Tag: Boeing

Starliner decision expected tomorrow, August 24

9:04 am

According to a NASA update today, the agency will hold “an internal Agency Test Flight Readiness Review” to discuss whether to return Starliner manned or unmanned on Saturday morning, August 24, 2024 and then hold a press conference immediately afterward to discuss the results of that review.

What makes this review and press conference different from all previous Starliner reviews and conferences is that NASA administrator Bill Nelson will attend.

NASA Administrator Bill Nelson and leadership will hold an internal Agency Test Flight Readiness Review on Saturday, Aug. 24, for NASA’s Boeing Crew Flight Test. About an hour later, NASA will host a live news conference at 1 p.m. EDT from the agency’s Johnson Space Center in Houston.

The only reason a politico like Nelson would participate in such proceedings is because he has taken control of the decision-making process, and will make the decision himself. The review is likely to educate him as best as can be done in this short time, and he will then decide whether the two astronauts who launched on Starliner, Butch Wilmore and Suni Williams, will return on it in the next week or so, or will stay on board ISS until February 2025 and return on the next Dragon crew capsule scheduled to launch to ISS in late September.

Nelson might have decided to get involved on his own, but I am certain that if so it was strongly “encouraged” by officials above him in the White House. There is an election coming up, and the risks involved in using Starliner to return the astronauts must be weighed in connection not just with its engineering concerns but with its political ramifications also.

Nelson’s decision will also provide us a strong indication of a future Harris administration’s attitude toward space.

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NASA delays Starliner return decision to end of month

9:17 am

In a short FAQ posted by NASA today, the agency quietly revealed that the decision on whether to bring Starliner back with its astronauts on board has been delayed till the end of August.

NASA now plans to conduct two reviews – a Program Control Board and an Agency Flight Readiness Review – before deciding how it will safely return Wilmore and Williams from the station. NASA expects to decide on the path forward by the end of August.

It appears the agency has decided to bring more people into the decision-making process. In the briefing last week, it was then planning only one review, expected to be completed before the end of this week. It now sounds like a second review will occur after the first, pushing the decision back one more week.

All of NASA’s actions in the past three weeks have suggested an increasing involvement by upper management, possibly including White House officials. With an election coming up, the politicans who are supposed to be in charge have apparently inserted themselves into this process and are demanding greater review. I expect in the end the decision will fall to them, and might even be announced by NASA administrator Bill Nelson himself.

These actions have also suggested that upper management does not like the risks involved in returning the crew on Starliner. Politicians do not like to have bad things happen on their watch. We should therefore not be surprised if the decision is made to send Starliner home unmanned.

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Sierra Space in negotiations to buy ULA

10:26 pm

According to the Reuters news agency, Sierra Space is negotiating with the joint owners of ULA, Boeing and Lockheed Martin, to buy the rocket company.

The sources, which are all anonymous, said the sale price is in the range of $2 to $3 billion. Those same sources said no deal has yet been worked out, and might not happen at all.

For Sierra, the deal would give it its own launch vehicle, Vulcan, for placing its Dream Chaser mini-shuttles into orbit. It would also give it a profit stream from the many military and commercial launch contracts already on ULA’s manifest. The combined cababilities of ULA and Sierra will create a formidable new player in the aerospace launch market.

For Boeing, it would provide it some much needed cash that it will be able to use to both restructure and revitalize its presently questionable operations.

It is unclear what Lockheed Martin will gain from the sale, other than the cash and the removal of this Frankenstein-like partnership with Boeing, which in the long run has probably not done it a lot of good.

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NASA leaning now to send Starliner astronauts home on Dragon, in February 2025

11:01 am

Though a decision will not be made until next week, during a press briefing today the nature of the briefing and the wording by NASA officials suggested that they are now leaning strongly to having the two Starliner astronauts, Butch Wilmore and Suni Williams, return on the next Dragon capsule to launch to the station on September 24, 2024 and return in February 2025.

My conclusion is based on several subtle things. First, no Boeing official participated, the second time in row that they were excluded. Second, this briefing included some new individuals who rank higher in the chain of command, and whose opening statements were clearly written carefully in advance and were read aloud.

Third, and most important, the wording of those statements repeatedly indicated they are looking at Dragon return more seriously. For example, NASA’s chief astronaut Joe Acaba suggested strongly that the two astronauts were now well prepared for an eight month mission, rather than coming home in August 2024. Other statements by officials suggested they themselves are less confident about returning on Starliner. Though the data suggests they can return safely, there remains enough uncertainty to make some people uncomfortable.

One factor not stated but is certainly controlling the situation now is the upcoming election in November. The Democrats who control Washington and the White House will allow nothing to happen that could hurt their election chances. We must therefore assume people in the White House are now in control and are the ones who now intend to make the decision about Starliner’s return.

