Propulsion System Modeling For Condition Monitoring and Control Part II ' Application To The SSME
Propulsion System Modeling For Condition Monitoring and Control Part II ' Application To The SSME
K. Kolcio A. J. Helmicki
1
to reflect degraded or anomalous conditions moti- Assume that the liquid is initially motionless and
vated this paper. Such anomalous models in ad- has the fixed properties p,, p,, , C everywhere in
dition to nominal models are important from both the constant area duct. Since the liquid is initially
the condition monitoring and robust control stand- motionless, 3, = 0. Consider a weak perturbation
point. A condition monitoring system detects var- in the fluid properties such that the pressure, den-
ious degraded plant behavior. A robust controller sity and velocity may be written in terms of the
must stabiliie a plant in the face of uncertainty in initial and perturbation quantities
the plant dynamics and extraneous signals perturb-
ing the nominal input and/or output [9].
Some anomalous conditions such as fuel leakage,
for example, can be thought of as additional dy-
namics, or uncertainty. Others such as sensor fail-
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ure may appear as extraneous signals. If anomalous Substituting the above quantities into Equation 1
conditions are modelled as either uncertain dynam- yields
ics or extraneous signals then some existing system-
theoretic tools can be used to handle these particu-
lar representations [9,14, 151.
This work is organized in the following manner.
First the discretized model equations are validated Because p, and limare constant their derivatives
against the full PDE equations. Second, the generic vanish giving
model developed in Part I is applied to Space Shut-
tle Main Engine (SSME) High Pressure Fuel Pump
(HPFP). Finally, some specific examples that illus-
trate the uncertainty and signal type represent& Expressing pressure as a function of density, p,
tions of anomalous behavior are presented and dis- and entropy, 5, the total derivative can be written
cussed.
as [I11
,
2 Simple Example
Before applying the generic model developed in Part
I [13] to the SSME,the validity of the nondimen- Under the isentropic assumption d5 = 0 and the
sional discretized equations will be examined using above becomes
the following simple example. This example was
chosen so that the PDE equations could solved in
closed form, thereby allowing direct comparison of
the full PDEderived results with those obtained
from the discretized, nondimensional ODES devel- Considering changes in li and in the z direction
oped in Part 1. we have
Starting with the PDE forms of the conservation
of mass and momentum given in [lo, 21, 31, the -=
additional assumptions of no area change and isen-
tropic flow reduce the continuity and momentum Now the speed of sound a is defined (3, 10, 191 as
equations to the following'
ali .
aa := (-)i
ap
The momentum equation is then written in terms of
the perturbation variables and speed of sound thus
2
small, for example, where
{
Ul(2,t) :=
iil[l+
{;I)*] 2n - 3 - 5 < i < 2 n - 1 - 5
a a
otherwise
and
otherwise
with n = 1,2,3,. . ..
A plot comparing the wave
equation and the dimensional discretized model ve-
The analysis leading to Equations 5 and 6 is locity at the inlet is shown in Figure l below where
known as small perturbation theory or acoustic a p the duct length L is set to 1.
proximation theory [lo, 31. Equations 5 and 6 can The initial assumptions and approximations
be combined by cross differentiation and elimina- made in forming the most general PDE and then
tion of cross terms to obtain the single
. linear second the additional isentropic and no area change simpli-
order PDE ficatiom are common to the wave equation and the
pi -az-a% = O , model equations. They differ in that the wave equa-
at2 a52
(7)
tion is linear but not discretized while the model
where the 6 notation has been dropped for brevity. equations are nonlinear but discretized. The sec-
Equation 7 is known as the one dimensional wave ond order wave equation evolves from the general
equation [3, 101. The solution to Equation 7 subject PDE’s by linearizing about the perturbations. The
to certain initial conditions (IC) and boundary con- model equations preserve the nonlinearity but are
, ditions (BC) can be found using Laplace methods diacretized by assuming the variables have a linear
[71. distribution in space 1131. In fact, the sinusoidal
Suppose the following experiment is run. Fluid shape of the generic model’s step response is a con-
in a constant area duct of unitlength is initially at sequence of discretization. It can be argued that as
rest so i is zero everywhere, P(0,O) = P(1,O) and the wave equation and the generic model equations
T(0,O)= p(l,O)as shown in Figure 1. A step input are based on different operations, linearization ua
is applied at the outlet end so that at timet = 0+, discretization, we are not any closer in validating
the velocity at the outlet is set to the constant value the generic model against the general PDE. How-
irl. We are interested to see what happens at the ever, the wave equation should closely approximate
5 = 0, or inlet, end. First, the appropriate IC and the PDE behavior in the neighborhood of the oper-
BC are found ating point. The wave equation then can be taken
as closer to the “real thing “. It is not entirely clear
IC: q&o)=iim=o; i(t,O)=O, at this point what exact dfect discretization has on
BC: i(l,q = Cil(i) ; i&(O,q = 0 , the PDE. From Figure 2, it is clear that qualita-
tively the behavior of the generic model equations
where l ( q is the unit step function and the sub- follows that of the wave equation. Indeed showing
script I denotes the partial derivative with respect this was the purpose of the simple example.
