April, 2006.

CONTENTS: 1. DESCRIPTION OF THE MOTOR

1.1. DESCRIPTION OF THE MOTOR STRUCTURE 1.2. MOTOR AND SUBSYSTEM PERFORMANCE

2. DESCRIPTION OF SERVICES OFFERED

2.1. PROJECTION COURSES FOR LIQUID PROPELLANT ROCKET ENGINES

2.2. DELIVERY OF COMPONENTS 2.3. TRANSFER OF PRODUCTION TECHNOLOGIES 2.4. DESIGNING, PRODUCTION AND DELIVERY TEST PLANTS 2.5. TESTING MOTORS AND SYSTEMS ON CUSTOMER’S PREMISES

TRM-3500

1. DESCRIPTION OF THE TRM-3500 MOTOR

1.1. DESCRIPTION OF THE MOTOR STRUCTURE

Liquid-propellant rocket engine TRM-3500 was designed as the main drive for rocket of different aims. This engine was designed, produced and assembled by company EDePro. The motor was developed from the already existing Russian motor which was used on rocket SAM-2 and SAM-3 (Dvina and Volkov), so that its combustion chamber was kept, a new turbopump was mounted, fuel type change, system for thrust vector control (TVC) was added, and motor operation span lengthened. System for digital control of motor operation and TVC system was also built in. IRFNA (AK-20) is used for propulsion of this motor as oxidizer and JP-4 (kerosene) as fuel. The motor basic design consists of combustion chamber, turbopump feed system whit two-component gas generator, system for digital control and thrust vector control system. Motor TRM-3500 has these basic characteristics compare with DVINA engine: Engine TRM-3500 DVINANominal thrust (daN) 3500 3300÷3400 Nominal specific impulse (Ns/kg) 2215 ÷ Maximal operation time (s) 100 60 Propellants: - oxidizer IRFNA AK-20 - fuel JP-4 TG-02 Total motor mass (kg) 60 60 Motor length (mm) 1030 950 Overall diameter (mm) 500 500

Motor TRM-3500 is of a relatively simple construction and low production costs. Its structure is based on the already existing technologies, which have, up to now, been applied in the production of liquid-propellant rocket engines.

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Fig. 1 Liquid-propellant rocket engine TRM-3500

TRM-3500

Thrust Chamber

Gas Generator

Gimbal Bearing

Turbopump

Hypergolic Cartridge Delay Tank

Turbine Exhaust

Main oxidizer Valve

Main Fuel Valve

Oxidizer Outlet

Pressure Regulators

Air Start Conector

Pyrotechnic Igniter

Gimbal Actuator Attach Point (2nd 90° CCW)

Fig. 2 Components of Liquid-propellant rocket engine TRM-3500

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Turbopump feed system TPA-160 is of completely new construction compared to the existing Russian one, because fuel type has been change. The structure is whole consists of a single-stage axial turbine, two centrifugal pump and gas generator. The turbine is located between the bearings and at shaft ends are symmetrically placed fuel and oxidizer pumps. Gases from gas generator are used for turbine propulsion. Gas generator is two-zone type, with its primary zone used for combustion oxidizer and fuel and secondary zone where the fuel cools products of combustion. This is a cooled gas generator with a separator of solid particles at its exit. A fuse with pyrocartridge is used for starting gas generator. Compressed air from ground source is used for starting turbopump.

Fig. 3 Turbopump feed system TPA-160

TRM-3500

Combustion chamber, original designed for DVINA engine, is of metal structure with regenerative cooling of chamber and nozzle walls. Oxidizer is used for cooling. A fuel film also additionally cools inner side of the chamber wall. Hypergolic fuel, laced in a small tank in fuel line and in front of chamber inlet, is used for ignition. Support of turbopump and frame connections, as well as connections with actuators of the TVC system, are located on the chamber. Thrust vector control system is used for rotating the motor around two axes, which are perpendicularly to the extended motor axis. Motor support, shaped like a frame, is connected to universal joint. Hydraulic actuators, which use highly pressurized kerosene (pressure at the back of the fuel pump), are used for propulsion. TVC system has these features: minimal angular acceleration 1rad/s maxsimal angular speed 10°/s maximal deviation ±7° System for digital conrtol serves for control of motor operation and TVC system. Motor operation control is accomplished by keeping the set pressure in combustion chamber. The control is done with a command valve by means of a step-motor. This valve serves to regulate control pressure of nitrogen in regulating valves, which regulate the flow of oxidizer and fuel in gas generator and which, in turn, changes the gas generator operational regime, i.e. the turbopump operational regime. Pressure transducer in combustion chamber sends information on instant pressure value in the chamber to the computer which, based on calculation deviation from the set value of this pressure, commands the step-motor either open or close the command valve. System for digital control is linked to rocket flight control system, and it receives information on instantaneous rocket position and thus can control the motor deviation angle, i.e. correct the rocket trajectory with reference to the set one. System for digital control also controls sequences for start and shutdown the motor. Picture 4 offers an outline of motor with its system for digital control.