Based on these factors, we should expect NASA to announce next week that the crew will return in a Dragon capsule. In order for the return to happen on Starliner NASA and Boeing engineers must somehow convince those politicos that the return would be entirely safe. Since these politicos are always risk adverse, it would shock me if they can be convinced. It could happen, but understanding the politically framework is important.

The officials stated that they have scheduled the final review next week, and it appears the decision will be announced then.

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NASA inspector general blasts Boeing’s management relating to its work on SLS’s new more powerful upper stage

9:52 am

Boeing's schedule slips in building SLS's upper stage
Boeing’s schedule slips in building SLS’s upper stage

In a report issued today [pdf], NASA’s inspector general harshly criticized the Boeing managment and operations at its Michoud facility, where the company is developing SLS’s new more powerful upper stage. From the report’s executive summary:

Quality control issues at Michoud are largely due to the lack of a sufficient number of rained and experienced aerospace workers at Boeing. To mitigate these challenges, Boeing provides training and work orders to its employees. Considering the significant quality control deficiencies at Michoud, we found these efforts to be inadequate. For example, during our visit to Michoud in April 2023, we observed a liquid oxygen fuel tank dome—a critical component of the SLS Core Stage 3—segregated and pending disposition on whether and how it can safely be used going forward due to welds that did not meet NASA specifications. According to NASA officials, the welding issues arose due to Boeing’s inexperienced technicians and inadequate work order planning and supervision. The lack of a trained and qualified workforce increases the risk that Boeing will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards.

The report also notes that delivery of that upper stage has been delayed from 2021 to 2027 (as shown by the graph to the right, taken from the IG report), and its cost has risen from $962 million to almost $2.8 billion. It also notes quite bluntly that:

Boeing’s quality management system at Michoud does not effectively adhere to industry standards or NASA requirements, resulting in production delays to the SLS core and upper stages and increased risk to the integrated spacecraft. … Boeing’s process for addressing contractual noncompliance has been ineffective, and the company has generally been nonresponsive in taking corrective actions when the same quality control issues reoccur.

Sound familiar? It should. These issues appear to be the same kind of quality control problems that have plagued Starliner, and are also the same kind of problems that had NASA reject Boeing’s bid to provide cargo to its Lunar Gateway station, and state while doing so that it will no longer consider future Boeing bids until the company straightens itself out.

It appears from today’s inspector general report that Boeing has fixed nothing. The report recommends some additional supervision of Boeing from NASA, and more importantly suggests the agency “institute financial penalties for Boeing’s noncompliance with quality control standards.”

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NASA has decided to consider bringing Starliner down unmanned

10:32 am

Starliner docked to ISS
Starliner docked to ISS.

It appears that upper management at NASA has decided to force the agency to consider bringing Starliner down unmanned and extending the ISS mission of the two Starliner astronauts to a nine month mission.

The situation is definitely complicated, and no change as yet as been made. The schedule of dockings to ISS has been reconfigured to make this option possible. It appears this is the present plan:

First, they need to upgrade the software on Starliner for an unmanned mission. Apparently the present software on board is not satisfactory for an unmanned docking, even though a different Starliner has already done an unmanned docking last year. For this mission, the software relied on the astronauts to take over manually should there be an issue during undocking. In the previous unmanned demo, the software would react and prevent a problem. For reasons that make no sense, the software on the manned mission did not have this capability. Reinstalling this software will give them the option to send the two astronauts down on Dragon and returning Starliner unmanned.

Second, the next Dragon manned mission has been delayed until late September to allow time for these software upgrades, as well as give NASA and Boeing more time to analyze the situation and decide if a manned return on Starliner is possible. If they decide to not use Starliner, the Dragon capsule would come up to ISS with only two astronauts, and the two Starliner astronauts would then join them on their six month mission, coming home in the spring. For the Starliner astronauts Butch Wilmore and Suni Williams this would mean their mission will now be 8-9 months long, far longer than the original one-two week mission.

As to why these options are now being considered, it appears to me that both Boeing and NASA engineers were willing to return the astronauts on Starliner, but have been ordered to consider these options by higher ups. It appears that the last hot-fire thruster tests on ISS left everyone with some uncertainties about the situation. Engineers are fairly certain that the reasons some thrusters did not fire as planned during docking was because teflon seals expanded because of heat to block fuel flow. The problem is that these seals showed no problem at all in the most recent test on ISS. That difference creates some uncertainty as to whether they have really identified the cause of the problem. Imagine having an intermittent problem your car mechanic cannot constently make happen.

Because the thrusters did work as intended, Boeing and NASA seemed ready to return Starliner manned. In the agency review last week it appears others at the top were less sanguine (including Bill Nelson, NASA’s administrator), and demanded these new options be considered. Based on this speculation, it is almost certain Starliner will come home empty.

Whether this will have significant consequences remains uncertain. During the press briefing today, NASA officials said the agency might still certify Starliner for operational manned missions even if the capsule comes home unmanned.

