a t e l y2 8 %l o w e rf l o w -
r a t e t h a nn e c e s s a r yt oe x p l a i nt h eh i g ht e m p e r a t u r e a t t h eb e a r i n ge x i t .

Reducingth eg a p a t A t o 0.025 mm (0.001 i n c h )w h i l es i m u l t a n e o u s l yr e d u c i n g

t h eg a p a t A 7 a t o 0 . 0 b 5 nm ( 0 . 0 0 0 2 i n c h ) y i e l d s a f l o w r a t et h r o u g ht h eb e a r i n g
o fa p p r o x i m a t e l y 0 . 0 0 1 5 k g / s ( 0 . 0 0 3 3l b / s e c ) .T h i s i s 15% b e l o wt h ef l o w r a t e
e x p e c t e dt h r o u g ht h eb e a r i n gd u et ot h eh i g hm e a s u r e db e a r i n g e x i t temperature.
T h eo r i g i n a lg a p a t A i s 0 . 8 1 mm ( 0 . 0 3 2 i n c h ) .
1
Ineffect,toget 6 3 f l o w r a t en e a rt h ef l o w r a t eg i v i n gt h eh i g ht e m p e r a t u r e
measured a t t h e b e a r i n g e x i t , t h e g a p areas o f A 1 and A7a mustbereduced to
a p p r o x i m a t e l y 3% o ft h e i ro r i g i n a lv a l u e s .T h i sa p p e a r st ob e a l a r g e rr e d u c -
t i o nt h a nw o u l db ee x p e c t e db u t , a t t h ep r e s e n t time, t h e r e i s n oo t h e re x p l a -
n a t i o n o ft h eh i g hb e a r i n gc o o l a n tt e m p e r a t u r e .E x a m i n a t i o no ft h eb e a r i n g s
a f t e r t e s t i n g d i d n o t show a n yh e a t - b a n d i n ge f f e c t s on t h e b e a r i n g b a l l s . Ad-
d i t i o n a lt e s t i n gw i t h more i n s t r u m e n t a t i o n i s r e q u i r e d t o f u r t h e r c l a r i f y t h i s
area.

B a l a n c eP i s t o nP e r f o r m a n c e .I n a l l o ft h e t e s t s , t h eb a l a n c ep i s t o n ap-
p e a r e dt ob ef u n c t i o n i n gt oa c h i e v e a good a x i a l t h r u s tb a l a n c e .I n t e r n a l

230
p r e s s u r e s were a v a i l a b l e a t t h e t h i r d i m p e l l e r d i s c h a r g e , w i t h i n t h e b a l a n c e
c a v i t y ,a n d a t t h eb a l a n c ep i s t o n sump. T h ep r e s s u r ew i t h i nt h eb a l a n c ec a v i t y
w o u l db ee x p e c t e d to h a v e a m a g n i t u d eb e t w e e nt h eo t h e rt w op r e s s u r e s .O b s e r -
vationofthedataindicatedthatthebalancecavitypressurealso seemed t o
m a i n t a i n a r e l a t i v e l yc o n s t a n tp o s i t i o nb e t w e e nt h eo t h e rt w o ,i n d i c a t i n ga v e r y
s t a b l eo p e r a t i o nt h r o u g h a l l of t h e t e s t e d p o i n t s o f o p e r a t i o n .S e l e c t e dd a t a
s l i c e s are p r e s e n t e di nF i g . 154 t o i l l u s t r a t e t h i s . Data fromtwo t i m e s l i c e s
are shown as s o l i d symbols t o d i s t i n g u i s h t h e c o r r e s p o n d i n g p r e s s u r e b e c a u s e
these did not fall in the same r e l a t i o n s h i p w i t h s p e e d as t h e o t h e r s .

Two s l i c e s were examined i n more d e t a i l t o d e t e r m i n e t h e p o s i t i o n of t h e b a l a n c e

p i s t o nb o t hg e o m e t r i c a l l ya n dw i t h i nt h ea v a i l a b l et h r u s tr a n g e . The r e s u l t s
are shown i n t h e f o l l o w i n g t a b l e :

TABLE28. BALANCE PISTON POSITION

-
Test 6 9 . Design P o i n t
S1 ice 10 7 -
S p e e d , rpm 58,500 90,000 95,000
B a l a n c eP i s t o nP o s i t i o n , X/S:; 0.327 0.356 0.36
B a l a n c eP i s t o nP o s i t i o n , F/Fmax?:;'; 0.679 0.722 0.75

';X i s t h e a x i a lg a pa t t h e h i g h - p r e s s u r eo r i f i c e , and S i s t h e
t o t a lb a l a n c e piston travel.
-:ijtF i s t h e t h r u s t on t h e b a l a n c ep i s t o nf a c e , and Fmax i s t h e maxi-
m u m a v a i l a b l et h r u s ta tt h a to p e r a t i n gc o n d i t i o n . Fmax o c c u r s
w h e n t h e l o w - p r e s s u r eo r i f i c ei sc l o s e d .

T h ep r e d i c t e dv a l u eo fb o t h XIS and P/F,,, i s a l m o s ti d e n t i c a lt ot h ev a l u e s

a c h i e v e d a t t h e 9 0 , 0 0 0 -rp mco nd i t i o n .T h ei n t e r n a lp r e s s u r em e a s u r e m e n t so f
t h e pump a l s oa g r e e d we11 w i t hp r e d i c t e dv a l u e s .T h e r e f o r e ,t h ei n t e r n a lp r e s -
s u r e so ft h et u r b i n e must a l s o b e v e r y c l o s e t o t h e p r e d i c t e d v a l u e s t o a c h i e v e
t h ep r e d i c t e do v e r a l lt h r u s t .

T u r b i n eP e r f o r m a n c e .T h ef i r s t - p h a s ep e r f o r m a n c ee v a l u a t i o n t e s t s of t h e Plark
48-F turbopumpassembly were c o n d u c t e dw i t h (342 t u r b i n ew o r k i n gf l u i d ,a n dw i t h
LH2 f l o wt h r o u g ht h e pump. The r e s u l t s o ft h e s e t e s t s p r o v i d e a comparison of
t h e power d e v e l o p e d b y t h e t u r b i n e w i t h t h e power r e q u i r e d by t h e pump t o
d e l i v e rt h em e a s u r e d pump h e a d sa n df l o w s .T h e s ed a t aa d d i t i o n a l l y w i l l establish
t h eo v e r a l lt u r b o p u m pp e r f o r m a n c e .

