NASA/TM--2002-212095 AIAA-2003-7362

The Revamping of an Ignition Test Facility

Kimberly A. Kearns

Glenn Research Center, Cleveland, Ohio

December 2002
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NASA/TM--2002-212095 AIAA-2003-7362

The Revamping of an Ignition Test Facility

Kimberly A. Kearns

Glenn Research Center, Cleveland, Ohio

Prepared for the

41st Aerospace Sciences Meeting and Exhibit

sponsored by the American Institute of Aeronautics and Astronautics

Reno, Nevada, January 6-9, 2003

National Aeronautics and

Space Administration

Glenn Research Center

December 2002
Acknowledgments

Thank you to Roger Scheman, Joe Zoeckler, Luke Ogorzaly, Chris Hegedus, Paul Asmondy, Karl Hagelin, and the

outstanding crew members at the Research Combustion Laboratory who are too numerous to mention.

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of changes that may be made before formal publication, this preprint is made

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permission of the author.

Trade names or manufacturers' names are used in this report for

identification only. This usage does not constitute an official

endorsement, either expressed or implied, by the National

Aeronautics and Space Administration.

The Aerospace Propulsion and Power Program at

NASA Glenn Research Center sponsored this work.

NASA Center for Aerospace Information

7121 Standard Drive

Hanover, MD 21076

Available from

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22100

Available electronically at http://gltrs.grc.nasa.gov
THE REVAMPING OF AN IGNITION TEST FACILITY

Kimberly A. Kearns

National Aeronautics and Space Administration

Glenn Research Center

Cleveland, Ohio 44135

ABSTRACT

The revamping of an Ignition Test Facility,

located in the Research Combustion Laboratory at the

NASA Glenn Research Center, is presented. The history

of how the test cell has adapted efficiently to a variety of

test programs is discussed. The addition of a second test

stand for ignition and small-scale rocket testing is

detailed. An overview of the facility and the current test

programs is offered. Planned upgrades for the future are

outlined.

INTRODUCTION

During the spring of 2000, a decision was made

to construct an ignition and small-scale rocket test stand

at an Ignition Test Facility located in the Research

Combustion Laboratory (RCL) at the NASA Glenn

Research Center. This new stand would be constructed

next to an existing test stand as part of the refurbishment

of Cell 21.

The major drivers for this decision were to

increase testing throughput and add flexibility by

operating two test stands with interchangeable fuel and

oxidizer supplies. The additional test stand, Stand B,

built along side the original, was needed to support an

upcoming three-year test program, the Pulse Detonation

Engine Testbed (PDE). This test program needed a

semi-permanent home due to the varied phases of the

PDE testbed and the length of time the PDE hardware

would exist in the test cell. The original test stand,

Stand A, used for all previous testing, was being setup to

support a Ceramic Rocket Engine (CRI), and could be

used for other short-term programs. By expanding and

revamping the test cell, the desire was to continue to do

ignition work, but also to support research in small

thrusters, combustion technology, and advanced

materials applications. By adding more fuels, oxidizers,

gases and liquids, and increasing flow rate capacity, it

was hoped Cell 21 could support a multiple combination

of programs.

Cell 21 has a long history of supporting widely

varying research programs, seldom running the same

fuels or oxidizers from test to test. Adapting the cell to

a variety of test programs led to many quick changes,

crossed actuation lines, and ad hoc installations. The

electrical inputs and outputs, and control panel circuits

also were used and reused for multiple research

programs. The current renovation of the cell was

designed to eliminate the discontinuous systems created

by the past programs and to end the cannibalization of

circuits and installations and make engineering future

systems easier.

HISTORY

Cell 21 is an older test cell, built forty to fifty

years ago, originally designed to be a Rocket Thruster

Test Facility. In the mid-80s, the cell was gutted, and a

small vacuum chamber was installed, along with an

altitude exhaust system, low-flow gaseous oxygen

(GOX) and low-flow gaseous hydrogen (GH2) feed

systems. A small RP-1 (kerosene) system was also

implemented. The plan was to perform ignition work at

altitude conditions; in reality, only a few programs used

the altitude capability. Other systems began to spring up

around these: metallized propellant (MP) and carbon

monoxide ignition. Then a purged laser equipment

room was built inside the cell for spray characterization

studies and plume analysis. This was dismantled later to

make room for the Combustion Wave Ignition (CWI)

and eventually the X-33 ignition system test.