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Next manned Dragon mission to ISS delayed until September 24, 2024

12:10 am

NASA tonight announced that the next manned Dragon mission to ISS has been delayed until September 24, 2024, a pushback of more than a month caused by the thruster issues on Boeing’s Starliner capsule presently docked to the station.

This adjustment allows more time for mission managers to finalize return planning for the agency’s Boeing Crew Flight Test currently docked to the orbiting laboratory. Starliner ground teams are taking their time to analyze the results of recent docked hot-fire testing, finalize flight rationale for the spacecraft’s integrated propulsion system, and confirm system reliability ahead of Starliner’s return to Earth. NASA and Boeing continue to evaluate the spacecraft’s readiness, and no decisions have been made regarding Starliner’s return.

Since both manned capsule use the same port, Starliner must undock before a Dragon can arrive.

The schedule change also eliminates scheduling conflicts with a Soyuz capsule bringing Russian astronauts to the station in mid-September, and will also allow the launch to switch launchpads so as to not conflict with the SpaceX launch of Europa Clipper, scheduled for October 10, 2024 (though that launch remains in doubt due to other problems with the spacecraft itself).

NASA will be holding a briefing on the status of Starliner at 12:30 pm (Eastern) on Wednesday, August 7, 2024.

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NASA/Boeing push back final decision of Starliner return

8:58 am

Starliner docked to ISS
Starliner docked to ISS.

Someone at NASA getting cold feet? According to a NASA posting today, the review that was supposed to happen this week to determine a return date for Starliner and its two-astronaut crew has been postponed until next week as engineers continue analzying the results of the recent thruster hot fire tests, both on the ground and on ISS.

The wording of this posting is intriguing, to say the least:

Teams are taking their time to analyze the results of recent docked hot-fire testing, finalize flight rationale for the spacecraft’s integrated propulsion system, and confirm system reliability ahead of Starliner’s return to Earth from the International Space Station.

Forward work for the team also includes finalizing the spacecraft’s undocking procedures and operational mitigations that could be used in flight, if needed, to build further confidence in the system. Meanwhile, Starliner ground and mission support teams are continuing to prepare for undocking by participating in integrated simulations with space station operations teams.

Following the completion of Starliner’s return planning, which is expected to continue into next week, more information will be shared about the agency’s return readiness review preparations and subsequent media briefing. As always, astronaut safety remains the top priority for both NASA and Boeing. [emphasis mine]

Up until this posting, I have been confidently predicting the two astronauts would return on Starliner. Now I am not so sure. It seems the data from the hot fire tests, especially the most recent tests on the Starliner capsule docked to ISS, was not as encouraging or did not confirm the conclusions drawn from the previous ground-based tests, and have required further analysis. This might not in the end make a difference, but the wording of this NASA’s press release, including the highlighted emphasis on astronaut safety, suggests NASA is at least considering the idea of bringing the astronauts home on a Dragon capsule.

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Boeing names new CEO, set to take over on August 8, 2024

10:32 am

Boeing today named a new CEO, Robert “Kelly” Ortberg, who among the candidates being considered appears to be the only one who did not have a long career at Boeing.

Ortberg emerged as a leading candidate only recently. Others who were reportedly considered for the job included Patrick Shanahan, a former Boeing executive and now CEO of its most important supplier, Spirit AeroSystems, and another longtime Boeing executive, Stephanie Pope, who recently took over the commercial airplanes division.

Ortberg led Rockwell Collins from 2013 to 2018, when it merged with United Technologies and wound up as part of RTX, the company formerly known as Raytheon. He retired from RTX in 2021.

He will take charge of the company as of August 8, 2024.

It remains to be seen if Ortberg can fix things. As the article notes, since 2019 Boeing has lost more than $25 billion, and has been saddled with numerous quality control failures in almost all its technical divisions, from building airplanes to providing maintenance to building space capsules. The failures in its airplane divisions resulted in several crashes that killed 346 people, and caused it to accept a deal with the Justice Department that included a fine of $243.6 million to avoid a criminal trial. That deal however has not yet been accepted by the judge in the case.

Ortberg will have to demonstrate somehow that the culture at Boeing itself has changed. The first thing he could do to indicate he is serious about doing so would be to shut down entirely Boeing’s Diversity, Equity, and Inclusion (DEI) bureaucracy. Getting rid of that poisonous race-based anti-quality program would go a long way in convincing others that Ortberg means business, and wants to put talent, skills, experience first in everything Boeing does, something previous CEOs have clearly not done.

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Boeing completes full series of static hot fire engine burns on Starliner while docked to ISS

9:38 am

Boeing announced today that engineers have successfully completed a full series of static hot fire engine burns testing all of Starliner’s attitude thrusters while still dockecd to ISS.