The f o l l o w i n g power c a l c u l a t i o n s were made:

1. T u r b i n e - d e v e l o p e dh o r s e p o w e rc a l c u l a t e dw i t ht u r b i n ei s e n t r o p i ce n -
t h a l p y 1Astr-r),. -
] a v a i l a b l e a t t h e t e s t p r e s s u r e r a t i o , GI12 working
I

f l u i d m a s sf l o w r a t e [ b t ] , turbopumpspeed [ N t ] , andturbinecomponent
e f f i c i e n c y a t t h er e s p e c t i v e t e s t c o n d i t i o n s

231
 0 T H I R DI M P E L L E RD I S C H A R G ES T A T I C
PRESSURE
4000
I7 BALANCE P I STON SUMP PRESSURE

3500

3000
200(

c\1
E
V
\
z
.
w
cz
3
ln
m
w
cz
a

1 ooc

a
SPEED,
RPN X 10”
1 I I -
~. ~ I I
5000 6000 8000 10,000
SPEED, r a d j s
F i g u r e 154. Balance P i s t o n Pressures

232
 2. Turbinehorsepobrercalculatedwithworking.fluidtotaltemperature
d r o p [AT T-T)] m e a s u r e da c r o s st h et u r b i n e ,a n d GB2 w o r k i n g f l u i d mass
f l o w [Gc f
3. Pump h o r s e p o w e rc a l c u l a t e dw i t h pump h e a da n df l o wd a t a a t t h er e s p e c -
tive s p e e d ss e l e c t e df o rt h ea n a l y s i s

T u r b i n e t e s t i n s t r u m e n t a t i o n w a s l o c a t e d as shown on t h e turbopumpassembly
dr awing( Fi g . 155) t o o b t a i n t h e f o l l o w i n g t u r b i n e t e s t p a r a m e t e r sf o rt h ep e r -
formance analysis :

1. T u r b i n e t o t a l i n l e t t e m p e r a t u r e ,T t l ,m e a s u r e d at t h e t u r b i n e i n l e t ,
d o w n s t r e a mo ft h ep r e b u r n e r
2. T u r b i n ei n l e t s t a t i c p r e s s u r e , Psl, measured a t t h ee n t r a n c et ot h e
first-stage nozzle
3. T u r b i n ee x h a u s tt o t a lp r e s s u r e ,P t 2 ,m e a s u r e dd o w n s t r e a mo ft h et u r b i n e
e x h a u s tf l a n g e
4T
. u r b i n ee x h a u s t o t a lt e m p e r a t u r e , T t 2 , measureddownstreamofthe
t u r b i n ee x h a u s tf l a n g e
5. T u r b i nsep e e d ,
Nt
T u r b i n em a s sf l o w r a t e was calculatedwithdataobtainedwith a venturiand
o r i f i c e which were l o c a t e d ,r e s p e c t i v e l y ,u p s t r e a ma n dd o w n s t r e a mo ft h et u r b i n e .

The a n a l y s i s was p e r f o r m e df o r a r a n g e of t u r b i n ev e l o c i t yr a t i o s (lJ/Co T-T)

f r o m0 . 0 7 7t o 0 . 4 3 0 , a n dt u r b i n es p e e d sf r o m 1550 t o 9737 r a d / s( 1 4 , 8 0 0t o9 3 , 0 0 0
rpm). A t a b u l a t i o no fp e r t i n e n t t e s t d a t a a p p e a r s i nT a b l e 29. The per-
f o r m a n c ec a l c u l a t i o n s ,w h i c hu t i l i z e dp r o c e s sh y d r o g e ng a sp r o p e r t i e s a t t h e test
s t a t e c o n d i t i o n s ,a r ei d e n t i c a lt ot h o s eu s e dp r e v i o u s l yt oe s t a b l i s ht u r b i n e
aer other m o d y n a m i cp e rfo rm a n cew i t h GN2 a t t h e Wyle L a b o r a t o r i e s , E l Segundo,
California .
T u r b i n e i n l e t t o t a l p r e s s u r e was c a l c u l a t e d a s t h e sum of t h e f i r s t - s t a g e n o z z l e
i n l e t s t a t i c p r e s s u r e ,a n dd y n a m i cp r e s s u r ec a l c u l a t e d a t t h ee n t r a n c ep l a n eo f
t h ef i r s t - s t a g en o z z l e . The t o t a l - t o - t o t a lp r e s s u r er a t i o was e s t a b l i s h e dw i t h
c a l c u l a t e di n l e tt o t a lp r e s s u r ea n dt u r b i n e t e s t e x h a u s t l t o t a lp r e s s u r e . The
t u r b i n e - d e v e l o p e dh o r s e p o w e rc a l c u l a t i o nu t i l i z e dt u r b i n ei s e n t r o p i ca v a i l a b l e
e n e r g y (T-T) f o r t h e r e s p e c t i v e t e s t p r e s s u r er a t i o ,c a l c u l a t e d GI12 mass flow-
r a t e c o r r e c t e d f o r GH2 c o m p r e s s i b i l i t y ( Z ) e f f e c t s , a n d t u r b i n e e f f i c i e n c y (T-T)
c o r r e s p o n d i n g t o t h e t e s t v e l o c i t yr a t i o , as p l o t t e di nF i g . 138.

T u rb i n e -d e v el o p ehdo rs e p o w e r , hptd = 1.415 AT * c - G

(T-T) P t
where

C = p r o c e s ss p e c i f i ch e a t
P
Pump hor s e p o we r[h p
P
] r e q u i r e dt od r i v et h el i q u i d - h y d r o g e n pump s t a g e s was
e s t a b l i s h e d w i t h pump f l u i d h o r s e p o w e r [ h p p f ] a n d t h e pump i s e n t r o p i c e f f i c i e n c y
parameter q as f o l l o w s .
Pi

233
 /"'
I -r. -- .I--I

t "1

F i g u r e 155. T u r b i n e Instrumentation
.. .
.I .

TABLE 29. T

. (SI
~
~ ~~

1 4 .4a 5 8 9 IO
I I

Specific
Temperature Temperature vo 1 urne
ro:tal ,I.nlet - . l o t ~ a lE x i t a t N-I,
Run . .' "'.::(.T ) ,.K -.-(Tt ), K Vsp .RTZ/pr
tl
Number ''/

._. . . . . _ i . .. . e m3/kg

2
"

29 I 233 2.49
-
0.40
t-
0.11 48.4 0.37 48.7
. .....
4 296 26 3 0.47 2.12 0.54 262.0- . .1.76
".." 263.7
5 288. 264 - 0.35 2.87 0.73 -2.34 347.3 350
6 2 79 253 0. I6 6.20 . I .57 1299 4.99 75 3
9 2 86 25 I 0.06 15.7 4.04 2 102 2115 13.2

9 285 258 0.07 15.3 3.93 204 1 12.7 205 3

9 280 -253 0.08 12.3 3.15 1564 12.9 I574

I I

1 2 3 4 4a 5 6 8 9 10

-. ..
Spec1.f ic Pt
Vol urn ' Inlet Toti1
, . . . a t N-1 m a m ic Inlet
Temperature Temperat u r e
(vsp) Pressure Pressurc
Run Time
T o t a Il n l e t T o t a lE x l t D ;.
.. Dens 1 ty, (pd n) (8+9) ,
Numbel SI I c e ( T t l ) ,R ' (Tt,) s R
'ft3/1br; l b / f t.3 . ., . psYa .
. . . ,
. > ,
ps1a
- ..

