Space Shuttle Main Engine:

The First Twenty Years and Beyond

by Robert E. (Bob) Biggs

Donald C. Elder, Series Editor

AAS History Series, Volume 29

A Supplement to Advances in the Astronautical Sciences

Copyright 2008
by
AMERICAN ASTRONAUTICAL SOCIETY
AAS Publications Office
P.O. Box 28130
San Diego, California 92198

Affiliated with the American Association for the Advancement of Science

Member of the International Astronautical Federation

First Printing 2008

ISSN 0730-3564
ISBN 978-0-87703-546-6 (Hard Cover)
ISBN 978-0-87703-547-3 (Soft Cover)

Published for the American Astronautical Society

by Univelt, Incorporated, P.O. Box 28130, San Diego, California 92198
Web Site: http://www.univelt.com
Printed and Bound in the U.S.A.
iv

Contents
Page
Foreword
Preface

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PART I

The First Ten Years

Introduction

Chapter 1. The Engine .

Chapter 2. The Beginning .

11

Chapter 3. The Requirements .

15

Chapter 4. The Obstacles . . . . . . . . . .

Getting Started . . . . . . . . . . . .
Component Testing . . . . . . . . . .
Engine Testing . . . . . . . . . . . .
Problem Management . . . . . . . . . .
Start and Shutdown . . . . . . . . . .
High Pressure Fuel Turbopump Sub-Synchronous Whirl
High Pressure Oxidizer Turbopump Explosions. . .
High Pressure Fuel Turbopump Turbine Blade Failures
Engine 2001 Main Oxidizer Valve Fire . . . . .
Engine 2002 Main Fuel Valve Fracture . . . . .
Nozzle Feed Line Failures . . . . . . . .
Fuel Preburner Burn Through . . . . . . .

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Chapter 5. The Goals .

61

Chapter 6. The First Flight .

65

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Page
PART II

The Second Decade

Introduction

71

Chapter 7. The Glory of Columbia

73

Chapter 8. Full Power Level Moratorium .

79

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Chapter 9. Full Power Level Development . . . .

Main Injector LOX Post Failures. . . . . .
Fuel Preburner Injector LOX Post Failures . . .
Engine 0204 High Pressure Fuel Turbopump Failure

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100

Chapter 10. Full Power Level Certification . . . . . . .

Engine 2010 First Certification Cycle . . . . . . .
Engine 0110 Fuel Preburner Fuel Blockage by Ice . . .
Engine 2010 Second Certification Cycle . . . . . .
Engine 2013 and the HPFTP Kaiser Hat Nut . . . . .
Engine 0107 Oxidizer Preburner Oxidizer Valve Ball Seal .
Engine 2014 First Certification Cycle . . . . . . .
Engine 2208 Ultrasonic Flowmeter . . . . . . . .
Time Out for Acceptance Tests . . . . . . . . .
High Pressure Oxidizer Turbopump De-certification . . .
Challenger Flight Readiness Firing and Leaks . . . . .
Engine 2014 Second Cycle and the Second FPL Moratorium

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Chapter 11. Program Reassessment and Realignment .

145

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Chapter 12. Phase II Development . . . . . . . .

Engine 0108 High Pressure Fuel Turbopump Coolant Liner
Engine 2308 High Pressure Fuel Turbopump Impeller .
Engine 0207 Fuel Preburner Boss . . . . . . .
Engine 2308 Main Combustion Chamber . . . . .
Phase II Certification: Engine 2105 and Engine 2116 . .
Main LOX Dome Inlet Tee Four Kilohertz . . . .

Chapter 13. Phase I Flight Program . . . . . . . . . .

STS-6 Engine 2015 Fuel Preburner ASI LOX Supply Line . .
STS-7
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STS-8 Engine 2017 Fuel Preburner ASI LOX Supply Line . .
STS-9 (41-A) . . . . . . . . . . . . . . .
STS-11 (41-B) Engine 2015 Oxidizer Preburner ASI Fuel Supply
STS-13 (41-C) . . . . . . . . . . . . . .
STS-14 (41-D) Abort Engine 2017 Main Fuel Valve Actuator .
STS-17 (41-G) . . . . . . . . . . . . . .
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Page
STS-19 (51-A) . . . . . . . . . . . . . . .
STS-20 (51-C) . . . . . . . . . . . . . . .
STS-23 (51-D) . . . . . . . . . . . . . . .
STS-24 (51-B) . . . . . . . . . . . . . . .
STS-25 (51-G) . . . . . . . . . . . . . . .
STS-26 (51-F) Abort Engine 2020 Chamber Coolant Valve Actuator
STS-26 (51-F) Engine 2023 In-Flight Erroneous Shutdown . . .
STS-27 (51-I). . . . . . . . . . . . . . . .
STS-28 (51-J) . . . . . . . . . . . . . . .
STS-30 (61-A) . . . . . . . . . . . . . . .
STS-31 (61-B) . . . . . . . . . . . . . . .
STS-32 (61-C) . . . . . . . . . . . . . . .
STS-33 (51-L) . . . . . . . . . . . . . . .
Chapter 14. The Tragedy of Challenger .

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Chapter 15. Return to Flight . . . . . . . . . . . . .

Engine 2106 Oxidizer Preburner Injector Inter-Propellant Plate Braze
Engine 2105 Flight Certification Extension and More . . . .
Return to Flight Development: Engine 0211 and Engine 2206 . .
Return to Flight: STS-26R . . . . . . . . . . . .
Engine 2206 Low Pressure Fuel Duct Flex Joint Tripod . . . .
Engine 0212 4 KHz Certification and HPOTP Number Two Bearing
Engine 0215 HPFTP Second Stage Turbine Blade . . . . .

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Chapter 16. Building Margin . . . . .

Large Throat Main Combustion Chamber
Technology Test Bed . . . . .
Phase II+ Powerhead. . . . . .
External Heat Exchanger . . . .
Alternate Turbopumps . . . . .

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Appendix A. Space Shuttle Main Engine Management History

233

Appendix B. Space Shuttle Launch and Landing History .

234

PART III

Beyond the Second Decade

Chapter 17. Beyond the Second Decade: Summary .
APPENDICES

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Page
Appendix C. Acronyms and Abbreviations .

240

Appendix D. List of Illustrations .

244

Appendix E. References The First Ten Years .

247

Appendix F. References The Second Decade and Beyond .

250

xiv