The one-pulse firings were designed to confirm the performance of each thruster. Aft-facing thrusters were fired for 1.2 seconds and all others for .40 seconds. Between each firing, the team reviewed real-time data and all thrusters performed at peak thrust rating values, ranging from 97-102%. The helium system also remained stable. Additionally, an RCS oxidizer isolation valve that was not fully seated previously, was cycled several times during today’s testing and is now operating normally.

This is the second time the spacecraft has been hot fired successfully while docked, an integrated operation the station and Starliner teams will also conduct during future long-duration missions.

This result is not a surprise, based on the information provided during the most recent briefing. It confirms the data obtained during previous hot fire tests both on a Starliner on the ground and the Starliner docked to ISS. Not only does it appear that Boeing has enough information to fix this problem so it does not occur again, it has proven unequivocally that these thrusters as well as the helium leaks inside the thruster systems pose no unusual risk for a return in the capsule.

NASA and Boeing have a planned review of these results this coming week, when we should expect them to name a return date, likely sometime in the first two weeks of August.

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NASA/Boeing: Cause of Starliner thruster failure identified

10:21 am

According to NASA and Boeing officials, ground static fire engine tests have now identified the likely cause of the thruster failures on the Starliner capsule during its docking to ISS in early June, and puts them in a position next week to determine a return date for the capsule and its two astronauts.

It appears the problem is related to teflon seals in the thrusters, detected while engineers did a series of tests on the ground with another Starliner capsule. Based on this information, Boeing thinks it can fix the problem on future capsules, while also insuring there will be no problems returning the astronauts from ISS.

The thrusters in question are all attitude thrusters, where there is a lot of redundancy and the issue has been seen to be well controlled from the start. The larger thrusters used for the undocking and de-orbit burn have been tested as well, and have not shown any similar issues at all.

The ground tests have also identified the cause of the helium leaks within the capsule engine system. Boeing will use this data to fix later capsules as well. These leaks are not a concern for the return to Earth.

The plan now is to do in the next few days one more set of static fire tests with the capsule docked on ISS, doing short bursts with all the attitude thrusters to further confirm what has been learned on the ground. If that goes as expected, a final meeting next week will determine the return date for the capsule and crew.

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NASA and Boeing complete ground static fire tests of Starliner

11:20 pm

According to a press announcement tonight from NASA, the agency and Boeing have now completed the static fire tests using a Starliner ground capsule to duplicate the engine burns required to bring the in-space capsule back to Earth, carrying its two astronauts.

Teams completed ground hot fire testing at White Sands and are working to evaluate the test data and inspect the test engine. The ongoing ground analysis is expected to continue throughout the week. Working with a reaction control system thruster built for a future Starliner spacecraft, ground teams fired the engine through similar inflight conditions the spacecraft experienced on the way to the space station. The ground tests also included stress-case firings, and replicated conditions Starliner’s thrusters will experience from undocking to deorbit burn, where the thrusters will fire to slow Starliner’s speed to bring it out of orbit for landing in the southwestern United States.

Engineers now need to complete a review of those tests, followed by a full review leading to a decision as to when the astronauts will return on Starliner. No dates have yet been set, but expect these reviews to be completed within two weeks, and that Starliner will likely be scheduled for return in early August, prior to the scheduled launch of the next Dragon manned mission in mid-August.

All this assumes the FAA will clear SpaceX to resume launches before then. SpaceX is apparently ready to resume this week, but we have no indication the FAA will go along.

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Starliner return delayed until after ground thruster tests are completed and analyzed

9:15 am

Starliner docked to ISS
Starliner docked during the unmanned demo
flight in May 2022

According the NASA and Boeing officials yesterday, they are in the process of doing ground thruster tests to emulate the problems that occurred on the thrusters during docking procedures to ISS in early June, and will not decide on a return date for Starliner until after those tests are completed and analyzed, expected sometime in the next two weeks.

It appears some of the ground tests were delayed slightly due to the arrival of Hurricane Beryl in Texas.

It is very important to note that the astronauts are not “stranded” on the station, as a lot of news organizations are still claiming. The thrusters on Starliner that failed are part of the service module, which will not return to Earth when the astronauts come home on the the capsule. They therefore want to do as much research as possible beforehand in order to determine the cause of the failures in order to prevent them on future capsule flights. For example, the ground tests are first attempting to duplicate precisely what happened during docking, and will then do tests attempting to duplicate what will happen during de-orbit.

In the meantime, they appear to have no doubt that they can use Starliner for return, no matter what. At the moment only one thruster appears out-of-commission, and none of the thrusters that failed during docking are used for the de-orbit burn. They are only used for orientation, and the capsule has ample redundancy for this function sufficient for de-orbit.

In addition, it is a good thing for them to extend Starliner’s total flight time. I suspect even if everything had worked as planned they would have extended this mission as they have. This allows them to prove out the in-space operation of the capsule and service module. So far it appears that operation has been excellent, which is one reason they are willing to delay the return to do the ground tests.