The X-33 program required significant

changes to the cell. A 30-gallon liquid nitrogen (LN2)-

bath jacketed liquid oxygen (LOX) run tank along with a

30-gallon liquid hydrogen (LH2) system were installed.

The test rig itself was located outdoors behind the cell.

Many actuation valves needed to be relocated or have

new actuation lines run to them.

After the X-33 ignition system program was

completed, the single test stand was built up to support a

torch igniter test using LOX and ethanol. Because of

the low LOX flow rates and run pressures, and a need

for close-coupled, conditioned LOX at the igniter, a

small 1800-cc run tank was mounted directly to the

stand, as seen in Figure 1. The tank exterior was

wrapped with LN2 coolant coils with the LOX lines

extending through an LN2 bath (approx. 1.8 gallons).

NASA/TM--2002-212095 1

American Institute of Aeronautics and Astronautics
Insulationmaterial thenwaswrappedaroundthecoolant

coils.Thesmallruntankwasfilledfroma50-gallon

LOXdewarat 50psiginstalledadjacent to thenow

disconnected 30-gallonLN2-bathjacketedruntank.The

restoftheX-33rigeventuallywasdismantled, butnot

beforepartsofthesystemwerestrippedandreusedfor

theLOX/Ethanol test.

Figure1.--LOX/Ethanol runtanksonstand;theX-33

ignitionrigcanbeseenoutsidethedoor.

Theoriginalstandin Cell21waspartof the

vacuumchamber.TheLOX/Ethanol testwasmounted

onamobilecartstandinfrontofthisfixedstand.See

Figure2. TheCRItest,usingLOX andgaseous

methane, wasdesignedto demonstrate thefabrication

andoperationof a rocketenginemadeof ceramic

materials.Thistestwasto startbeforea newstand

wouldbeneededandwasdesignedtouseseveral ofthe

existingcomponentsleft from the LOX/Ethanol

program.Asaresult,thecartwasleftinplace.Anew

fixedstandwasbuiltinitsplaceastimepermitted. The

CRItestoriginallybuiltuponthecartwasrelocatedto

thepermanent stand.

Figure2.--LOX/Ethanol andaltitudeignitionstands.

MODIFICATION REQUIREMENTS

To increase testing throughput, Cell 21 was

modified to provide two sea level test stands, Stand A

and Stand B. Figure 3 shows the layout of the test cell.

Original objectives included re-introducing several past

capabilities and introducing new capabilities. The desire

was to do ignition work, but also to support research in

small thrusters, combustion technology, and advanced

materials applications.

Some of the specific goals were to add more

fuels (RP-l(kerosene) and gaseous methane), and more

oxidizers (such as revamping the large LOX tank),

re-introduce a pump-driven water system, build a

permanent LN2 station, and install larger regulators and

larger line sizes for GOX and GH2.

The test rigs were separated from the facility

valves by a steel bulkhead. The test stand was designed

so that all valves considered facility valves, main

purges, main vents, main shutoff valves, venturis, and a

bank of solenoids to run these valves, were installed on

the facility-side of the bulkhead. All oxidizers and fuels

have a shut off valve at the supply, another shut off

valve behind the bulkhead in the test cell, and then an

optional fire valve located on the test stand to service

the test article.

The test stand, any specialized test article

electronics, and solenoids to operate the fire valves,

were installed on the test stand side of the bulkhead.

Any resulting piping modifications required for specific

test programs would be made on this side of the

bulkhead, minimizing the changes required to get the

next test operational. The feed lines, valves and venturi

stations were installed on the facility side of the

bulkhead, with the goal being to keep all systems up to

the bulkhead permanent. The gaseous nitrogen (GN2)

purge systems were located between the two test stands

to keep from having duplicate systems.

NEW TEST STAND DESIGN

Test Stand A was designed to support testing

with GH2, GOX, LOX, gaseous methane and liquid

RP-1. Test Stand B initially was designed to support

only GH2 and "air", provided by bringing GOX and

nitrogen to the stand and mixing them. The new

bulkhead was designed with a doorway through it to

allow personnel access to both stands. Both stands were

located far enough from the rear overhead roll-up door

to allow for portable test stands to be placed in front of

either of them. An existing bulkhead located

NASA/TM--2002-212095 2

American Institute of Aeronautics and Astronautics
GH2 STATION

EARTH MOUND

Figure 3.--Test cell layout.

outside by the LOX tank remains in place. A new

bulkhead was installed to support the methane and RP-1

fuel tanks. Figures 4 and 5 show the views behind and

in front of the bulkhead, respectively.