'2 5 523.7 4l9.1 39.95 0.025 .. 0.24' 70.2 0.54 70.0

4 8 532.5 473.0 7.58 0.132 1.20 379.9 2.56 382.5

5 4 517.9 475.0 5.59 0 . I79 1.61 503.8 '3.40 507- 2

6 13 , 502.8 455.4 2.58 . 0.387 3.46 1884.4 7.24 1091.6

, 9 5 515.6 451.6 1.02 0.978 8.89 3048.5 19.04 3067.5

9. . 7 513.9 465.0 1-05 0.956 8.65 2959.8 18.43 2978- 2

9 11 503.3 455.5 1.3 0.769 6.94 2269.1 18.79 2283.0

 ( S I UNITS)

12 17 .. I 8 ' 19 20
,I

1 I
P
t2 Ic
I sent rop
Tota I---
Ex1 t ::; '' . ., HP Pp':
Pressyre Cornpres.
(AP,Ah,ht),
AT(T-T).&t, hPfluid/np'
N/cm Jlkg ( U ) , m/s kW kW (2) kW

68.9
Turbine1
: T:u; ine
0.655 892 .a*07a
184 0.693 151 917 0.164
24 7 0.667 203 900 0.225 1 .Ol5 204 259 162
518 0.673 790 905 0.317 I . 032 493 590 42 1
1340 0.837 4 33 1008 0.430 1 095-
1472 1489 1417
1302 0.833 420 1006 0.417 1.092 1455 1501 1371
1036 0.752 377 955 0.395 1.070 1078 I199 1032

(ENGL I SH UN ITS)

~~ ~~

11 13 I8 19 20
-
~. "

Pt2 I s e n t r o1.pc
Tota 1 Ava il p b 1e Turbine pump
HP
Exit 'ressure Energy HP
PressurC, Ratlo (Ah ') :ompres. LT(T-T) ,it
hpf1 ul dl'
psla (T-T) . Btu?l6'.
1 . 42) hPAt (T) hPp (P)
.... .....

50.0 1.4148 . , ~ j oj ...;.

.. ..
1.0031 17.79 126.8 12.4
, : . ."
266.5 1.4350 :"
180.4 1.01 12 175 . f 358.9 146

358.0 173.9 1.0148 273.3 346.9 217

752.1 175.5 1.0321 662 792 565

1944.0''. 218.1 1.0945 I999 1977 1902

\ 1889.3 216.9 1.0918 I953 2015 1840

I503.3 195.8 I ;0702 1447 ' 1609 1385

235

-
 ....
. ~~ .".
~

. . . . . .
. .. . . . .
-, . .

hP
. . .. Pump h o r s e p o w e r , a p f
<.
hPP 'lpi

, A p l o to f test h p t ,h p t ,a n dh p p vs t u r b i n ev e l o c i t yr a t i o [U/Co (T-T) 1 d a t a

a p p e a r s i n F i g .1 5 6 -f o rt h e t e s t p o i n t sa p p e a r i n g ffi T a b l e2 9 . The o v e r a l l
agreemen,t i s v e r y . g o o d . The t u r b i n eh o r s e p o w e rc a l c u l a t i o n sw o u l db ee x p e c t , e d
t o b e somewhat l a r g e r t h a n the pump h o r s e p o w e r b e c a u s e o f p a r a s i t i c l o s s e s .

1. The m i x i n g l o s s r e s u l t i n gf r o mh y d r o g e n seal l e a k a g e e n t e r i n g t h e
t u r b i n eg a sp a t h .T h i sc o l d e rh y d r o g e nf l o wo r i g i n a t e s a t t h e pump
a n dr e d u c e st h ea v a i l a b l ee n e r g yo ft h eg a sp a t ht u r b i n ew o r k i n gf l u i d
bydisruptingchannel state c o n d i t i o n s and v e l o c i t i e s .
2. T u r b i n e mass f l o w d a t a were c a l c u l a t e d w i t h v e n t u r i and o r i f i c e t e s t
p a r a m e t e r sw h i c he x p e r i e n c e d some c a l i b r a t i o n s h i f t s and i n s t a b i l i t i e s
i nt h eh i g h e rt u r b i n e power t e s t p o i n t s . A r e v i e wo f test c o n d i t i o n s
anddataindicatesthatcalculatedturbine mass f l o w s were h i g h e r t h a n
e x p e r i e n c e dd u r i n gt h e t e s t . An a d d i t i o n a l mass f l o wd i s r u p t i o n was
c a u s e db y seal l e a k a g e e n t e r i n g t h e t u r b i n e g a s p a t h .
3. T h ep r e c i s i o no ft h et u r b i n es p e e dd a t a a t t h e 9737 r a d / s (9300rpm)
test pointexperiencedslightoperationalvariationswhich were t r a c e d
t oi n s t r u m e n t a t i o nr e c o r d i n ge q u i p m e n t .T h i st y p eo fs p e e di n a c c u r a c y
adverselyaffectsthecalculatedturbinevelocityratioand,subse-
q u e n t l y ,t h er e f e r e n c e test efficiency.

The n e t e f f e c t o f a l l thesevariances.uponthecalculatedvalueofturbine-
d e v e l o p e dh o r s e p o w e r ,h p t d ,c o u l da c c o u n tf o r i t b e i n g4 . 5 8 %g r e a t e rt h a n pump-
r e q u i r e dh o r s e p o w e r . A c o n p a r i s o no ft u r b i n e( h p t )h o r s e p o w e r ,c a l c u l a t e dw i t h
tota1.temperaturedropacrosstheturbine,indicates a 3.79%power d i f f e r e n c e
: w i t h pump r e q u i r e d h o r s e p o w e r .
._. . I

. .
. Inconclusion, a review o f t h e t u r b i n e test r e s u l t s i n d i c a t e s t h e d e m o n s t r a t e d
1 overallturbopumpefficiencyhas m e t theperformanceobjectivesofthisprogram.