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1. High-pressure nitrogen tank. 2. On/off valve in nitrogen line. 3. Fuel tank pressure regulator. 4. Oxidizer tank pressure regulator. 5. Fuel tank. 6. Oxidizer tank. 7. Main fuel valve. 8. Main oxidizer valve. 9. Fuel pump. 10. Oxidizer pump. 11. Turbine 12. Gas generator. 13. Pyrotechnic igniter. 14. Pressure regulator in fuel line. 15. Pressure regulator in oxidizer line. 16. Pressure regulator for starting air.

17. On/off valve for air start. 18. Low-pressure nitrogen tank. 19. Pressure regulator in nitrogen line. 20. On/off valve in nitrogen line. 21. Step-motor. 22. Command valve. 23. Orifice. 24. Orifice in fuel line. 25. Hypergolic cartridge. 26. Delay tank. 27. Thrust chamber. 28. Actuator. 29. Digital control unit. 30. TVC control. 31. Pressure regulator. 32. Electrical supply.

Fig. 4 Scheme of liquid-propellant rocket engine TRM-3500

TRM-3500

1.2. ENGINE OPERATING PARAMETERS

Engine (turbopump feed system): Turbine: Thrust N 35 000 Shaft speed rpm 25 000Specific impulse Ns/kg 2 215 Inlet gas pressure bar 35Oxidizer IRFNA: Inlet temperature K 1100

Flow rate kg/s 12.6 Pressure ratio 13.4Density kg/m3 1 575 Gas flow rate kg/s 0.58

Fuel JP-4: Efficiency % 21Flow rate kg/s 3.2 Power kW 140Density kg/m3 790 Disk diameter m 0.172

Operating time s 100 Combustion chamber: Oxidizer pump: Injector end pressure bar 59 Pump speed rpm 25 000Oxidizer flow rate kg/s 12.3 Inlet pressure bar 8Fuel flow rate kg/s 2.9 Discharge pressure bar 85.2Total mass flow rate kg/s 15.2 Pump head J/kg 4 900Mixture ratio O/F 4.24 Mass flow rate kg/s 12.6C* m/s 1 560 Efficiency % 64Cf 1.56 Power kW 96.5Specific impulse Ns/kg 2 300 Expansion ratio 6.5 Chamber inner diameter m 0.190 Fuel pump: Chamber length m 0.305 Pump speed rpm 25 000Throat diameter m 0.070 Inlet pressure bar 8 Discharge pressure bar 78.0Gas generator: Pump head J/kg 8 880Gas generator pressure bar 35 Mass flow rate kg/s 3.2Oxidizer flow rate kg/s 0.28 Efficiency % 66Fuel flow rate kg/s 0.30 Power kW 43.5Total mass flow rate kg/s 0.58 Total mixture ratio O/F 0.95

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2. DESCRIPTION OF SERVICES OFFERED

2.1. PROJECTION COURSES FOR LIQUID PROPELLANT ROCKET ENGINES

We organise courses where students are acquainted with the complete procedure of projecting liquid-propellant rocket engines. Students work on the project of an actual motor during the course. As part of the project, a student can choose the type of motor, determine optimal parameters of motor operation, choose the concept of structure, calculate concordance of elements, calculate basic propulsion elements, define motor aggregates, define starting systems, and choose the concept of control systems. When elaborating the project, students have at their disposal commercial and specialised computer programmes, as well as assistance of experts in the fields of gas-dynamics, thermo-dynamics, and calculation of structure and technology of production. This way a course attendant can concretely and practically get to know all the elements and stages of real projecting. Detailed course programme, conditions for enrolling candidates, and work conditions are offered in Appendix B.

2.2. DELIVERY OF COMPONENTS We are able to do projections according to demands of customers and organise production of all components (combustion chambers, turbopump, turbines, pumps, pressure-regulation valves, etc) for liquid-propellant rocket motors (especially for old Russian systems as “Dvina”, “Volkov” and “Volga”) as well as their subsystems. Production of parts, semiproducts or subsystems according to customer’s documentation is also feasible. The technologies we have at our disposal are: machine processing on numerical machines, processing by deformation, technologies of precise casting, furnace brazing and welding by most up-to-date methods, as well as quality product control according to ISO 9000 standard. We also cooperate with companies, which collaborate with leading firms in this field, such as Turbomeca, Boeing, Microturbo, Rolls-Roys, Snecma etc.

2.3. TRANSFER OF PRODUCTION TECHNOLOGIES We are capable of establishing complete production chains for our customers for all technologies we use in production liquid-propellant rocket motors. We also offer support as regards theoretical and practical training of customers in application of delivered technology.

TRM-3500

2.4. DESIGNING, PRODUCTION AND DELIVERY OF TEST

PLANTS We project and built all plants for testing liquid-propellant rocket motors, their subsystems and elements, as well as deliver parts of individual systems of these plant. We provide completed building, machine and power projects, as well as the project for the system of measurement and control of test plant. An agreement with customer for building a test plant in the way “key in hand” is also possible.

2.5. TESTING MOTORS AND SYSTEMS ON CUSTOMER’S PREMISES

All motors and systems produced and delivered by us, can be tested on customer’s premises. We can also test motors, subsystems and elements projected and produced by a customer on his test plant.

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EDePro Kralja Milutina 33, 11000 Belgrade, Serbia, Europe

Tel. +381 11 36 29 554, +381 11 80 64 380; Fax. +381 11 36 29 554 e-mail: edepro@EUnet.yu