Saturn V engines

[edit] F-1 engine

First, a description of the engine. A large combustion chamber and bell have an injector plate at the top, through which, RP-1 fuel and LOX are injected at high pressure. Above the injector is the LOX dome which also transmits the force of the thrust from the engine to the rocket's structure. A single-shaft turbopump is mounted beside the combustion chamber. The turbine is at the bottom and is driven by the exhaust gas from burning RP-1 and LOX in a fuel-rich mixture in a gas generator. After powering the turbine, the exhaust gas passes through a heat exchanger, then to a wrap-around exhaust manifold which feeds it into the periphery of the engine bell. The final task for these hot gases is to cool and protect the nozzle extension from the far hotter exhaust of the main engine itself. Above the turbine, on the same shaft, is the fuel pump with two inlets from the fuel tank and two outlets going, via shutoff valves, to the injector plate. A line from one of these 'feeds' supplies the gas generator with fuel. Fuel is also used within the engine as a lubricant and as a hydraulic working fluid, though before launch, RJ-1 ramjet fuel is supplied from the ground for this purpose. At the top of the turbopump shaft is the LOX pump with a single, large inlet in-line with the turboshaft axis. This pump also has two outlet lines, with valves, to feed the injector plate. One line also supplies LOX to the gas generator. The interior lining of the combustion chamber and engine bell consists of a myriad of pipework through which a large portion of the fuel supply is fed. This cools the chamber and bell structure while also pre-warming the fuel. Lastly, an igniter, containing a cartridge of hypergolic fluid with burst diaphragms at either end, is in the high pressure fuel circuit and has its own inject point in the combustion chamber. This fluid is triethylboron with 10-15% triethylaluminium. (ap15fj)

[edit] F-1 engine start

At T minus 8.9 seconds, a signal from the automatic sequencer fires four pyrotechnic devices. Two cause the fuel rich turbine exhaust gas to ignite when it enters the engine bell. Another begins combustion within the gas generator while the fourth ignites the exhaust from the turbine. Links are burned away by these igniters to generate an electrical signal to move the start solenoid. The start solenoid directs hydraulic pressure from the ground supply to open the main LOX valves. LOX begins to flow through the LOX pump, starting it to rotate, then into the combustion chamber. The opening of both LOX valves also causes a valve to allow fuel and LOX into the gas generator, where they ignite and accelerate the turbine. Fuel and LOX pressures rise as the turbine gains speed. The fuel-rich exhaust from the gas generator ignites in the engine bell to prevent backfiring and burping of the engine. The increasing pressure in the fuel lines opens a valve, the igniter fuel valve, letting fuel pressure reach the hypergol cartridge which promptly ruptures. Hypergolic fluid, followed by fuel, enters the chamber through its port where it spontaneously ignites on contact with the LOX already in the chamber.

Rising combustion-induced pressure on the injector plate actuates the ignition monitor valve, directing hydraulic fluid to open the main fuel valves. These are the valves in the fuel lines between the turbopump and the injector plate. The fuel flushes out ethylene glycol which had been preloaded into the cooling pipework around the combustion chamber and nozzle. The heavy load of ethylene glycol mixed with the first injection of fuel slows the buildup of thrust, giving a gentler start. Fluid pressure through calibrated orifices completes the opening of the fuel valves and fuel enters the combustion chamber where it burns in the already flaming gases. The exact time that the main fuel valves open is sequenced across the five engines to spread the rise in applied force that the structure of the rocket must withstand.

As fuel and LOX flow increase to maximum, the rise in chamber pressure, and therefore thrust, is monitored to confirm that the required force has been achieved. With the turbopump at full speed, fuel pressure exceeds hydraulic pressure supplied from ground equipment. Check valves switch the engine's hydraulic supply to be fed from the rocket's fuel instead of from the ground. (ap15fj)

[edit] J-2 engine

The S-II stage carries five J-2 uprated engines which burn LH2 and LOX to produce up to 1,041 kN (234,000 pounds) thrust each. They are capable of being restarted in flight but this feature is only implemented in the engine used in the S-IVB.

The thrust chamber and bell of each engine is fabricated from stainless steel tubes brazed together in a single unit. Supercold LH2 is pumped through these tubes to cool the thrust chamber and simultaneously prewarm the fuel. The engine carries two separate turbopumps, both powered in turn by the exhaust from a gas generator which burns the stage's main propellants. The hot gas exhaust is fed from the gas generator, first to the fuel turbopump, then to the LOX turbopump before being routed to a heat exchanger and finally into the engine bell. The fuel and LOX outputs of both turbopumps are fed, via main control valves, to the thrust chamber injector via the LOX dome. Unlike the solid steel injector of the F-1, the J-2 injector is fabricated from layers of stainless steel mesh sintered into a single porous unit. A solid LOX injector behind this carries 614 posts which pass LOX through the injector and into the combustion chamber. Each post has a concentric fuel orifice around it and these orifices are attached to the porous injector. The fuel delivery is arranged to ensure that about 5 percent seeps through the injector face to cool it, the rest passing through the annular orifices.

The ASI (Augmented Spark Igniter), fed with propellant and mounted to the injector face, provides a flame to initiate full combustion. Valves are provided to bleed propellant through the supply system well before ignition to chill all components to their operating temperatures otherwise gas would be formed which would interfere with the engine's use of propellant as a lubricant in the turbopump bearings. A tank of gaseous helium is fabricated within a larger tank of gaseous hydrogen. This is the Start Tank. The helium provides control pressure for the engine's valves while the hydrogen spins up the turbopumps before the gas generator is ignited. A PU (Propellant Utilization) valve on the output of the LOX turbopump can open to reduce the LOX flowrate. This adjusts engine thrust down to 890 kN (200,000 pounds) during flight to optimise engine performance. (ap15fj)

[edit] J-2 engine start

To start the J-2 engine, spark plugs in the ASI and gas generator are energised. The Helium Control and Ignition Phase valves are actuated. Helium pressure closes the Propellant Bleed valves, it purges the LOX dome and other parts of the engine. The Main Fuel valve and the ASI Oxidiser valves are opened. Flame from the ASI enters the thrust chamber while fuel begins to circulate through its walls under pressure from the fuel tank. After a delay to allow the thrust chamber walls to become conditioned to the chill of the fuel, the Start Tank is discharged through the turbines to spin them up. This delay depends on the role of the engine. A one second delay is used for the S-II engines. Half a second later, the Mainstage Control Solenoid begins the major sequence of the engine start. It opens the control valve of the gas generator where combustion begins and the exhaust supplies power for the turbopumps. The Main Oxidiser valve is opened 14° allowing LOX to begin burning with the fuel which has been circulating through the chamber walls. A valve which has been allowing the gas generator exhaust to bypass the LOX turbopump is closed allowing its turbine to build up to full speed. Finally, the pressure holding the Main Fuel valve at 14° is allowed to bleed away and the valve gradually opens, building the engine up to its rated thrust. (ap15fj)