rd-180-pres-052002

AIAA Technical ActivitiesJoint Propulsion Conference Indianapolis, IN July 2002

Liquid Propulsion Short Course

1

Development and Development and Characteristics of theCharacteristics of theRussian / American Russian / American

RDRD--180 Rocket Engine180 Rocket Engine

Liquid Propulsion Short CourseLiquid Propulsion Short Course

Presented by:Lawrence G. Tanner

P&W RD-180 Chief Engineer12 July 2002



2

RD-180 Engine Development

Course OverviewCourse Overview

• Background• Engine Characteristics• Design Considerations• Development Approach• Development Summary• RD-180 Flight Program• EELV and Future Uses



3

RDRD--180 Overview180 Overview

! Russian Program Background! RD-180 Engine Characteristics! RD-180 Program Status

• Development• Flight



4

RDRD--180 Background180 Background

• RD-180 Originally Pursued by General Dynamics in early 90’s for Atlas upgrade

• After General Dynamics merged with Martin Marietta which later became Lockheed Martin, engine studies solidified.

• In 1995, Lockheed Martin selected the joint venture team of NPO Energomash and Pratt & Whitney, (RD AMROSS) to provide the RD-180 for the Atlas IIAR (now Atlas III) and for their EELV LV designs.

• A three-phased development and certification program has now been completed which certifies the RD-180 for use on the Atlas III, Atlas V MLV, Atlas V HLV Strap-on LRBs and the Atlas V HLV Core (Common Core Booster) launch vehicle models.

• The Russian-American cooperation in this endeavor is unprecedented.



5

RDRD--180 Design Background180 Design Background

! RD-180 derived from the NPO Energomash designed RD-170• man-rated, reusable - Energia / Buran• more than 900 tests and 100,000 seconds of testing time• RD-180 70% similar

RD-170(1.8M lb thrust)

RD-180(0.9M lb thrust)

1/2



6

RDRD--180 Engine Characteristics180 Engine Characteristics

! Two chamber derivative of the RD-170! Identical chambers, scaled turbopumps! Staged combustion cycle - LOX rich PB! LOX/kerosene propellants! 2 thrust chambers (+/- 8o gimbal)! LOX & fuel boost pumps! Single shaft high pressure turbopump

– 2 stage fuel pump– single stage LOX pump– single stage turbine

! Self contained hydraulic system (valves, TVC) powered with kerosene from fuel pump

! Hypergolic ignition

Characteristics demonstrate heritage to RD-170



7

RDRD--180 Technical Data180 Technical Data

Powerful and Dependable

Full Power (100%) Minimum Power (47%)Chamber Pressure (psi) 3,722 1,755Flow Rate (lb/s) 2,756 1,152Total Sea Level Thrust (lb) 860,200 365,500Total Vacuum Thrust (lb) 933,400 438,700Sea Level Isp (sec) 311.9 278.7Vacuum Isp (sec) 338.4 334.6Mixture Ratio 2.72Nozzle Area Ratio 36.9Throat Area (in2) 67.5Engine Length (in) 141Circumscribed Exit Diameter (in) 124Single Nozzle Exit Diameter (in) 56.9Gimbal Angle +/- 8 degWeight, Dry (lb) 12,225Weight, Wet (lb) 13,260Thrust/Wt (Sea Level, with TVC ) 70.4Thrust/Wt (Sea Level, No TVC ) 74.5



8

Overall Interface DrawingOverall Interface Drawing

FrameTurbine

Hot Gas Ducts

LOX Boost Pump

Fuel Boost PumpLOX

Pump

Fuel Pump

Gimbal Actuator

Heat Exchanger

Preburner

Nozzle

Gimbal Unit

Combustion Chamber(2)

Fuel Inlet Valve



9

RDRD--180 Engine Schematic180 Engine SchematicFuelInlet

HeatExchanger

LOX BoostPump

Fuel BoostPump

Fuel InletValve

FuelPump

LOXPump

Preburner

Turbine

ChamberMain Fuel

Valve

StartBottle

MixtureRatio Valve

ThrustControlValve

Main LOX Valve

HypergolicStart

Ampoule

Hot GasBellows

LOXInlet



10

Single Shaft TurbopumpSingle Shaft Turbopump

! Cycle implications:• robust, repeatable start

characteristics• both pumps spool up

together - simple open loopcontrol system for engine

• low parts count (1 turbine)• low cost, high reliability

! Sub-critical rotor operation:• no vibratory resonance

! High Capacity• 750 lb/sec Fuel (6700 gal/min)• 2000 lb/sec LOX (12,600 gal/min)

