Operational life improvement of SSME high-pressure turbopumps

The current Space Shuttle Main Engine Phase I engine has demonstrated excellent flight performance at power levels up to 104% of rated power level. Early certification testing at 109% power level showed the operational life of the high pressure turbopumps to be limited. A development program, Phase II, has been under way since 1983 to increase the operational life and provide additional margin. The history of the SSME Phase I engine and the design and results of the SSME Phase II Program are presented. Operational life limits and high-maintenance areas of the high-pressure turbopumps are identified. The Phase II design improvements, supporting analyses, and test results are described. The formal certification test program is discussed. Modifications have been made to the high-pressure fuel turbopump to reduce turbine operating temperature, to extend the life of the first- and second-stage turbine blades, and to reduce sheet metal maintenance. Modifications have been made to the high-pressure oxidizer turbopump to improve bearing life and to eliminate subsynchronous whirl. These are discussed in detail, as is the design and use of special instrumentation to provide for rapid evaluation of merit.