M e c h a n i c a lP e r f o r m a n c e .T e s t i n go ft h e LH2 turbopumpextendedover10 starts,

w i t h ' a t o t a l a c c u m u l a t e d t i m e o f8 8 4s e c o n d s . The l o n g e s t s i n g l e t e s t d u r a t i o n
w a s 1 6 8s e c o n d s .O p e r a t i o ne x t e n d e do v e r a r o t o rs p e e dr a n g eo f 0 t o 9737 r a d / s
. (0 t o 9 3 , 0 0 0 r p m ) ; a m a x i m u m pump d i s c h a r g e p r e s s u r e o f 2 8 6 1 N./cm2 (4150 p s i )
was a c h i e v e d .

The mechanica l p erfo rm an c e o f t h e t u rb o p u m p was excellent for an initial test

exposure. A satisfactorycontrolovertherotor axial p o s i t i o n w a s m a i n t a i n e d

236
 SOURCE

hptd, TURBINE* - u A H ~ ,W,, N, DATA

3200 hpht, TURBINE ~ - T ; F A T ~ - 9
~,, DATA
hpp, PUMP --"----o FLUID HORSEPOWER, '7,
2800

2400

- 2000

1200

800

400

hP
0
0.2
0 0.1 0.3 0.4 0.5

VELOCITY RATIO U/C [TOTAL-TO-TOTAL]

OR

F i g u r e 156. Horsepower C o r r e l a t i o n

237
 I'

b yt h eb a l a n c ep i s t o nt h r o u g h o u tt h e test series a t a l l s p e e d levels. It w a s

. e v i d e n tf r o mt h er o t o r d y n a m i ci n d i c a t o r ss u c h as a c c e l e r o m e t e r sa n dB e n t l y
p r o x i m i t yt r a n s d u c e r st h a tt h er o t o r w a s b a l a n c e d t o a v e r y f i n e d e g r e e .I n
g e n e r a l ,t h er o t o rd e f l e c t i o n sa n ds y n c h r o n o u sa c c e l e r a t i o n levels were v e r y
. low ,appr oxi m at e l y0 . 0 7 6 mm ( 0 . 0 0 3i n c h )a n d 5 g p e a k t o p e a k ,r e s p e c t i v e l y .
Onlyminor increase i n t h e s e i n d i c a t o r s w a s e v i d e n t when t h e r o t o r p a s s e d t h r o u g h
t h e f i r s t an ds e co n d c r i t i c a l s p e e d s . The a c t u a l l e v e l s o ft h e c r i t i c a l speeds
were d e t e r m i n e d t o b e a t 3874 r a d / s( 3 7 , 0 0 0 rpm) a n d5 3 7 1r a d / s( 5 1 , 3 0 0r p m ) ,
c l o s et ot h ep r e d i c t e dv a l u eo f 3141 r a d / s (30,000 rapm) f o r t h e f i r s t c r i t i c a l
and5444 r a d / s( 5 2 , 0 0 0 rpm) f o rt h es e c o n d c r i t i c a l . T h e r e w a s no e v i d e n c eo f
s ubs ynchr o n o u sm o t i o n a t a n y s p e e d l e v e l w i t h i n t h e e x p l o r e d r a n g e o f 0 t o 9737
r a d / s (0 t o 93,000 rpm).

The o p e r a t i o no ft h et u r b o p u m pa p p e a r e ds m o o t hd u r i n gt h e t e s t series. Each

t e s t w a s c h a r a c t e r i z e d by a smoothquic:kresponse s t a r t as w e l l as a smooth
coastdown a t c u t o f f , i n d i c a t i n g a s a t i s f a c t o r yt r a n s i t i o ni nt h ea x i a lc o n t r o l
oftheshaftpositionfromthebearings t o thebalancepiston.

T h et u r b o p u m pw a sd i s a s s e m b l e da f t e rt h bc o n c l u s i o no ft h e t e s t series t o p e r m i t
v i s u a li n s p e c t i o no ft h ec o m p o n e n t s .F i g u r e1 5 7 shows t h ec o n d i t i o no ft h e more
s i g n i f i c a n tp a r t s . The pumps components are shown s e p a r a t e l yi nF i g .1 5 8 . None
o ft h ec o m p o n e n t sd i s c l o s e da n ys i g no fs t r u c t u r a ld i s t r e s s ,i m p e n d i n gf a i l u r e ,
o re x c e s s i v ed e f l e c t i o n .

M i n o rd i s c r e p a n c i e s were n o t e d i n two areas o ft h e pump. A s shown i nF i g . 159,

t h e s i l v e r p l a t i n gf r o mt h ew e a r - r i n gp l a t f o r m s a t t h et h i r d - s t a g ei m p e l l e r
f r o n ts h r o u dh a dp a r t i a l l yf l a k e do f f ,p r o b a b l y as a r e s u l to fp o o rb o n d i n gb e -
tween t h ep l a t i n ga n dp a r e n t metal. It i s e x p e c t e dt h a t more s t r i n g e n tp r o c e s s
c o n t r o l a t t h ev e n d o r w i l l e l i m i n a t e a s i m i l a r p r o b l e m i n t h e f u t u r e .

The o t h e r m i n o r d i s c r e p a n c y was a s l i g h t l y more e x t e n s i v e r u b b i n g b e t w e e n t h e

b a l a n c ep i s t o nl o w - p r e s s u r eo r i f i c es u r f a c e st h a n was a n t i c i p a t e d . Thecondi-
t i o n of t h e r o t a t i n g a n d s t a t i o n a r y o r i f , i c e s u r f a c e s is illustratedinthe en-
l a r g e dp h o t o g r a p h s o f F i g .1 6 0a n dF i g .1 6 1 . On f u t u r eb u i l d s ,t h ee x t e n to f
t h er u b b i n gs h o u l db er e d u c e db yi n c r e a s i n gt h eb e a r i n ga x i a ll o a d .

The b e a r i n g s a r e shown i n F i g . 1 6 2 w i t h . t h e b e a r i n g c a r t r i d g e s , s p r i n g s , and

s p a c e r s .T h es u r f a c ec o n d i t i o no ft h e races and b a l l s w a s s a t i s f a c t o r y .B a s e d
on t h e wear t r a c k , i t i s e s t i m a t e d t h a t t h e t u r b i n e a n db e a r i n g s were s u b j e c t e d
t o a maximum a x i a l l o a d of 530 pounds.

The p o s t t e s tc o n d i t i o no ft h es h a f td y n a m i cs e a l was e x c e l l e n t .T h e r e was n o

i n d i c a t i o n o f o v e r h e a t i n g ,s c o r i n g ,o rg r o o v i n g ,e i t h e r on t h e s e a l r i n g so f
t h em a t i n gs u r f a c eo rt h es h a f t .