FACILITY OVERVIEW

Tube trailers, pressurized to 2400 psig, supply

the GOX and GH2. The GH2 tank contains 70,000 SCF

(1.98 million standard liters) and the GOX tank contains

50,000 SCF (1.4 million standard liters). Figure 6 shows

a simplified schematic of a gas feed system. Each

supply line splits at the outside wall of the test cell into

three lines that supply the shutoff valves behind the

bulkhead. All six lines use dome-loaded pressure

regulators to deliver a constant pressure to a critical flow

orifice or venturi. Relief valves protect all six lines and

are set depending on program. The lines continue

through the sidewall of the test cell and run to the supply

shutoff valve behind the bulkhead. The smaller two

lines for both the oxygen and hydrogen, including vent

valves, are located on the bulkhead behind Test

Stand A. The larger size lines for both the hydrogen and

oxygen, including vent valves, are located on the

bulkhead behind Test Stand B.

Traditionally, the secondary legs are

considered the medium range lines, and with 3/8" tubing

and regulators with Cv = 1.3, are used the most. The

third legs have been recently installed and are the

largest; these lines contain larger regulators

Figure 4.-New bulkhead looking from the facility side.

NASA/TM--2002-212095 3

American Institute of Aeronautics and Astronautics
Figure5.--TeststandsB andA lookingfromthe

outsidein.

(Cv= 3.3)and3⁄4"lines.Theprimarylegsareusually

reservedforignition,pressurization orotherspecialized

needs.Theyarealso3/8"linesandregulatorswith

Cv=0.46.

Eachof thethreelinesizessupplieseither

StandAorStandB;thelinesruntobothstandsbutonly

oneisactiveatatime.Eachlinehasonesupplyshutoff

valvebehindthebulkhead.TheswitchbetweenTest

StandAandTestStandBisaccomplished byresetting

anelbowinthelinedownstreamofthevalvetooperate

oneteststandortheother.

ThePDEiscurrentlyinstalledonStandB.The

objectiveof the PDEProgramis to establishthe

feasibilityofPDEbasedHybrid-CycleandCombinedCyclepropulsionsystemstomeetNASA'sAviationand

SpaceAccessgoals.ThePDEprogramstartedinMarch

2001.Thisprogramrequiredre-introductionof GH2

intothecellandalargeflowrateof"air". Duetothe

researcher's requirements torunoxygen-richattimes,it

wasdecidedto combineGN2(at0.62lbm/sec)and

GOX(at0.18lbm/sec)fromtheexistingtubetrailersto

achievethedesiredairflowof 0.80lbm/sec.Thiswas

accomplished byutilizingthelargerlinesizesinstalled

forbothhydrogenandoxygen.Byaddingateeoffthe

nitrogenbuildingsupply(usedfor actuationand

purging), nitrogenwassuppliedtothecellusingoneof

thehydrogenlegs.

Inadditiontothegaseousmethane, whichwas

usedtosupporttheCRItesting,thebottleracklocated

outsidethetestcellcouldbeusedfor othergaseous

fuelsaswell.AsseeninFigure3,therackislocated

adjacent toCell21andcanholdfourcylinders.It is

separatedfromthecellbyasteelbulkheadandaligned

parallel withthesidewall ofCell21.

ALOXstoragedewarandthelargeruntank

fromtheX-33programarelocatedoutdoors, adjacent

tothecell.Theseareseparatedfromthegaseousfuel

andRP-1tanksbyanothersteelbulkhead. Thesmall

accumulator-size LOXruntankwasretainedfromthe

LOX/Ethanol programandislocatedadjacent tothetest

hardwareinsidethecell.

Table1.--MaximumFlowRatesofFuels

andOxidizers

Maximum

flowrate,

(lbm/s)

0.3

2.0

LiquidHydrogen

LiquidOxygen

GaseousHydrogen

GaseousOxygen

Ethanol

0.3

1.0

0.1

GaseousMethane 0.5

RP-1 0.5

All feedsystemsareprotectedfromoverpressurization byreliefvalvesandaredesignedtofailsafein theeventof anemergencyshutdownorpower

failure.A manually-operated CO2systemprovidesfire

protectionforthestands.Thetestcellisequippedwith

variouscombustiblegasdetectorswith alarms.In

addition,thereis onelow-oxygenalarmto warnthe

operatorif alargeleakorLN2boil-offshouldcreatean

asphyxiationhazard.A largeoverheaddoorisopened

duringtestingandaroof-mounted ventilationfanisrun

continuously duringtesting.