Overall, my impression is that the situation is entirely under control, and in fact NASA is reasonably satisfied with the capsule’s operation in general. It appears that the agency will likely have no problem in flying future manned missions with Starliner, though it will want the thruster issue solved beforehand.

As for Boeing, these problems have stained its reputation further, and have likely made it much more difficult to sell future capsule flights to other customers. I would say however that after listening to the last few press briefings it seems to me that Boeing’s manned space division is now doing the proper due diligence it should have done before. For example, the thruster problems appear to be related to overheating during use, which is a very fixable issue.

These facts actually makes me more confident in the capsule, and future potential customers should do the same review themselves.

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$243.6 million plea deal allows Boeing to avoid a criminal trial

9:59 pm

The Justice Department and Boeing have made a plea deal so that the company can avoid a criminal trial for breaking its previous plea deal over 737-Max plane crashes that killed 346 people.

Under the agreement, Boeing will plead guilty to a criminal fraud charge stemming from the fatal crashes in Indonesia in October 2018 and in Ethiopia less than five months later that killed a combined 346 people.

Boeing must also pay the hefty fine [$243.6 million], invest at least $455 million in compliance and safety programs, and have an independent monitor oversee Boeing’s safety and quality procedures for three years

The company had made similar deal in 2021 with Justice when it became clear it had deceived FAA regulators about the software on new 737-Max planes that caused these crashes. This new deal is because the company apparently violated that 2021 deal, and allows it to avoid a criminal trial.

A judge still has to approve this new plea deal. Many families of the deceased oppose it, demanding instead that company managers be put on trial. Even if the judge accepts it, Boeing will still be liable for other more recent incidents.

All in all, Boeing comes off as a morally corrupt and incompetent company that was willing to cut corners, lie about it, thus allow more planes to crash because of its actions.

No wonder everyone wants to blame Boeing for every single incident that has recently occurred on various commercial jets, even though in many cases the blame resides more with the maintenance departments of the airlines that had purchased the planes. And no wonder no one believes the claim that the astronauts that flew up to ISS in June are not “stuck” there. They probably aren’t, but why believe anyone from such a compny.

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Starliner return delayed again, until July

10:08 pm

NASA tonight announced that it is once again delaying the undocking from ISS and the return to Earth of Boeing’s Starliner capsule, carrying two astronauts, with the return date a as-yet unspecified date in July.

The move off Wednesday, June 26, deconflicts Starliner’s undocking and landing from a series of planned International Space Station spacewalks while allowing mission teams time to review propulsion system data.

It seems to me that they have decided the more time Starliner spends in space right now, the more data they can gather about its flightworthiness in the future. Remember, the first manned Dragon demo mission stayed at ISS for more than two months.

Their approach however — announcing small delays over and over again — is extremely poor PR. It makes it seem as if the capsule’s various issues — thrusters, helium leaks, and valves — are a more serious than I think they are.

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Starliner return delayed again to June 26th

10:23 am

In a press briefing today, Boeing and NASA announced that they have decided to delay the return of Boeing’s Starliner capsule, carrying two astronauts, another four days to June 26, 2024. The landing would take place just before dawn, landing at White Sands in New Mexico.

The decision to delay is related to the results from the hot fire tests of the aft thrusters of Starliner on June 15, 2024. Engineers want to review the data, which included finding that one of the eight thrusters is producing unacceptable results and will not be used for the rest of the flight. The other seven thrusters however produced acceptable results, “good thrust” as noted by one official.

The extra time to review the data is also because these thrusters are on the service module, which will not return to Earth. They want to make sure they understand the issues entirely. The longer time docked to ISS is also giving them better data for future longer missions.

As for the helium leaks, the level of leaking appears to be dropping, and in fact dropped after the hot fire burns, and “appears to be somehow related to the thrusters.” Either way, the safety margins remain sufficient so that the return is not threatened in any way by these leaks.

The valve issue also seems under control, with all the valves now working as expected.

Overvall, engineers have decided they have a safe vehicle that can not only be used to return to Earth as scheduled, they are confident that they could also use Starliner as a lifeboat in a sudden emergency.

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New evidence suggests some titanium on Boeing and Airbus planes might be fake

12:36 pm

According to information provided to the FAA from Boeing, the documentation from a subcontractor for some of the titanium used on some Boeing and Airbus planes might be faked, suggesting that the titanium is fake as well.

Boeing discovered this possibility when one of its suppliers discovered holes in some metal pieces due to corrosion.

Apparently, Italian parts supplier Titanium International Group found small holes in titanium in December 2023, and also raised suspicions about the authenticity of documentation. It notified Spirit AeroSystems of the issue, which in turn informed Airbus and Boeing in January 2024. According to three anonymous sources close to the matter, affected planes include those built between 2019 and 2023 and involve the Boeing 737 MAX, 787 Dreamliner and Airbus A220 programs.