Thetwo t u r b i n ew h e e l sa n dt h es e c o n d - s t a g en o z z l e a r e shown i n F i g . 1 6 3 . No
s i g no fa x i a lr u b b i n g was e v i d e n to nt h et u r b i n ec o m p o n e n t s .R a d i a l l ym i n o r
r u b b i n go c c u r r e da tt h es e a l i n gl a n ds u r f a c e sa se x p e c t e d .T h ec o p p e rp l a t i n g
u s e do nt h es t a t i o n a r ys e a l i n gs u r f a c e st o o kt h ec o n t a c t w e l l ; t h e r e were no
s i g n s of e r o s i o n ,g a l l i n g ,o rf l a k i n g .

238
 lHS55-6/23/76-ClF*

Figure 157. Mark 48-F Turbopump Hardware After Testing

N
w
W
 lHS55-6/23/76-ClA*

Figure 158. Mark 48-F Pump Components After Testing

Fi g ur e1 5 9 . Mark 48-F Pump Third-StageFront Wear-Ring
SilverPlatingFlaking
*
N
N

lHS55-6/23/76-ClG*

Figure 160. Mark 48-F Balance Piston Low-Pressure Orifice After Testing
 lHS55-6/23/76-CID*

Figure 161. Mark 48-F Balance P i s t o n Low-Pressure Orifice Rub Ring After Testing
 lHS55-6/23/76-ClE*

Figure 162. Mark 48-F B e a r i n g sP o s t t e s t

 lHS55-6/23/76-ClB*

F i g u r e 163. Mark 48-F TurbineComponents Posttest

 APPENDIX A

MARK 48-F DESIGN

GROUND RULES
 APPENDIX A
I

DESIGN GROUND RULES

General

Componentswhich a r e s u b j e c t t o a 1cn~c y c l e f a t i g u e 'nodeof failure

s h a l l b ed e s i g n e df o r a minimum of 300 c y c l e s t i m e s a s a f e t y f n c ' t o r
of 4.

Conlponentswhich a r e s u b j e c t t o a f r a c t u r e mode o f f a i l u r e shall be

d e s i g n e d f o r a minimwn o f 300 c y c l e s t i m e s a s a f e t y f a c t o r of 4.

C o m p o n e n t sw h i c ha r es u b j e c tt o a h i g hc y c l ef a t i g u e mode o f f a i l -
u r es h a l l be d e s i g n e dw i t h i nt h ea l l o w a b l es t r e s sr a n g ed i a g r a m
( b a s e do nt h em a t e r ' i a le n d u r a n c e limit), I f s t r e s sr a n g em a t e r i a l
p r o p e r t yd a t aa r en o t available, m o d i f i e d Goodman d i a g r a m sc o n -
s t r u c t e d a s shown b e l m s h a l l be u t i l i z e d .

ul
a - Fe
u 1.33
&.I
m

F, = M a t e r i a lE n d u r a n c e Limit
F t y = M a t e r i a lY i e l dS t r e n g t h (.2% o f f s e t )
Ft, E M a t e r i a l U l t i m a t e S t r e n g t h

24 7
 E f f c c t l v c stress shrill be b a s e d on t h eM i s c s - l k n c k yc o n s t a n te n e r g y
of d i s t o r t i o n t h e o r y .

Unl.cne o t h e r w i s en o t c du n d e rc o m p o n e n tg r o u n d r u l e s s p e c i f i e dh e r e -
in, t h e f o l l m i n g minimum f a c t o r s o f s a f c t y s h a l l bc u t i l i z e d :

F a c t o r of S a f e t y (.2% y i e l d ) = 1.1 ?i L i m i t Load

F a c t o ro fS a f e t y( U l t i m a t e ) = 1.4 x L i m i t Load

L i m i t Load:The maximum p r e d i c t e dl o a do rp r e s s u r ea t
t h em o s tc r i t i c a lo p e r a t i n gc o n d i t i o n

C o m p o n e n t ss u b j e c tt op r e s s u r el o a d i n gs h a l lb ed e s i g n e dt ot h e
f o l l o w i n g minimum p r o o fa n db u r s tp r e s s u r e s :

ProofPressure = 1.2 x L i m i t P r e s s u r e

BurstPressure = 1.5 x L i m i t P r e s s u r e

Impcllcr

I n d u c e r sa n d / o ri m ' p c l l e r su t i l i z e di nt h eh i g hp r e s s u r e pumps s h a l l
bedeGigned f o ro p e r a t i o na b o v ei n c i p i e n tc a v i t a t i o n .

I m p e l l e rb u r s ts p e e ds h a l l be a t l e a s t 20% a b o v et h e maximum o p e r -
a t i n gs p e e d .

Impellereffectivestressat 5% a b o v et h e maximum o p e r a t i n gs p e e d
s h a l ln o te x c e e dt h ea l l o w a b l e .2% y i e l ds t r e s s . (Does n o ta p p l y
t oa r e a si nw h i c h 10~31 y i e l d i n g i s permitted.)

Turbine

B l a d er o o ts t e a d y - s t a t es t r e s ss h a l ln o te x c e e dt h ea l l o w a b l e 1%
t e nh o u rc r e e ps t r e s s .

Stress s t a t e a t t h e b l a d e r o o t a s d e f i n e d by t h e s t e a d y - s t a t e s t r e s s
a n da na s s u m e dv i b r a t o r ys t r e s se q u a lt ot h eg a sb e n d i n gs t r e s s
s h a l l be w i t h i n t h e a l l o w a b l e s t r e s s r a n g e d i a g r a m o r m o d i f i e d Good-
man diagram.

No b l a d e n a t u r a l f r e q u e n c i e s w i t h i n ~15%
of known s o u r c e s of e x c i t a -
t i o na ts t e a d y - s t a t eo p e r a t i n gs p e e d s ,

D i s k b u r s ts p e e ds h a l l he a t l e a s t 20% a b o v et h e maximum o p e r a t i n g
speed.

248
 Disk maximum c f f c c t i v e s t r e s s a t 5% a b o v e t h e maximum o p e r a t i n g
s p c c d 's h a l ln o tc x c c e dt h en l l o w a b l e .2% y i e l d s t r e s s . (Docs not:
applytoareasinwhichlocal'yiclding i s permitted'.)

Bearinps

Turbopump d e s i g n s s h a l l u t i l i z e b a l lb e a r i n g s .
6
Maximum DN: 2.0~10

B ~ ol i 1f e0h 0o u r s
Material:

Rolling E l e m en t s 44oc
Races 44oc
Seala

Turbopump designs s h a l l u t i l i z e c o n v e n t i o n a l t y p e s e a l s .