Current fuelsandoxidizersandtheirmaximum

flowratesareshowninTable1.Theselimitsaredefined

bythegoalsof thecell. Pastresearchprogramshave

usedotherfuelssuchascarbonmonoxide, aluminum

powder,andgelledRP-1/aluminum. Capabilitystill

existsto resuscitatesomeof thesesystemsin a

reasonable timeframe.

NASA/TM--2002-212095 4

AmericanIstituteofAeronautics andAstronautics
[13-

TO CELL 22

F_

P A

F_

PRESSURE

REnULATOR

BLBO VALVE

FROM TRAILER

° I

I

RELIEF

VALVE

AUTONATIC t

VALVE

CHECK

VALVE

-- -- I VENTURI sonic

FLOW FACILITY i I

METER SHUTOFF L ..... I

VALVE B I

..i

12

Figure 6._Gas feed system.

CLOSE

COUPLED

__r-j7

LIJ

FIRE

VALVE

The gaseous tube trailers mentioned previously

are shared with the adjacent facility, Cell 22, on an

alternating basis. This means that only one of these cells

can run at a time. Control panel power also is shared.

However, during the oft-run days, each cell is accessible

while the other cell is running.

ELECTRONIC SYSTEMS

Controls, Instrumentation. & Data Acquisition

Automatic valve operation and data trigger

control reside in the Modicon Quantum Programmable

Logic Controller (PLC). The current PLC operates with

an overall scan rate less than 10 mSec, which allows

discrete output timing resolution to 0.01 second. There

are three 10-slot racks for Input/Output (I/O), with a

total I/O capability in excess of 600 points.

Typical instrumentation includes strain gage

pressure transducers; Type T (copper-constantan),

Type K (chromel-alumel), Type E (chromel-constantan)

thermocouples; turbine flow meters; silicon diode

temperature sensors; and photographic recording. An

automatic abort system consists of ten-channel analog

comparator circuitry with a response time of less than

30 mSec.

The cell data acquisition system is configured

for 128 channels of data acquisition programmed with

Labview TM Version 5.1. It uses National Instruments

Signal Conditioning extensions for Instrumentation

(SCXI TM) chassis architecture and features 8m order

lowpass elliptical signal conditioning modules. The

Labview TM program is configured for zeroing, maximum

engineering unit, and zero offset calibrations for

increased accuracy. It currently supports 500 Hz data

recording rate per channel with capabilities to 1 kHz

with channel number limitations and polynomial postprocessing. An instrument patching system allows

versatility of displays such as digital panel meters and

16-channel chart recorders for trend analysis. Figure 7

shows a simplified instrumentation block diagram.

Post-processing of raw data from the

acquisition system is available on separate PCs coded in

Visual Fortran. An Excel-based user interface is used

for creating spreadsheets and graphing functions.

Within the past year, and for temporary use

with the PDE, a new high-speed data system was

introduced into the cell, the Concurrent Computer

Corporation Model 740 High Speed Data Acquisition TM

system. Prior to this, dynamic pressure transducers

required for the PDE testing could only be wired to and

recorded on either a spectrum analyzer or oscilloscope.

Neither one has the capability to distinguish every

detonation peak when running at 45-50 Hz. The

Concurrent can support a 950 MHz sampling rate per

channel at either a 16-channel or 32-channel set. The

PDE program required the use of five channels.

NASA/TM--2002-212095 5

American Institute of Aeronautics and Astronautics
TEST CELL

THER_OCOUPLEJ--_" f OVEN

150"F REFERENCE

TRANSDUCER PRESSURE ]

I CONTROL ROOM

I

I

I

I

_r DATAsYsTE_ACQUISITIONJ

_.t GAIN = |O_,./ABORT RELAY I

GA,N=,DO I SY TE I

_I s,GN,,

--ICOND'T'D"ER I

_J DATA ACQUISITION sYmzk4

l --I GAIN = 100

GAIN = 100 E_D,-I-_"';_,_.-;;_';-_' I

i i i

Figure 7. Instrumentation block diagram.