to I. The second BC is derived from Equation 5
evaluated at I = 0. Since j(0,i) in fixed then
3 Nominal Model
In this section the generic model, matrix Equa-
tion 9, developed in [13] is applied to the specific
Equation 7 is then solved by the general Laplace example of the SSME HPFP.
methods noted above and by applying the above IC
and BC to get
i(t,i)= U1(2,t)+Uz(z,t)
/
(8)
3
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J
,
4
Figure 1: Duct schematic for wave equation example
The nominal model for the HPFP is then given by which in turn in steady state and nondimensional
variables implies that
Mi - Mo = 0 .
- [ &-;;
?J*
fl
SF*.%
Consequently, fl drops out as well.
Therefore, under incompressible isentropic con-
stant area flow conditions, only one map fz n e d
Some additional steady state experiments where be found to determine the unknown forcing. The
, input and output temperatures are measured must RTM, DTM and MARSYAS models consider the
be carried out in order to obtain f3. After con- flow through the HPFP as incompressible and adi-
structing fs the fact that at steady state the mass abatic. In light of the above first principles analy-
flow at the input must equal the mas8 flow at the sis, it would seem that additional assumptions of
output is used to relate fi to fz and fa. Thus, one isentropic flow and no area change were applied
additional map f3 must be found to complete the as well. However, steady state data available for
nominal model of the SSME HPFP. the SSME shows that in fact there are temperature
Although it seems that more steady state infor- rises in the ducts leading to and from the HPFP
mation is needed to actually complete the HPFP 1171. Most likely, there is a temperature rise across
nominal model compared to existing models, we the pump as well. Yet, no equations characterizing
now show that the model developed here is the gen- change in temperature are given in the RTM for liq-
eral case while existing models employ some addi- uid flow. Temperature enters the calculations only
tional a s m p t i o n s . Indeed, recall that no initial as- when gaseous flows are assumed. Even if the tem-
sumptions regarding compressibility or friction were perature rises were lumped in the ducts surrounding
made for the models developed in [6,13].Now, sup the HPFP, the model does not provide a means of
pose that incompressible isentropic flow is assumed. calculating these temperature changes.
In this case there is no friction or heat transfer so Apparently there exists the following inconais-
that fw and Q are zero. The energy equation in tency. If incompressible and adiabatic conditions
steady state then reduces to prevail then the pump map accounts for both shaft
force and friction. However, a means to account for
-d?= o . the temperature rise due to the friction is not pro-
d6 vided. If incompressible and isentropic conditions
It can be shown in this case that f3 = 0 [12]. prevail then the pump map accounts solely for the
If there is no area change then the incompressible shaft force and from the isentropic assumption, the
continuity equation implies that inlet to outlet temperature change should be zero.