F a c ec o n t a c ts e a l maximum PV, FV, andPfV factors:*

PV Factor 50,000 10,000

FV Factor 4,000 800
PfV F a c t o r 200,000 20,000
2
jcpV = u n i tl o a dt i m e sr u b b i n gv e l o c i t y( l b / i n x ft/sec)
FV = f a c e l o a d per u n i t l e n g t h t i m e s r u b b i n g v e l o c i t y
(lb/in x ft/sec)
PfV c f l u i dp r e s s u r ed i f f e r e n t i a l times r u b b i n g v e l o c i t y
(psig x ft/sec)

C r i t i c a l Speed

.
R o t o rb e n d i n gf r e q u e n c ys h a l lb ea tl e a s t
mum o p e r a t i n g s p e e d
25% a b o v et h er o t o rm a x i -

A minimum m a r g i no f 20% s h a l l b e m a i n t a i n e d b e t w e e n r o t o r r i g i d
body c r i t i c a l s p e e d s and r o t o r s t c a d y - s t a t e o p e r a t i n g s p e e d s at
f u l tl h r u s t a ntdhpeu m p e d - i d lteh r u scto n d i t i o nR. i g ibdo d y
c r i t i c a ls p e e d sw i t h i n the t h r o t t l c d - t o - f u l l t h r u s t r a n g e s h a l l b e
p e r m i t t e do n l yi f deemed n e c e s s a r yb yb o t ht h eC o n t r a c t o rP r o g r a m
N a n a g c ra n dt h e NASA P r o j e c t E n g i n e e r .

249
 APPENDIX B

MARK 48-F TURBOPUMP

ASSEMBLY DRAWING
RS009601E
 APPENDIX C

MARK 48-F TEST

.SEQUENCE
 c

LH2 Pump Inlet Conditioning and Sequence Start (Sheet 1)

 I

OPEN GH1 SPIN

PRETEST LH? T I P SHEET
V A L V E TO TEST
SPlNUP 3
POSITION
1

SPIN "I\L"E

J
NO
I 1

Turbopump Spin-Up and Test S t a r t (Sheet 2 )

 I '
A

I I

Mainstage and Cutoff (Sheet 3)

.
 APPENDIX D

I
MARK 48-F TEST
1.
DATA
 PK48-F PAGE 9. 1
LIQUID HYCROGEN T U K P C P l l H PA S S E M B L Y

PRECESSING CAT E 05-5-76

I;L;MMc.dTs

TbG I'IJPIIJ K E C U C T I i YR E S E A R C HS T A V C C16

T U k QHZ FLOW IS C A L C U L b T E D F R t Y T L R B C I S C H C R I F I C E DELTA P. * NO C A T b

A A d I E N T PRESSURE 13.5703

LJZ VEUTuXI (GGI

IIPLIRIEAM C I A M E T E R C.9570
TFXCAT CIANETER c.3743
THqdAI C C t.9883

G H Z VE.'JTUKI ( T U R B )
L P S T X E A H DIAi!ETER S.3OOO
T H J . ~ J ACTI A V E T E R 1,3085
THZUAT CC 9.99 13

LHZ V E N T a K I I G G )
UPSTitEAP C I A P E T E R 1 6890
THRUAT C IAqETER 0.7090
THilcjUT CC C .Y 763

L t i Z VE'qldRI(PUMP O I S C H 1
LiPSritEAY C I A P E T E R 1.6390
JHdUAT C I A M E T E R C. 8903
THRCkl CC C.9710

.
 CK48-F PAGE 9. 2
LIQUID H Y D R O G E h TUSBCFUlYP b S S E M B L Y

R L h hUYHEK 3 PROCESSING C A T €
TEST C P T E

l i A S t J J S H Y D R C G E N T C i R E I . \ I E D R I V E P A R A M E T E R S

TI;iE REG VEXTURI VEK T L R I SFLK FAC TUR B

SL I C E u/ s u/s LIS VPLVE CUC T Gh'2
Xd iJ2 PK 1 E1.I ? FCSb PRESS f195
(PSIA) (PSIA) IDEG R ) (PSI P ) LB/SEC

1 4269, il 4246.17 5 1 L.33 c. 7 7 68-02 7.336

2 42d6.67 4181.87 510. 7 d 0.7d 65-54 7.460
3 4 i4 I . S 7 4115.E7 51C.63 C.42 76*83 8.144
4 4230.47 3093.37 53s. 71 - 3 . LS 84-53 8,938
5 4C26. c7 3965.67 5cs.59 -0. LC u 3. I2 8.tiCl
6
I
5
3281 e 7 7
3843.1 I
314J.77
3942 -37
2893.37
37Cd.67
5cs.54
5G8.2'5
5c.7.43
-0.
-0.20
33
-0.54
83.17
OL.39
8d 27
8.827
8.049
8.532
9 35LS.61 34 72.51 5c5.03 -c. 55 75.54 6.076
1 .I 22 I S . 17 3259.57 592.18 -#J.;57
7C. i 6 7.6C8
11 2316. 5 7 2EEC.27 4S7.13 -5.55 62-92
12 2CL2.47 2CEi.F 7 .
4 ' j 1 70 -0.54 5t.45
6.940
6.324
 ..

C K48-F Y 4GE 9. 3
L I C U I O H Y D R O G E NT t i R B O P U Y P ASSEMBLY

PROCESSING C A T E

T U R B I PN AE R A M E T E R S

T IYE rURB T URB TUH B TLR P TCRB TUKe T U RTBU RTBU R B

SLICE INLET I \ILET MANIF 1 S T NCZZ SEPL E XH EXH INLET E XH
NO 3 r ~
PR ~TOT PR PR CPSIRTSAP HT F R T G T C TP R TFYP T O T TEPP
(PSIAl (PSIA) (PSIA) (PSIPI IPSIA) (PSIP) IPSIA) (CEG R) lDFG R )
1 2473.67 2117.57 2752.37 1650.77 1615.e7 521.37 472.26
2 2527.4 I 2163.11 2781.07 168.r.37 1642.27 520.54 471.75
3 2802.47 23SF.07 3CC7.47 1863.37 1789.97 51Y.eO 470.c7
4 3363.77 2623.61 3305.37 2027.97 1953.27 515.61 456.57
5 3348.47 2665.47 3303.27 2017.47 1943.97 515.55 4h6.l:
6 3027.17 2502.37 32dE.37 Z(334.57 1929.77 515.49 465.97
7 2959.77 2534.67 3227.67 1561.57 ltidY.27 513.07 464.95
d 2913.07 2 4 9 E . 57 3 193.97 1933.87 1362.07 512.97 464.09
9 2735.17 2.342.17 3C29.77 1617.2i 1759.67 510.49 462.12
10 2549.27 2'1R3.67 LY6J.57 1695.57 1654.27 508.07 459.78
11 22 69. C 7 15.39.27 26333.77 1512.17 1503.27 503.34 4 5 5 05 3
12 20?1.37 1134.47 2373.57 1357.9T 13ti.67 498.24 451.55
 PK4d-F PACE 9. 4
L I C U I D HYDKUGEW T U A B C P U M A
PSSEMBLY