…The problem has been traced back to a Chinese supplier that sold titanium to Turkish company Turkish Aerospace Industries in 2019. Documentation from this Chinese supplier claimed that the titanium had been sourced from another Chinese firm, Baoji Titanium Industry – however, Baoji Titanium has confirmed that it did not provide this batch of titanium “and has no business dealing with this company.” [emphasis in original]

In other words, no one has any idea where that first Chinese supplier got the titanium, because its documentation was false.

Both Airbus and Boeing have done numerous tests and found no problems, though both have said they will remove any suspect parts. Spirit meanwhile has removed all the suspect parts, even though tests suggested the parts were “of sufficient quality for the aerospace industry.”

The real story here is not that these parts are unsafe (they apparently are not). The real story is the dependence by these airplane companies on so many subcontractors, some of which are subcontractors of subcontractors of subcontractors and also come from a hostile power. It leaves them all very vulnerable to others’ mistakes or malfeasance. During the Cold War it would have been inconceivable to rely on Soviet-built parts. Yet, today American airlines routine rely on Chinese companies when the Chinese government has made it clear it sees us as an enemy to be defeated.

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Starliner’s return delayed again

8:44 am

NASA today announced that the return of Starliner from ISS, carrying two astronauts, has been delayed again, from June 18th to June 22nd.

It appears engineers want to perform more tests of the the spacecraft’s attitude thrusters before undocking. The failure of some thrusters during docking on June 6th has raised some concerns.

NASA and Boeing teams also prepared plans for Starliner to fire seven of its eight aft-facing thrusters while docked to the station to evaluate thruster performance for the remainder of the mission. Known as a “hot fire test,” the process will see two bursts of the thrusters, totaling about a second, as part of a pathfinder process to evaluate how the spacecraft will perform during future operational missions after being docked to the space station for six months. [emphasis mine]

The highlighted words are kind of a lie. While there is no doubt this test will tell engineers a lot about future operations, such a test, while attached to ISS, would never have been approved had the thrusters all worked as planned during docking. The real reason for this static fire test is to make sure the thrusters will work once undocked.

If they don’t work, there could be a safety issue putting the astronauts in Starliner for return to Earth.

NASA plans a press briefing on June 18th at noon (Eastern) to outline in better detail the situation.

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Starliner at ISS: One thruster shut down, another helium leak found, and a new valve issue

9:45 am

According to an update from NASA yesterday, engineers are evaluating three different on-going technical issues with Boeing’s Starliner capsule, presently docked at ISS.

First, of the 28 attitude thrusters on the capsule’s service module, one remains what NASA calls “deselected”, which means it is presently shut down and not in the loop during operations.

Ground teams plan to fire all 28 RCS thrusters after undocking to collect additional data signatures on the service module thrusters before the hardware is expended.

Since the service module is ejected and burns up in the atmosphere, they want to test each thruster beforehand, probably one-by-one to gather as much data as possible. They have to do this after undocking because testing the thrusters while attached to ISS is too risky.

Second, it appears engineers have detected a fifth small helium leak.
» Read more

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Starliner’s stay at ISS extended several days

9:10 am

NASA revealed yesterday that it has extended the time that Boeing’s Starliner capsule will remained docked at ISS several days, with undocking now set for June 18, 2024.

New station visitors Butch Wilmore and Suni Williams, both veteran NASA astronauts, learned on Sunday they will orbit Earth until June 18 before returning home aboard Boeing’s Starliner spacecraft. The extra days in space will allow teams more time to checkout Starliner’s systems and free up the Expedition crew’s schedule for more spacewalk preparations.

I also suspect that Boeing engineers wanted more time to analyze the data on Starliner’s attitude thrusters and why several failed to work on the flight up to the station. Once the spacecraft undocks with Wilmore and Williams, it will be esssential for those thrusters to work reliably to get both home safely. The capsule can return home even with some of the spacecraft’s 28 attitude thrusters non-functioning, but if a failure occurs at an unexpected moment the results could still be bad.

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Boeing’s Starliner successfully docks with ISS

10:57 am

Despite several minor helium leaks and the failure of 6 of its 28 small attitude thrusters (four of which were reactivated during an improvised hot fire test during rendezvous operations), Boeing’s Starliner has successfully docked with ISS today.

Though now safely arrived at ISS, the hatch has not yet opened. The spacecraft carries NASA astronauts Butch Wilmore and Suni Williams, and will now spend about a week at the space station checking out its systems before undocking and returning to Earth.

All told, this docking is a success, though the various thruster issues are a concern that must be addressed by Boeing, especially because there were thruster issues as well during the previous unmanned demo flight.

