RPL Test Stand Users Guide Main Document
Description of Guide
Purpose
This document serves as the main resource for the Rose Rocketry and Rose Propulsion Laboratory Teams, as well as others that are interested, concerning the design, construction, and usage of the Liquid Bi-Propellant Rocket Engine and Test Stand Multidisciplinary Senior Capstone Team’s Project (referred to later as “MDS project”). The MDS project is meant to be “square one” for the future design and construction of larger scale competition-level rocket engines and the test stands that would test such engines. It is thus expected that future iterations of test stands and rocket engines built using the MDS project are documented similarly to this document, using this document as a template, and updating information and knowledge recorded as the new information is acquired.
IMPORTANT NOTES
It is important that safety is always at the forefront when working with this (or similar) rocket engine and test stand. Always make sure test sites are approved ahead of time, that high-pressure testing is never done indoors, more than one person is present when operating the test stand, and if anything seems amiss during testing that the system is powered down and depressurized before approaching.
Safety was, and is, an enormous factor in our designs and operations when working on these projects, and will thus often be mentioned in this document, and should also be emphasized in later iterations of this document as well.
Understanding Our Test Stand
Background
Including some of the founding members of the Rose Rocketry Team, our Multidisciplinary Senior Design Team got together to provide the groundwork for future development of liquid bi-propellant rocket engines and test stands, as Rose-Hulman lacked resources in this area for students to utilize. A full description of our project; breakdown of stakeholders, requirements, systems, design decisions, and implementation processes; and the diagrams of our individual systems and flows can be found in the team’s Final Report here: Final Report.
Feel free to review the Final Report for a deep, technical look into our design and implementation, which is highly recommended if currently in the process of building a new system (rocket engine and/or test stand).
Understanding the Test Stand
Split into three overall systems, with smaller systems connected to them, the test stand is complex and requires some understanding before using it for tests. The three systems are the Feed System, Software System, and the Electrical System that connects the two together.
Feed System
The Feed System is complex and handles the physical load of propellant, oxidizer, and pressure delivery to the rocket engine. Figure P-1 above is the main diagram of the Feed System, and below is a thorough video on understanding this diagram, as well as including important decisions made in the construction of the Feed System.
Software System
Electrical System
Using the Test Stand
IMPORTANT NOTES
When using this, or other, rocket engine test stands, always be careful, wear personal protective gear, and always be accompanied by at least one person experienced in working with the test stand!
Always use prepared procedures for all tests performed on test stands with rocket engines. There will be a section that links the testing procedures our team created for our tests so that we were safe, consistent, and could adjust our procedures as we learned more.
Storage and Relocation of Materials
Location for Testing
Pre-Test Preparation of Test Stand
Safety Checklist
Choosing Which Test to Perform BEFORE Hot-Fire
Checklists
Hot-Fire Procedures
After Hot-Fire
How to build/understand test stand
Include instructional videos
How to safely prepare test stand
Relocation
Cleaning
Fire location
Mechanical Set up
Safety procedures to review
Safety checklist (review what checklists are needed, which could be seen in FMEAs)
Before Test Fire
Perform solenoid diagnostic
Perform dry test run
Ensure lines are clean (include how to expel normal air from lines)
Test that pressurized system is safe