The Concurrent system uses two UNIX

computers. The first computer is used to provide highspeed data acquisition. The system hardware consists of

a 32-channel high-speed data acquisition board, a timing

board, a UNIX file system hard drive, and a multi-drive

disk system. Proprietary software applications to

perform the data acquisition within a shell window are

accessed via scripts. The PLC controller sends a trigger

signal to start the actual acquisition process once the

system is armed. The multi-drive disk system is used to

allow high data streaming storage data during the

capture phase in a binary format. Once capture activity

is completed, a script is run automatically to convert the

data to a format that can be stored on a standard hard

drive containing a standard UNIX file system.

The second computer is a dual 700 MHz

INTEL TM processor PC with 512 MB of RAM running a

version of the Linux operating system and X windows.

Its purpose is to display the captured data using the

MATLAB TM software application by depicting the data

in time history graphical format. The Linux system is

networked to the data computer via the NFS protocol. A

menu presented within a shell window on the Linux PC

is used to invoke a data scan arm and trigger command

on the PowerMAX TM computer. Another script is run to

start a Java process once the data capture is complete.

The Java process uses a proprietary library command set

to access the data file and convert the format into one

acceptable to MATLAB TM. MATLAB TM uses standard

plot routines within its toolboxes and libraries to display

the data for review and/or to print a hard copy.

Specialized Controls

During the LOX/Ethanol testing, a Variable

Ignition System (VIS) TM, manufactured by Unison

Industries, was procured to vary the valve and spark

timing and the spark exciter frequency and energy

levels. The version of PLC in place at the time could

not provide the desired time resolution for the control

sequence. Overall, the control capability needed to

facilitate a rapid 80-millisecond startup and

8-millisecond shutdown response of the igniter. Run

devices controlled were the LOX valve, ethanol valve,

and the spark. The variable ignition system operates

from a computer program loaded on a PC located in the

Control Room. The exact timing program gets

downloaded to a unit in the test cell prior to firing the

engine.

A variation of the Unison spark exciter system

was procured for the PDE test on Stand B. This system

was necessary because of the high-speed action required

of the hydrogen and air valves, in addition to the spark.

The current PLC system in use for timing other valves in

and out could not produce the quick cycle time required

for the PDE firing. Valves can be activated as many

times as is necessary within a single period, and it is

possible to spark more than once within the same period.

However, the system always requires a charging time

before all spark events. One spark plug is installed on

the hardware and fired at the cycle rate of the

device (+35 Hz). Spark energy is 500 mJ per spark. See

Figure 8.

NASA/TM--2002-212095 6

American Institute of Aeronautics and Astronautics
I I

PC

CONTROL ROOM

RCc"o ##ER

m

/

l

TEST CELL

IGNITION

i EXCITER

CONTROL

BOX

IGNITER PLUG

[ H

MIPOWER SUPPLY _--

M u

1 120VAC i

PURGED CABINET _

Figure 8.--Ignition system block diagram.

Power supplies, which are installed in a purged

cabinet in the test cell and enabled by a pushbutton on

the control console, supply the power for the high-speed

valves. They are 24VDC power supplies, but are

adjusted to supply approximately 8-9VDC. This is the

voltage range that yielded optimal valve performance at

35 Hz. The 120VAC power to the power supplies is

applied at the start of a run cycle and is shut off one

second into the post-run cycle. The Unison spark power

supply can supply 3kV to the spark plug.

the spark event. If the system is working properly these

codes should be between E6-E3.

There is a 'SPARK CONFIRMATION' signal

that is fed out of the PDE Valve Interface Box and

displayed on the chart recorder. This signal means that

the Unison charged for the spark event. It is possible,

however, that the system charged, but a spark did not

take place because of a malfunctioning spark plug.

The Unison's timing sequence is programmed

on a PC using proprietary development software. The

sequence then is downloaded to the controller unit

installed in the cell on the PDE test stand. After the

download and prior to hitting the START button on the

control console, the operator passes control to the

Unison by keying in 'GO' on the PC. In this state, the

Unison waits for a 'RUN/GO' signal from the PLC. The

PLC output is 24VDC. A circuit in the cell converts this

signal into a low trigger 'RUN' command, which

initiates the programmed run sequence. The 'RUN'

signal is fed into the PDE Valve Interface Box that is

mounted above the test stand.