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ULA’s Atlas-5 launches Boeing’s Starliner capsule on its first manned mission

9:17 am

After many delays and scrubs involving both the rocket and the capsule, ULA’s Atlas-5 rocket today successfully launched Boeing’s Starliner capsule on its first manned mission, carrying NASA astronauts Butch Wilmore and Suni Williams.

I have embedded the live stream below, cued to just before liftoff. The spacecraft will dock with ISS tomorrow, where Wilmore and Williams will spend a week checking out the capsule’s operations before undocking and returning to Earth.

As this was only the third launch this year for ULA, the leader board for the 2024 launch race doesn’t change:

59 SpaceX
26 China
8 Russia
7 Rocket Lab

American private enterprise now leads the world combined in successful launches, 69 to 40, while SpaceX by itself leads the entire world, including other American companies, 59 to 50.

» Read more

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NASA confirms June 5th as new launch date for Starliner

8:33 am

NASA yesterday evening confirmed that the agency, ULA, and Boeing are now targeting June 5, 2024 at 10:52 am (Eastern) for the launch of the first manned launch of Boeing’s Starliner capsule carrying two astronauts to ISS for a two week checkout mission.

Technicians and engineers with ULA (United Launch Alliance) worked overnight and on Sunday to assess the ground support equipment at the launch pad that encountered issues during the countdown and scrubbed the June 1 launch attempt. The ULA team identified an issue with a single ground power supply within one of the three redundant chassis that provides power to a subset of computer cards controlling various system functions, including the card responsible for the stable replenishment topping valves for the Centaur upper stage. All three of these chassis are required to enter the terminal phase of the launch countdown to ensure crew safety.

On Sunday, the chassis containing the faulty ground power unit was removed, visually inspected, and replaced with a spare chassis. No signs of physical damage were observed. A full failure analysis of the power unit will be performed to better understand root cause. Meanwhile, ULA has completed functional checkouts of the new chassis and the cards, and all hardware is performing normally.

These kinds of technical issues happen too often on ULA launches. Company engineers always fix them, but it never appears they fix them permanently. Too often on launches they pop up again, causing more scrubs.

The goal should be to fix them so they never pop up again, and your launches can begin to launch reliably, on time. And we know it can be done, because SpaceX has done it.

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Boeing Starliner launch scrubbed at T-3:50

10:10 am

UPDATE: The launch is now scheduled for June 5, 2024 at 10:52 am (Eastern).

For reasons that appeared related to the ground system’s of ULA’s Atlas-5 rocket, the first manned launch of Boeing’s Starliner’s capsule was scrubbed today at T-3:50.

It appears they want to try again tomorrow at 12:03 pm (Eastern), assuming ULA can figure out what happened.

The repeated scrubs and delays that have so far prevented this launch are beginning to remind my of my childhood watching the early NASA launch attempts during the Mercury program. Then, they hadn’t done this before, and were being very careful about everything.

Now, it seems that NASA, ULA, and Boeing are acting the same way, and that is probably because they are very nervous about Starliner and don’t want anything to go wrong.

I had intended to embed the live stream, but slept late (it IS the weekend, y’know). Sorry.

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Watching the first manned launch of Boeing’s Starliner capsule

9:31 am

NASA has now announced the broadcast schedule for tomorrow’s 12:35 pm (Eastern) launch of Boeing’s Starliner capsule on its first manned mission to ISS.

NASA will provide live coverage of prelaunch and launch activities for the agency’s Boeing Crew Flight Test, which will carry NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station.

Launch of the ULA (United Launch Alliance) Atlas V rocket and Boeing Starliner spacecraft is targeted for 12:25 p.m. EDT Saturday, June 1, from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida. Starliner will dock to the forward-facing port of the station’s Harmony module at approximately 1:50 p.m., Sunday, June 2.

The live stream will begin on NASA TV at 8:15 am (Eastern). I will embed that live stream here tomorrow. As this start time is more than four hours before launch, expect there to be endless NASA propaganda for most of that time. My advice is to tune in at around noon.

Let us all pray that all goes well on this flight. Boeing’s recent track record has generally be horrible. We can only hope its engineers have gotten all of the kinks out of this capsule.

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NASA/Boeing/ULA confirm new June 1st launch date for Starliner

9:36 am

In a press briefing this morning officials from NASA, Boeing, and ULA confirmed the new June 1, 12:25 pm (Eastern) launch date for the first manned flight of Boeing’s Starliner manned capsule.

The officials provided a more detailed explanation of the helium leak in a valve that effects the capsule’s service module attitude thruster system, noting that it is not a design flaw but some specific issue in this particular valve. Because of this, they are confident the system can function safely even with the leak, which is relatively small.

However, the officials also noted that during their reviews in the past two weeks they discovered a new software issue in the spacecraft’s de-orbit engines that — under very unusual and unlikely circumstances — could actually cause those engines to fail to operate. They have figured out a work-around, whereby they fire the engines at a lower thrust in two stages rather than once.

