SpaceX finds clogged valves in several Merlin engines
Capitalism in space: SpaceX has discovered that the problem that caused a recent launch abort of a GPS satellite was a coating that clogged valves in several newer Merlin engines.
Hans Koenigsmann, vice president of build and flight reliability at SpaceX, said teams initially weren’t able to figure out why two of nine engines triggered early-start sensors on Oct. 2, which forced computers to automatically scrub seconds before liftoff. After the engines were removed and shipped to Texas for testing, the anomaly surfaced again when sensors detected higher-than-expected engine chamber pressures.
The cause: a minuscule, almost undetectable amount of “masking lacquer,” which is used to protect engine components and surfaces during the production process. The lacquer is almost like a bright red nail polish. “We found a relief valve – a little line that goes to the relief valve – blocked in the gas generator,” Koenigsmann told reporters Wednesday. “That little red substance was blocking a relief valve that caused it to function a little bit earlier than it was supposed to.”
The gas generators are almost like little rocket engines themselves – they’re used to power a pump that then feeds propellants into the main engine chamber. But the blockage caused certain processes to begin too early.
Once the lacquer was removed the engines functioned perfectly.
The issue was also found in two engines on the new booster that was going to launch astronauts to ISS, which explains why that mission was delayed. The company is swapping out the engines, and is still targeting November 14th for that launch. In addition, NASA wants it to fly at least two missions beforehand to demonstrate the problem is fixed. One will be that GPS satellite, on November 4th. The other could be one of three different payloads on SpaceX’s busy schedule.
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Capitalism in space: SpaceX has discovered that the problem that caused a recent launch abort of a GPS satellite was a coating that clogged valves in several newer Merlin engines.
Hans Koenigsmann, vice president of build and flight reliability at SpaceX, said teams initially weren’t able to figure out why two of nine engines triggered early-start sensors on Oct. 2, which forced computers to automatically scrub seconds before liftoff. After the engines were removed and shipped to Texas for testing, the anomaly surfaced again when sensors detected higher-than-expected engine chamber pressures.
The cause: a minuscule, almost undetectable amount of “masking lacquer,” which is used to protect engine components and surfaces during the production process. The lacquer is almost like a bright red nail polish. “We found a relief valve – a little line that goes to the relief valve – blocked in the gas generator,” Koenigsmann told reporters Wednesday. “That little red substance was blocking a relief valve that caused it to function a little bit earlier than it was supposed to.”
The gas generators are almost like little rocket engines themselves – they’re used to power a pump that then feeds propellants into the main engine chamber. But the blockage caused certain processes to begin too early.
Once the lacquer was removed the engines functioned perfectly.
The issue was also found in two engines on the new booster that was going to launch astronauts to ISS, which explains why that mission was delayed. The company is swapping out the engines, and is still targeting November 14th for that launch. In addition, NASA wants it to fly at least two missions beforehand to demonstrate the problem is fixed. One will be that GPS satellite, on November 4th. The other could be one of three different payloads on SpaceX’s busy schedule.
Readers!
My annual February birthday fund-raising drive for Behind the Black is now over. Thank you to everyone who donated or subscribed. While not a record-setter, the donations were more than sufficient and slightly above average.
As I have said many times before, I can’t express what it means to me to get such support, especially as no one is required to pay anything to read my work. Thank you all again!
For those readers who like my work here at Behind the Black and haven't contributed so far, please consider donating or subscribing. My analysis of space, politics, and culture, taken from the perspective of an historian, is almost always on the money and ahead of the game. For example, in 2020 I correctly predicted that the COVID panic was unnecessary, that the virus was apparently simply a variation of the flu, that masks were not simply pointless but if worn incorrectly were a health threat, that the lockdowns were a disaster and did nothing to stop the spread of COVID. Every one of those 2020 conclusions has turned out right.
Your help allows me to do this kind of intelligent analysis. I take no advertising or sponsors, so my reporting isn't influenced by donations by established space or drug companies. Instead, I rely entirely on donations and subscriptions from my readers, which gives me the freedom to write what I think, unencumbered by outside influences.
You can support me either by giving a one-time contribution or a regular subscription. There are four ways of doing so:
1. Zelle: This is the only internet method that charges no fees. All you have to do is use the Zelle link at your internet bank and give my name and email address (zimmerman at nasw dot org). What you donate is what I get.
2. Patreon: Go to my website there and pick one of five monthly subscription amounts, or by making a one-time donation.
3. A Paypal Donation or subscription:
4. Donate by check, payable to Robert Zimmerman and mailed to
Behind The Black
c/o Robert Zimmerman
P.O.Box 1262
Cortaro, AZ 85652
You can also support me by buying one of my books, as noted in the boxes interspersed throughout the webpage or shown in the menu above.
Interesting piece of troubleshooting!
“NASA wants it to fly at least two missions beforehand to demonstrate the problem is fixed.”
For any other contractor, or government-run project, that would be a significant delay.
Yeah, for SpaceX two missions is just a few weeks.
Currently reading the Space Barons.
Interesting “high level” background of the private space race.
Does not get into the weeds as much as I would like, but a good starter book to give me framework.
If you need background, written in an enthusiastic manner, it is a good read.
A lot of that stuff happened in the early 2000’s when I was preoccupied in geo-political conflicts in the middle east, and other personal matters. I missed so much of the begining.
Red nail polish huh?
I told Elon not to let Jamie Farr on the factory floor, but noo….
No ‘tolerance’ for the trans community here