While the Unison is sequencing, a series of

hexadecimal digits appears on the PC running the

Unison software. These digits represent the voltage

levels divided by 10 at the time immediately preceding

CURRENT TEST PROGRAMS

Stand A

Ceramic Engine

CRI originally consisted of three phases:

Phase I: Ceramic Rocket Injector (CRI); Phase II:

Ceramic Rocket Chamber and Nozzle; Phase III:

Combined Ceramic Rocket Injector, Chamber, and

Nozzle. Each of these phases will be described below.

In the first phase of this effort, two rocket

engine injectors of standard designs (triplet and coaxial) were to be fabricated out of silicon nitride (Si3N4)

and tested with a copper heat sink engine. The

propellants are LOX (0.224 lbm/sec) and gaseous

methane (0.064 lbm/sec). The faceplate of the co-axial

injector will be porous, and between 5 to 10 percent of

NASA/TM--2002-212095 7

American Institute of Aeronautics and Astronautics
themethanewill flowthroughthefaceto provide

cooling.

Theresearchhardwareis agoodmatchfora

Marsascentengine,onepotentialbeneficiaryof this

technology.Thechamber pressureis setat200psia.

Sealevelthrustisbetween50and100lbfthatiswell

withinthecapabilitiesofCell21.

PhaseI TestPlanshaveeachinjectortestedat

several mixtureratiosinadditionto thenominal value

of 3.5. Dependingonthesuccessof testsatnominal

pressure, afewtestsatchamber pressures upto300psia

andthrustupto110lbfmayalsobeconducted. Initial

durationof individual testswillbe3 seconds, butlater

testdurationswillbestretchedtothelimitsof theheat

sinkchamber andnozzle.

Aftersuccessful demonstration oftheinjector,

originalPhaseII planswereto fabricatea Si3N 4

chamber and nozzle and to test with a metal injector.

Test conditions were to be similar to those in Phase I.

Phase III will fabricate a one-piece rocket engine, where

the injector, chamber, and nozzle are an integral Si3N4

piece.

The initial injector was fabricated using a layer

technique. The chamber/nozzle configuration was being

fabricated using a mold-cast technique. However,

significant effort has been expended on connecting and

sealing the ceramic injector to a metal chamber; a

skill/technique not needed for the final objective.

Meanwhile, progress has been made in fabricating a

Si3N4 injector using the mold-and-cast technique. If this

technique can be used for the relatively complex

injector, then the testing will progress directly to the

single component engine test originally planned for

Phase III.

Stand B

On Test Stand B, the PDE testbed has served

as a platform for additional test series: the PDE Ejector,

an RP-1 Combustion Wave Ignition (CWI), a liquid

hydrocarbon (HC) PDE experiment, and the current

PDE NOx Sampling Testing. Each of these testing

series will be described below.

PDE Eiector

The PDE Ejector test uses the existing C21

PDE as the unsteady driver. The initial tests were single

detonations, followed by short multiple detonation

firings, and building up to the desired longer durations.

The test hardware was connected to the last

section of existing PDE in the "short" configuration (the

one used for higher detonation frequencies) and, at

42 inches in length, terminated just short of the existing

test cell roll-up door. A new smooth wall PDE tube

section was fabricated for use as the driver "nozzle".

Movable ramps were placed inside a rectangular

pressure housing to form the ejector contour. A fixed

pressure was maintained upstream of the ejector throat

using GN2 supplied from a 70,000 cubic foot temporary

tube trailer station, located in the alleyway outside. The

GN2 was fed to the ejector through 50 feet of 1-1/2" Sch

40 pipe.

A 3-foot square thrust plate and 200-1bf load

cell were mounted just outside the test cell roll-up door

and bolted to the concrete pad. The maximum design

flow for the ejector was 8.2 lbm/sec of GN2, plus the

0.82 lbm/sec of PDE exhaust produced at 35 Hz.

After configuring the ejector for a given test

and setting up the facility for PDE operation, the GN2

ejector flow supply was set up manually. Flow traveled

through the ejector prior to the start of the test. A newly

acquired water pump was installed in the cell to supply

the necessary cooling for the dynamic transducers,

although the pump was never utilized due to the

shortened run times. This test also required the use of

absolute pressure transducers on the GN2 line. A

vacuum pump was brought in each day to calibrate

them.