However, as mentioned above, a rise in temperature
-dir= o , is known to exist.
di
So it is seen that under the assumptions of in- correction factors, it is crucial to obtain the actual
compressible and isentropic flow, the steady state lengths and areas in order to match both steady
~
maps used in models such as the RTM, are suffi- state and dynamic HPFP behavior. Unfortunately,
cient to complete the nominal HPFP model devel- attempts to glean geometry information from the
oped here. In other words, models like the RTM RTM, DTM and MARSYAS models have failed as
can be viewed as special cases of the more general the information is buried so deeply or combined
model with respect to the assumptions made for the with other parameters that extraction of the necw
forcing functions. sary lengths and areas is impoeaible. Once a work-
We consider now the validity of the incompress- ing model is up and running, it wiIl be difficult to
ible assumption made in the RTM and MARSYAS compare to the DTM HPFP model because it is un-
HPFP models. Taking pressures and tempera- dear how to isolate the HPFP component. Again,
tures from a 109% RPL SSME schematic at a p this is a reflection of the rather vague component
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proximately the inlet and outlet of the HPFP, and boundaries typical of the DTM. However, compari-
the steady state flow through the HPFP from the son of the simulations derived herein against actual
RLOOOOI document, some rough Mach number and SSME hotfire data are currently underway.
density calculations can be made. The density and The next section discusses how certain anomalous
speed of sound are calculated using the EOS devel- conditions can be modelled using the uncertainty
oped in this work. A 17% decrease in Mach number and signal representations.
from inlet to outlet is observed. Moreover, calcula-
tions show roughly a 45% increase in density from
inlet to outlet. By most engineering standards such 4 Anomalous Model
a large gradient must be taken into account. Ac-
cording to [2], only density changes ofnot more than In order to apply model based condition monitor-
7
. . ..
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I
0
8
depicts the three ways the delta block can be aug- at the inlet volute. Since temperatures and pres-
mented to the nominal model. The delta block con- s u r e are the same then it follows that the densities
tains dynamic representations of anomalous condi- should also be the same. From these assumptions
tions and reflects the uncertainty about the system the following equations hold:
behavior introduced by the anomalies. A zero value
for delta reduces to the nominal model. The choice DWo = D W & iDW,,
of scheme depends on the type of anomalous con-
or by expanding the flow terms,
dition. If an anomaly has some dynamics ssaoci-
ated with it, then the uncertainty representation is h&k- = &ioA&6& - - hiAlk6lk
appropriate. If the anomaly manifests itself as an
O = P&=flk
P
extraneous signal independent of the inputs, then
the signal representation is applicable. The basic To = ?&do=&
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S p p , so that the actual input to the pump becomes applies. The dimensionless orifice coefficient is de-
fined as
= SFP l
/-
SFP 65FP 9
Cdl :=
where S p p is the nominal speed. As the disturbance
is assumed independent of the input nominal speed,
where c, is the contraction coefficient which de-
it is seen that 6 S ~ pcan be modelled as a signal
pends on the type of orifice. Here we assume a
injected at the input to the nominal model as shown
-I sharp edged orifice. In this caae, c, is taken from
in the left part of Figure 5. Note that j p p appears
[22] to be c. = .62. The pressure, pa,is the ambi-
as one of the external inputs to the steady state
ent pressure present on the other side of the leak.
map, fa. Simplifying the above continuity equation yields
9
To complete the leaky model, Equation 13 is aug- a constant area duct, the generic model equations
mented to the nominal model by an additional dy- show qualitative fidelity to the linearized continuity,
namic block consisting of momentum and energy PDE’s.
Several important points arise in the application
of the generic model equations to the SSME HPFP.
First, the steady state maps used in some exist-
ing SSME HPFP models are not enough to cover
all the forcing t e r n in the model equations used
here. This is a direct consequence of the fact that
Note that the Mach number associated with the leak the those existing models assume incompresaibility.
is given by MIX= c d d m . Substituting this In this sense, the existing models are special cases
relation into the A equation yields of the models developed in these two works, which
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The control based approach to modelling propul- Validation of nominal and anomolous models
sion systems developed in the Part I companion pa- against SSME hotfire data, and
per for the nominal case is validated, applied to the
SSME HPFP and extended to include the anoma- Investigation of the various trade-0% incurred
lous case. As demonstrated in a simple example in the design of an integrated control and con-
/ wherein the generic model equations are applied to dition monitoring system.
10
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