Evolutionary heritage of proven concept

InducerImpeller

Shaft

TurbineBlisk

LOX pump/turbinerotor assembly



11

RDRD--180 Enables LV Family Growth180 Enables LV Family Growth

Atlas Family of Launch Vehicles by Lockheed Martin Astronautics

Atlas V(HLV)

Atlas V(500 Series)(0-5 SRBs)

Atlas IIAS Atlas III(SEC)

Atlas III(DEC)

Atlas IIAtlas IIA

12/91 12/93 5/00First Flight

Atlas V(400 Series)(0-3 SRBs)

2

6

10

14

18

22

26

30(k kg) (k lb) 21st Century Growth

SingleEngineCentaur

LoxTankStretch

RD-180Engine

SRBs

CommonCentaur

3.8mCommonCoreBooster

5m PLFGSO Kit

SRBs LiquidStrapons

1

3

5

7

9

11

13

GTO

Cap

abili

ty

2/02

RD-180



12

High Thrust OperationHigh Thrust Operation

Time

Thrust

Throttlability allows for control of “Max Q” and propellant depletion structural loads

Engine health check during start transient

High power capability allows vehicle growth and flexibility in trajectory

Power Margin allows robust vehiclestructure and simpler manufacturingtechniques

Engine characteristics have direct benefit to vehicle



13

Mission variables drive test planningMission variables drive test planning

Atlas III vs. Atlas V Flight Thrust Profiles

0

10

20

30

40

50

60

70

80

90

100

0 50 100 150 200 250 300 350 400

Seconds

Pow

er L

evel

Atlas V MLVAtlas V HLVAtlas III

Pow

er L

evel

-%



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Program StatusProgram Status

! Atlas III Certification testing complete! Production engine deliveries completed (Atlas III only, 7

engines)! Delta Certification testing for MLV complete

MilestonesDesign & AnalysisComponent TestingCore Engine TestingDevelopment TestingCertification Testing

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q41996 1997 1998 1999 2000

PDR CDRAtlas III

CertAtlas V

Cert

Atlas III Atlas V

1st Atlas III Flight (8 Engines/14 Builds/70 tests / 10,596 Sec)4/5/25/4,618

3/5/21/3,781

1/1/5/1,024



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Program Status Program Status -- cont’dcont’d

Demonstration Testing

Certification Testing

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q42001 20022000

Atlas V HLV

1st Flight1st Atlas V MLV

12 Tests5 Tests

! Atlas V HLV demonstration tests completed! Production engine deliveries continue, common for Atlas III or V! Delta Certification testing for HLV, completed 3-Q 2001



16

RDRD--180 Engine Systems Level Test180 Engine Systems Level TestComprehensive Verification of RequirementsComprehensive Verification of RequirementsPerformance- Margins- Thrust & Isp- Mixture ratio range, margins- Helium HEX- Repeatability- Proven production

acceptance testControl- Propellant inlet extremes- Chilldown, pre-start, shutdown- Control capability, accuracy- Transient response- Throttling

Structure/Design- Vibration- Durability/life, margins

Integration- Thrust vector control, flight-

like gimbal actuations- Interface loads- Tolerance to vehicle

commanded start/launchabort



17

RDRD--180 Test Time Accumulation180 Test Time Accumulation

Consistent Progress Toward Program Goals

0

5000

10000

15000

20000

25000

30000

35000

01-Jan-96 31-Dec-96 31-Dec-97 31-Dec-98 31-Dec-99 30-Dec-00 30-Dec-01 30-Dec-02

Tim

e (S

econ

ds)