RP-1/CWI and HC PDE

Both the RP-1/CWI and HC PDE phases of the

PDE testing used RP-1 and GOX. The objective of the

RP-1/CWI test series was demonstrate the production of

nearly simultaneous ignition sources at two physically

separated locations using GOX and liquid RP-1 as the

oxidizer and fuel. The objective of the HC PDE test

series was a low cost effort to provide repetitive

detonations using a hydrocarbon fuel.

The RP-1 was fed to the cell using a newly

installed 9-gallon run tank and 5 feet of 3/8" piping.

The RP-1 run tank was pressurized by a newly installed

Tescom regulator, using an existing loader. The

maximum flow rate of RP-1 is 0.05 lbm/sec. The run

tank is located outside, adjacent to Cell 21. It is

separated from the cell by a steel bulkhead.

Maximum use was made of existing PDE

testbed, PDE hardware, instrumentation, and control

systems. The test article was a modification of the

existing PDE testbed. The current injector configuration

NASA/TM--2002-212095 8

American Institute of Aeronautics and Astronautics
wasremovedandreplacedwith an injectorhead

assembly.

At thetopof theinjectorheadassembly, a

modifiedcommercial fog nozzlewasmountedby

brazing.It wasusedtoproduceaveryfinesprayof

RP-1.A crossmemberon the nozzleprovided

connections fortheGOXandRP-1feedlines.Highspeedpressuretransducers(PcBTMs)wereusedto

detectdetonation/deflagration speedsto verifyproper

operationof thedevice.ThreexistingFlodynevalves

useduringthePDEbaselinetstingcontrolledtheflow

ofRP-1tothedevice.

For the RP-1/CWItest series,straight

detonationtubeswereattachedtothenewinjectorhead

assembly. Thesetubesweresubsequently removedfor

theHCPDEportionoftheprogram.

PDE NOx Sampling Testing

The purpose of the current PDE NOx sampling

testing is to assess pollutant formation in a PDE using

accepted sampling practices. The setup includes a

sampling oven, a two-channel nitrogen oxides analyzer,

and a vacuum pump to be installed in what used to be a

storage shed in the back of the test cell. No new fuels or

oxidizers are required for this phase of testing, but the

shed does need to have the electrical power modified

and a 30' heated line run to it for the sample collecting.

Due to the number of new valves that need to

be controlled during the sampling process, WonderWare

InTouch TM will be introduced into the cell for valve

control.

OBSERVATIONS

The existence of two test stands in Cell 21 with

interchangeable fuel and oxidizer supplies has proven to

be very successful. One stand is home to a long-term

program while shorter-term programs occupy the other

stand. Both test stands have been active at the same

time even though they were not designed to run at the

same time. This gives the test cell a lot of unforeseen

versatility

The PDE program continues on Stand B and is

being built-up to support the next phase of testing.

Stand A has been modified to checkout a Coupon

Degradation Injector (CDI) program to be done in Cell

22 eventually. From CRI to CDI, very few changes or

modifications were needed. CDI is running GOX, GH2,

and is using a hydrogen/oxygen spark igniter. The

methane bottles from CRI were disconnected and

relocated and the regulator was reconnected to the

medium-range hydrogen line. On the oxygen side, the

LOX tank was disconnected and the GOX used as the

pressurizing agent is now the oxidizer.

The use of both test stands at the same time

added flexibility to the cell as well. By juggling the like

systems from one stand to the other, testing on Stand A

one day then Stand B the next became possible. The

oxygen igniter purge was "borrowed" from the CRI test

on Stand A to purge the RP-1 system on Stand B during

the last phase of PDE testing. Additionally, the loader

used to operate the hydrogen igniter system on Stand A

was put into service to operate the RP-1 regulator on

Stand B. The ease with which the purge and loader

were swapped back and forth on corresponding test days

from the PDE CWI test on Stand B to the CDI test on

Stand A meant a substantial number of active test days

for the cell.

When the two test stands were erected, the

intent was to eliminate the sharing of circuits and

minimize the cross-use of actuation lines. It is hoped

that reusing existing systems installed for one purpose to

operate differing systems can be eliminated. As long as

like systems operate like systems, purges stay purges,

and the solenoids on the test stand stay dedicated to the

test stand, the discontinuous systems of the past will no

longer be the operating norm.

The FUTURE

The phased approach of the current expansion

of the test cell continues. The RP-1 system has been

brought back into service ahead of schedule. Stand B

can operate GOX, GH2, RP-1, simulated "air", and the

altitude exhaust system, originally installed for ignition

systems testing, is still functional. In February 2002, the

altitude ejectors were reinstated to support a test

feasibility exercise. The vacuum chamber has been

removed and put in storage, but plans are being

developed to reintroduce this capability.