Should the launch on June 1st be scrubbed for weather, they have back up dates on the next few days, though by June 4th ULA might have to swap out batteries on its Atlas-5 rocket that will require a longer stand down of several additional days.

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Boeing/NASA now targeting a June 1, 2024 launch of Starliner

9:28 am

In a brief update posted today by NASA, the agency announced that Boeing, NASA, and ULA have a new 12:25 pm (Eastern) June 1, 2024 launch date for the first manned flight of Boeing’s Starliner capsule.

The announcement was incredibly obscure about what the issues are that have caused this additional week delay:

Work continues to assess Starliner performance and redundancy following the discovery of a small helium leak in the spacecraft’s service module. As part of this work, and unrelated to the current leak which remains stable, teams are in the process of completing a follow-on propulsion system assessment to understand potential helium system impacts on some Starliner return scenarios. NASA also will conduct a Delta-Agency Flight Test Readiness Review to discuss the work that was performed since the last CFT launch attempt on May 6, and to evaluate issue closure and flight rationale ahead of the next attempt, as part of NASA’s process for assessing readiness. The date of the upcoming Flight Test Readiness Review is under consideration and will be announced once selected.

It appears that engineers are worried the leak — which is linked to one of the attitude thrusters in the capsule’s service module — might impact the ability of Starliner to return to Earth safely. It also appears there is concern about the spacecraft sitting on the launchpad for more than a month, and an evaluation is on-going on whether this might be an issue as well.

I am guessing however. A more detailed explanation might be forth-coming after press update scheduled for 11 am (Eastern) tomorrow.

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Starliner manned launch delayed again; no new launch announced

9:33 am

In a very terse statement that apparently was only sent out by email to some sources, NASA and Boeing announced last night that the May 25, 2024 launch of the first manned Starliner mission on ULA’s Atlas-5 rocket had been postponed, with no new launch date set.

NASA, Boeing, and ULA are foregoing the Saturday, May 25 launch attempt for NASA’s Boeing Crew Flight Test. The team has been in meetings for two consecutive days, assessing flight rationale, system performance, and redundancy. There is still forward work in these areas, and the next possible launch opportunity is still being discussed.

NASA will share more details once we have a clearer path forward,

The first launch scrub prior to the first launch date of May 6th was due to a valve issue on the Atlas-5 rocket. ULA quickly replaced that valve and the launch was rescheduled for May 17th. Then Boeing engineers detected a helium leak related to one of the attitude thrusters in the capsule’s service module. The launch was first delayed until May 21st, then delayed again until May 25th. Now it is delayed indefinitely.

Whether that helium leak remains the cause of this new delay remains unknown. That no new launch date has been proposed suggests the need to bring the rocket and capsule back to the assembly building to destack it in order to fix the problem. That NASA, Boeing, and ULA are being so coy about revealing any details suggests however that some additional issue might have been uncovered.

Regardless, this new extended delay is very bad publicity for Boeing. While the comparison is somewhat unfair, it continues to make Starliner look like an American version of a Yugo, not the kind of vehicle one would nonchalantly climb into for a flight into space.

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Starliner launch delayed again, to May 25, 2024

3:36 pm

Boeing, ULA, and NASA have decided to delay the first manned flight of Boeing’s Starliner capsule another four days to 3:09 pm (Eastern) on May 25, 2024.

The additional time allows teams to further assess a small helium leak in the Boeing Starliner spacecraft’s service module traced to a flange on a single reaction control system thruster. Pressure testing performed on May 15 on the spacecraft’s helium system showed the leak in the flange is stable and would not pose a risk at that level during the flight. The testing also indicated the rest of the thruster system is sealed effectively across the entire service module. Boeing teams are working to develop operational procedures to ensure the system retains sufficient performance capability and appropriate redundancy during the flight.

It appears they simply want to give themselves extra time to review their data thoroughly, with no rush, before lighting the rocket.

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Atlas-5 launch of Starliner slips to May 21, 2024

1:25 pm

While ULA has successfully replaced the valve in the upper stage of the Atlas-5 rocket, the first manned launch of Boeing’s Starliner capsule has slipped another four days, to May 21, 2024, because a newly discovered helium leak in the capsule’s service module.

Starliner teams are working to resolve a small helium leak detected in the spacecraft’s service module traced to a flange on a single reaction control system thruster. Helium is used in spacecraft thruster systems to allow the thrusters to fire and is not combustible or toxic.

NASA and Boeing are developing spacecraft testing and operational solutions to address the issue. As a part of the testing, Boeing will bring the propulsion system up to flight pressurization just as it does prior to launch, and then allow the helium system to vent naturally to validate existing data and strengthen flight rationale.

The prevous launch scrub was entirely due to the ULA’s rocket, not anything related to Boeing. This delay however is a Boeing issue, and it only reinforces the general uneasiness everyone feels about Boeing’s quality control work.

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