Atlas IIICert

MLVCert

HLVCert

1A 2A 5A2 4A 6A 7A 8A 6B 7B 9A 9A 5A5 10A 1TC 8B 5B5

4A, MSFC 8C 11A 13A 8D 11B 13B 11C 14A

2T 3T 4T 5T 6T 7T 2T 8T 9T 10T 10T 11T 12T 12T 13T

1B 3A 5B2 9A 1T 1T

12A 12A 12B

10T 11T

AC-201

AC-20429,385 seconds and 161 firingsas of 1 April 2002

0

5000

10000

15000

20000

25000

30000

35000

01-Jan-96 31-Dec-96 31-Dec-97 31-Dec-98 31-Dec-99 30-Dec-00 30-Dec-01 30-Dec-02

Tim

e (S

econ

ds)

Atlas IIICert

MLVCert

HLVCert

1A 2A 5A2 4A 6A 7A 8A 6B 7B 9A 9A 5A5 10A 1TC 8B 5B5

4A, MSFC 8C 11A 13A 8D 11B 13B 11C 14A

2T 3T 4T 5T 6T 7T 2T 8T 9T 10T 10T 11T 12T 12T 13T

1B 3A 5B2 9A 1T 1T

12A 12A 12B

10T 11T

AC-201

AC-20429,385 seconds and 161 firingsas of 1 April 2002



18

RDRD--180 Testing at MSFC180 Testing at MSFC

! Development RD-180 shippedfrom Khimky, Russia to MarshallSpace Flight Center in Huntsville, AL

! Engine mated to Atlas III thrust structure and tank simulator

! Four engine tests conducted• 130 seconds of test time• Verified vehicle/engine system interface• and operation• Validated engine start, abort, gimbal,

heat exchanger operation and shutdown.

! Lessons learned incorporatedinto flight procedures

• Double check all technical information - double check translation accuracy• Consultation with Russian experts key to successful procedure development



19

Production EnginesProduction Engines

! Engine Currently in Serial Production• 13 flight engines delivered to Lockheed Martin to date• 2 engines flown (successful launches of AC-201 and AC-204)• Built in Russia, flown to Denver, launched from Cape Canaveral



20

RDRD--180 Flight Program180 Flight Program

Lockheed Martin Denver OperationsEngine Delivery

Receiving Inspections

Engine-to-Vehicle Integration



21

Self Contained Propulsion PackageSelf Contained Propulsion Package

! All pneumatics/hydraulics, actuators and thrust frame contained in engine sub-assembly

! Minimum interfaces (11 fluid)! Fully tested prior to delivery to

customer! Minimum test and checkout - no

re-assembly required during vehicle connections

! LV integration activities reduced from 80 days to 12 compared to previous engine design

Efficient installation and checkout at Lockheed Martin Denver Operations



22

Boost Stage DeliveryBooster Erection

System Level Checkouts(Wet Dress

Rehearsal, etc)

RDRD--180 Flight Program180 Flight ProgramCape Canaveral Air Force Station Operations



23

RDRD--180 Flight Program 180 Flight Program –– First Atlas IIIAFirst Atlas IIIAWednesday May 24, 2000 7:10 PM

! AC-201 SUCCESS !!• Eutelsat W4 spacecraft placed in

above-nominal orbit• Nominal RD-180 performance

! Lessons Learned Minor In Nature! 80% of Atlas V Risk Retired

87% Cruise Operation

Boost StageSeparation

Payload FairingJettison



24

RDRD--180 Flight Program 180 Flight Program -- First Atlas IIIBFirst Atlas IIIB

! AC-204 SUCCESS • EchoStar 7 telecommunications satellite

placed in above-nominal orbit• Nominal RD-180 performance

! No Engine Issues

AC-204 EchoStar 7Thursday Feb. 21, 2002 7:43 AM



25

Delta Certification for EELVDelta Certification for EELV

! Atlas V to be used as Lockheed Martin’sEvolved Expendable Launch Vehicle

! Atlas V MLV engine testing completed• Additional engine builds, tests,

and test time• Certify operation at high power levels

and long durations! Atlas V MLV engine certification

completed-2001! Atlas V HLV Core demonstration tests

completed! Atlas V HLV engine certification testing

completed late-2001



26

?

RDRD--180 Future180 Future

Atlas IIIAtlas V

RFS

RD-180 ready for current and future

applications

Documents

rd-180-pres-052002