P R O C E S S I N GC A T €

P U P P T E M P E R A T U R E S

T LYE Sr'tED PU PP C ISCH

SLICE Ih L E T VEKT
KC TE'4P 2 L / S TE.YP
(CEG R ) (DEG R )

1 4C.30 9 4 .rc)
i 43-03 95.07
3 4c.I)c F,y.Y8
4 32.93 103.38
5 3s. 16 132 .q7
4 3s. 7 4 ld1.73
7 35.69 L D C .34
8 39.65 99.73
s 35.5 7 46.46
13 35.53 9 3.09
11 3 s . 53 r.3 - 2 8
li 35.5 1 83.23
 PK48-F PAGE 9. 5
L I P L I D H Y D R O G E N T U K E L P U M P ASSEMBLY

R U h hUYY ER PRCCESSING C4TE

TEST C ~ T E

P U M P P R E S S L R E S

T IHE L HZ PUMP PUVP 1ST IMP 1 S T XGVER 1ST X O V E R 1ST XOVER 2ND LMP
SLICE I AhK IhLET INLET D I SCH IhLET MID OUT FR SHD
- kU PR PR It1 PK # 2 Pd Pri PR PK PR
(PSI41 (PSIA) (PSIA) (PSIA) [PSIA) (PSI P 1 (PSIA) (PSIAI

1 Lid .34 59. C6 102.94 715.28 9 5 7 073 lOJ0.35 lOC9.40 1616.C7

2 1JS.73 98.36 102.25 70d.00 949.54 1000.69 1001.91 1617.77
3 11 1.39 S S . 13 lC3.29 727.53 584.32 1339. i7 1340.37 1710.57
4 LL4.23 1C1.89 104.40 819.02 1113.27 1168.17 1169.77 10Yd. 17
5 113.S3 101.22 105.S1 E2i.71 1125.77 1180.17 1131.57 1907.77
6 L i 3.68 1C1-40 105.54 d3J.52 I l L d -57 1182.C7 1184.17 19C5.17
7 112.33 59-91 104.36 31+.51 1105.67 1158.71 1160.47 1866.47
8 11 1.45 59.44 133.34 EJ0.35 1072.17 1145.57 1147.41 1847.27
9 lu9.d2 57.7c 131.95 IU4.50 1C5J.87 1111.17 1112.27 1773.97.
13
il
12
~ 9 . 3 1
146.73
LJ'j.c.9
57.63
57. S l
Y8.CJ
101.68
131.69
132.43
76t.57
733.26
7L4 . J 6
l(329.27

943.47
.
983 1 2
lU81.(37
1029.97
431 -44
10BL.77
1029.97
991.24
1696.Y7
158 1.47
14b6.27
 MK40-F PAGE 9. 6
N
Q\
L t Q b IO H Y U R G G E K T L K C C P U Y P A S S E M B L Y
N
R L h NUHi3EK s j PRGCESSING CAT€
T E S TC P T E

P U W PP R E S S l j R E S ( C Ch T I h U E D 1
TIME P UYP PAL P I S T PUPP PLMP PUP? PUMP 0 1 s
SLICE D I SCH CALITY VENT’JRI VEhTURI VEN I U R I VALVE
hO IJ I< PK L / S TEYP U/S PR DELTA P D/S’ PR
(PSIA) IPS141 (DEG R ) (PS I A ) (PSIC) (PSIA)

1 355c.37 2483.87 94.73 3533.47 30.25 948.90

2 3514.57 245E.07 95.c7 35th. 21 30.64 957.57
3 3E2 4.97 2679.97 99.98 3313.27 32 - 3 1 1C34.67
4 ilttL.27 2943.97 133.36 4 169.C7 33.04 1147.47
5 + 18.2. e l 2946.57 102.59 ‘t17G.77 3!.a5 1146.17
6 4165.67 2 Y 3 5 . Y7 10 1.18 4 154.57 32.94 114 1 - 0 7
7 4,9 1 . 2 7 2277.27 133.3L 4CE3.27 33.59 l.112.57
8 $347.57 2845.C7 99.73 4,336. 47 33.32 10C~7.57
9 3E61.57 273’3.67 96.46 3852.77 32.19 1037.37
LC >kt’+. I ? 2515.77 53.35 3655.17 3 1 e07 573.29
11 3363.57 2 3 t 1.77 88.28 3354.77 29.36 675.92
12 3032.37 2174.41 d3.23 3CE7.E7 28.03 787.90
 PK48-F PAGE 9. 7
L I Q U I D HYCROGEN TURBCPUNP
ASSEMBLY

R U N hUPBE44 9 P R O C E S S I N GC A T E
T E S TC d T E

C A L C U L A T E PDU K P P P R A M E T E R S

TIYE PUCP I-EAD PRESS FLU10 TURB OVERALL SPECIFIC

SL I C E FLCh I SEN RICE HP hP Ek F SPEtD
hC (LE/SEC) FT (PSI 1 (kP) (HP) (X)

1 4.6253 lC5579.9 3449.4 886.9 1 8 1 1.2 3 48.97

2 4.65C2 106254.9 3474.7 89d.4 18 6 2 076 48,023
3 4.7614 113382.c) 3 122.8 585.7 2106.27 46.80
4 4eYC40 122935.1 4077.2 1056.1 2295.77 47.66
5 4.91'5 122SCd.Z 4C79.1 lOSd.0 2284.14 4s.c7
-
6
I
r .Y 2 6 0
4.9333
122413.5
120368.5
4C62.0
3S8F. 1
lCY6.4
LC73 1
2290.75
2221.76
47.06
48.31)
3 4.lJ8i5 1131S5.5 3545.9 i058.1 2135.45 48.42
9 +.do27 1138St. 6 3762.1 3 9 4 06 2,325.7C 49.13
13 4.7213 lCLilY8.5 3564.5 92d.8 1861.72 49.89
3.26~.a
11
12
-r.SYCC
.1.4S56
SS6tl't. 0
SZC6q.4 2SS1.8
932.0
752.6
1631.87
13'94.14
51.94
.
5 3 S6
 P K4 8-F PAGF 9. 8
N L I Q U I D HYURGGEN TCIRBOPUMP A S S E M B L Y
o\
f-
R L h NUMtlEK Y PRECESSING K A T E
TEST C P T E

C A L C U L A T E D P U P F P P A A Y E T E R S

TIP€ N P Sh SUCT I E N 1ST SlG dEAD PUKP (Q/tii)