Stand A currently supports GOX, GH2, LOX,

gaseous methane, and ethanol. The LH2 system that was

disconnected after the X-33 currently is being revamped

and reconnected for future use. Reinstallation of the

larger LOX tank pressurization components and longer

duration test programs are on the list of improvements

as well.

In addition, evaluation and upgrade of the CO2

fire suppression system is needed. Improvements

planned for the entire RCL are replacement of the

central liquid CO2 tank; completion of new telephone

NASA/TM--2002-212095 9

American Institute of Aeronautics and Astronautics
system;andnewsignsforthebarricadeswithupdated

phonenumbersand improvedcommunications

instructions

Other plans for the test cell include

replacement of existingpressurecontrolhardwarewith

state-of-the-art equipment, controlroomchangesand

controlpanelreorganization, adexpandingtheuseof

WonderWare InTouchTM.

WonderWare InTouch TM is slowly being

incorporated into the cell. Initially, InTouch TM will be

used primarily for controlling hardware associated with

the PDE NOx Sampling testing. As time permits, the

plan is to remove most of the hardware control consoles

in Cell 21's control room and implement valve operation

and data trigger control using InTouch TM. It is

anticipated that InTouch TM will save time, money, and

control room space allowing Cell 21 to improve its

versatility and functionality even further.

REFERENCES

Green, J. M., "A Versatile Rocket Engine Hot Gas

Facility", AIAA-94-2487, June, 1994.

Galecki, D.L., "Ignition and Combustion of Metallized

Propellants", AIAA-89-2883, July, 1989.

NASA/TM--2002-212095 10

American Institute of Aeronautics and Astronautics
Form Approved REPORT DOCUMENTATION PAGE

OMB No. 0704-0188

Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources,

gathering and maintainingthe data needed, and completing and reviewingthe collection of information. Send comments regarding this burden estimate or any other aspect of this

collection of information, including suggestions for reducing this burden,to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson

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1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED

December 2002 Technical Memorandum

4. TITLE AND SUBTITLE 5. FUNDING NUMBERS

The Revamping of an Ignition Test Facility

6. AUTHOR(S)

Kimberly A. Kearns

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

John H. Glenn Research Center at Lewis Field

Cleveland, Ohio 44135-3191

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration

Washington, DC 20546-0001

WBS-22-708-48-04

8. PERFORMING ORGANIZATION

REPORT NUMBER

E- 13747

10. SPONSORING/MONITORING

AGENCY REPORT NUMBER

NASA TM--2002-212095

AIAA-2003-7362

11. SUPPLEMENTARY NOTES

Prepared for the 41st Aerospace Sciences Meeting and Exhibit sponsored by the American Institute of Aeronautics

and Astronautics, Reno, Nevada, January 6-9, 2003. Responsible person, Kimberly A. Kearns, organization code

7555, 216-433-3145.

12a. DISTRIBUTION/AVAILABILITY STATEMENT

Unclassified - Unlimited

Subject Category: 20 Distribution: Nonstandard

Available electronically at http://gltrs.arc.na.sa.gov

This publication is available from the NASA Center for AeroSpace Information, 301-621-0390.

12b. DISTRIBUTION CODE

13. ABSTRACT (Maximum 200 words)

The revamping of an Ignition Test Facility, located in the Research Combustion Laboratory at the NASA Glenn

Research Center, is presented. The history of how the test cell has adapted efficiently to a variety of test programs is

discussed. The addition of a second test stand for ignition and small-scale rocket testing is detailed. An overview of

the facility and the current test programs is offered. Planned upgrades for the future are outlined.

14. SUBJECT TERMS

Test facilities; Cryogenic rocket propellants; Low thrust propulsion; Ignition systems;

Test stands; Ground tests; X-33 reusable launch vehicle; RP-1 rocket propellants;

Flow velocity; Research facilities

17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION

OF REPORT OF THIS PAGE OF ABSTRACT

Unclassified Unclassified Unclassified

NSN 7540-01-280-5500

15. NUMBER OF PAGES

16

16. PRICE CODE

20. LIMITATION OF ABSTRACT

Standard Form 298 (Rev. 2-89)

Prescribed by ANSI Std. Z39-18

298-102