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Bipropellant Test Stand Development and Operation

Developed, constructed, and operated Atlas Dev 2, USC LPL's cryogenic bipropellant test stand capable of a combined 26 lb/s mass flow at a max expected operating pressure (MEOP) of 1500 psig.
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Connor Storey

Project Timeline

Jan 2025 - Current

HighlightS

  • Acted as Test Conductor for 6 successful hot fire tests
  • Resized purge valves, enabling full engine purge after pre-chill and hot fires
  • Co-authored research paper analyzing effects of thermal conditioning on startup transients

SKILLS

Fluid Systems Development
Testing Procedures
Cryogenics and High Pressure Handling
Data Analysis

Development

  • Fabricated Swagelok and AN tubing lines for cryogenic service, performed hydrostatic proof testing to 1.5x MEOP per SMC-S-016, oxygen-cleaned all hardware per NASA-STD-1740.15, and assembled the feed system plumbing.
  • Built test stand structural framework, installed tubing and valve supports, and designed and fabricated custom propellant tank support plates.
  • Updated test stand purge system to mitigate choked flow by sizing, selecting, and integrating new isolation valves.
  • Conducted FEA of worst case system failure modes to ensure sufficient structural margin of safety.

Operation

  • Acted as Test Conductor for two kerosene/liquid-oxygen engine campaigns involving leak checks (per NASA-STD-7012), cold-flow tests, and hot-fire operations on a cryogenic feed system.
    • Responsibilities included handling high-pressure GN₂ bottles, manually setting regulator pressures, wiring instrumentation and igniters, and performing cryogenic system operations.
    • Conducted three hot fires with LPL’s Jessie & James engine (540 lbf, ablatively cooled) and three hot fires with the Nomad engine (675 lbf, copper heatsink chamber).
  • Analyzed cold-flow test data to establish regulator set pressures satisfying injector inlet pressure constraints and to identify optimal valve actuation timings throughout the ignition sequence.
  • Co-authored a research paper published with the International Astronautics Congress (IAC) in 2025 analyzing the effects of thermal conditioning on startup transients in kerosene/liquid-oxygen engines. (IAC-25,C4,IP,41,x101208)

Gallery

Atlas Prime Test Stand P&ID - Copy of Copy of Atlas_Prime_P&ID_Rev1.svg

Fig. 1: Atlas test stand Piping and Instrumentation Diagram (P&ID)

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Fig. 2: Test stand set up for cold flows to determine valve actuation timings in ignition sequence

Atlas_HF_2025_TCing.jpg

Fig. 3: My teammate and I acting as Test Conductor for J&J hot-fire at Reaction Research Society (RRS)