SLICE SPEC1 F I C I N L FLCk CUEFF OELTA T CVER
&O SPEED COEFF ( Q / N ICES
(FT) (JEG R I

1 2434.92 5323.22 3.13122 1- 4 8 2 16 53.97 3.8553

247 c 0 2 7
2
3
4
25, S . i2
Lu~l.71
5277.54
5578.27
5649.70
0.13441
3.11110
3.12854
.
1.545 38
L 48502
1.49355
54.31
5.8. 3 3
62.96
9.8761
0.8545
9.8373
5 L O 3 4 .F4 57Gl. 10 0,126Y4 1.45835 62.37 3,8274
6 2 6 4 2 -61 5260.~34 0.13724 1.69855 61.62 o.ao49
7 2 > Y 9. c 4 5558.57 3.13344 1. 5 2 5 3 1 6G.26 s.aT'c2
 NK48-F PAGE 9. 9
L I Q U I O HYCHOGEN T U K P C P U M P ASSEMBLY

RUK N U N U E R 9 PROCESSING L A T E
TEST CAT€

"" 5 i A L E G TO TARGET N = 9CCOO. RFC ---- ""

SCALE0 TC N = 95000. RPM ----
T f PE f LOW hEAD PRESS HCRSE NP SH FLCk kEA3 PRESS HCRSE NPSH
SLICE RISE POWER RISE PGUER
hC LLiPM) (FT) (PSI) (BHP). (FT . (GPC) . (FT) (PSI) (CHPI ' (FT)

1 3az2.02 1034.46 2764.43 536.73 13C345.52 4258.48 1216.63 3080.12

2 3588.78 1104.57 2841.51 54'3.77 1359C5.69 4444.29 1299.55 3L66.01
3 3851.05 1036.67 2595.51 536.20 1 3 0 6 4 9 . 6 8 4290.83 1219.22 Z8Yl.92
4 3901.82 1325. 19 251E.53 5 2 5 . 7143 1 0 e 3 . 3 8 4347.41 1206.90 26LiO. 14
5 38 23-14 555. 1 5 246 7 - 6 9 519.22 128251-37 4 256 - 3 9 1170.39 2749.49
6 4448.65 12C6.5E 2894.15 561.55 1 4 9 3 7 5 . 6 3 4555 057 1477.~36 3224 .e5
7 3 S 8 9 . 14 1073.10 259S.O;t 5 3 3 . 5 3 1 3 4 1 14.25 4444 -69 126.2.07 2895.84
8 3945.53 1053.13 25d4.37 531.49 1323C7.37 4396.55 1244.46 2379.50
7 3S35.09 1063.93 2655.18 533.80132137.19 4384.47 1251.28 2958.39'
13
11
3549.6C
4C25.C4
.
1 0 8 3 3C
1141.30
za~k.77
1127.33
539.3'1 1 3 3 5 7 8 . 4 1
5 5 3 . 2 61 3 7 1 2 3 . 5 6
44CO -64
4495.36
1274.06 3127.3C
L342.28 3484.46
12 ' 4087.25 12C1.7G 3492 099 567.23 140145.1Y 4554.00 14 13.32 3 8 1.~ ea,
 CK48-F PAGE 9 -10
L I O L I O H Y C R O G E KT U R P C P U M P ASSEMYLY

P R O C E S S I N GC A T E

T l j R e I N E P C l R P M E T E R S

1 IUE SPEEJ EXHAUST IFiLET EZHACST FLCW PR TOPCUE BHP FHP

SLICE TCTAL TCTAL TOTAL K A T IO (CALI61 (DELTA TI
YC PK T EVP TEPP
PPI4 (PSIAJ iOEG R ) (OfG K) (LB/SEC) FT-LB 1 iF P J

1 52 1.37 472.26 7.34 1.5242 11I.22 1811.2 1Et3.2

2 52C.54 471.75 7-46 1.5315 116 - 4 2 1ec2.1) 1883.5
3 5 19.93 47c.c7 8.14 1.5579 1 2 + .S5 2136.3 2C59.0
4 515.61 466.57 8.94 1.5575 131 24 22S9.3 2281.3
5 515.55 460.11 6.89 1.5599 128 094 2284 1 22117.5
6 515.49 4 t 5- 5 7 8.83 1.561 1 13$.@4 2290.7 2274.4
7 513.g7 464.S5 U.65 1.55Yl 129.t3 2221.8 2202.0
d 512.97 464.09 8.53 1.55E5 127.48 21e5.5 2171.0
3 5 13.49 4tL. 1.2 8.38 1 5467 123.f5 2525.7 2032.9
10 503.c7 459.19 1.61 1.5325 114.32 1861.7 1 9 1 1.2
I! 552.34 455.53 6.94 i .5033 103.82 1 6 9 1- 9 1725. b
12 498.24 451.55 6.32 1.4131 95.13 1j Y 4 - 7 1536.3
 PK4@-F PAC E 9. 11
L I 9 L : I D HYDR’JGEN
TURBCPUIYP
ASSEMBLY

RLN NUYBER 9 P K C C E S S I N GC A T E
TEST CPTE

T R 8 I K E P A H A M E T E R S (CCNTIhUEC)

T IUE Sr‘tED u/c EFF AVAIL. GAMMA CP SPEEC FLOX TORQUE

SL I C E (T-11 ( T-T) ENERGY I T - 1 ) PAR P - PARA- PAHA-
NC I W M (%I w u m ) . (BTL/LBM-K 1 METER CETER METER

1 et062 2 1 61..5410 3 7 3 . €556 473.53 2 -67C9 0.0183

2 ec.73 1 .241083. 86 4 3.6582 465.59 2.6579 O.C’lE8
3 EC.54 226.59 1.4315 3 66d0 491.36 2.6141 0.3182
4 eo.15 226.94 1.4020 3 .t 7 9 3 512.37 2.6143 0.3175
5 30.31 22 7.31 1.4020 3 -6790 517.S 7 2.0145 0.3172
6 &IC. 7 2 227.30 1.4019 3.67Ob 419.Cl 2.6127 ’ 0.3188
7 80.37 225.94 1.4017 3.6754 532.C8 2.6143 C.017d
8 8C. 3 t 22 5 . 3 4 1.4015 3 -6797 502-51 2.6151 0.0178
9 t3C.47 220.36 1.4CJY 3 .C7d9 492.54 2.6331 0.5183
13 EC.55 214.65 104JJ2 3.6775 479.6s 2.6564 C.0183
11 E C . 72 202.13 1.3SU8 3.6767 456.57 2.7115 C. 0187
12 EC.75 192.98 1.39 73 3.6772 436.24 2.7468 0.3191

’.
APPENDIX E
REFERENCES
 REFERENCES

1. Advanced SpaceEnginePreliminaryReport, NASA CR-121236, R-9269

269
DISTRIBUTIONLIST
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2 78
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279