Unsteady Phenomena During Operation of the SSME Fuel Flowmeter

This report describes a part of the analysis carried in support of the SSME (Space Shuttle Main Engine) Fuel Flowmeter redesign, addressing an intensely researched phenomenon known as "shifting" of the flowmeter constant value. It consists of a sudden change in the flowmeter indication, which occurs simultaneously with the onset of an oscillatory variation of the rotor speed. The change in the flowmeter indications does not correspond to a real change in the volumetric flow through the device. Several causes have been investigated in detail, in the past, without conclusive evidence towards a cause of this phenomenon. The present analysis addresses the flow physics through the flowmeter by assembling results from 3-D CFD (computational fluid dynamics) calculations, airfoil C(sub D)/C(sub L) performance curves and mass moment of inertia characteristics of the rotor into a synergistic calculation which simulates the unsteady regime of the flowmeter operation. The results show that the 4-bladed rotor interacts with the periodic flow pattern created behind the flow straightener upstream in a manner that generates a steady, periodic fluctuation in the rotor's speed. The amplitude of this fluctuation is significantly smaller than the 0.5% of mean speed threshold which constitutes a flight operational limit. When manufacturing errors occur, however, the fluctuations are amplified and can generate a significant apparent change in the flowmeter indication. Two types of possible fabrication errors-which can occur even for parts fabricated within the accepted tolerances for the blade airfoil-are presented, together with their effect on the flowmeter operation.