Tag: Boeing

NASA completes Starliner review, finds more issues

9:15 am

Capitalism in space: NASA yesterday released the results of its investigation into the issues that prevented Boeing’s manned Starliner capsule from successfully completing its unmanned demo flight to ISS in December, finding an additional 20 issues over the 61 initially identified shortly after the mission.

In closing out the seven-month investigation, NASA officials said Tuesday they have now identified 80 corrective actions, mostly involving software and testing, that must be done before the Starliner capsule launches again. The previous count was 61.

NASA officials also admitted that they had been so focused on making sure SpaceX’s Dragon capsule was going to work that they became lax in reviewing Boeing’s work. Now they not only are going to focus more on Boeing, they actually want to use SpaceX’s approach to software development throughout NASA.

NASA is also borrowing SpaceX’s “robust” approach to software, which involves going back to the designers following testing for feedback, said Kathy Lueders, NASA’s new human spaceflight chief who until a month ago managed commercial crew. She wants to see more of that type of approach across other NASA programs.

Though it seems absurd and incredible that NASA has not been consulting with its designers after testing, it is also not surprising. When it comes to designing and building anything at NASA the management processes there have routinely done a bad job for many years.

As for Starliner, it is expected it will take a few more months to fix these issues, which means the next unmanned test flight is likely still set for sometime in the fall, with the manned mission to follow next spring.

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Boeing’s Starliner aces parachute test

9:26 am

Capitalism in space: Boeing last week successfully completed a Starliner parachute test designed to simulate the return of a capsule after a launch abort.

This is good news for the capsule and Boeing, but I am a bit puzzled why this test, to be followed by a second similar test, was done. These parachutes were supposedly tested thoroughly already, proven, and ready for use for manned missions. Part of that proof was an earlier launch abort test as well as Boeing’s unmanned orbital demo flight that failed to dock with ISS. Both returned to Earth safely using these parachutes. I wonder if during those latter flights they found issues with the parachutes that needed smoothing out by even more tests.

Either way, this success improves the chances that Starliner will finally fly manned early next year, giving the U.S. two different operational manned capsules for getting humans into space.

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New technical problems for SLS?

10:49 am

A new GAO report [pdf] issued yesterday has revealed that SLS engineers are concerned that the rocket’s core stage will develop leaks during its first full test, hopefully scheduled for this year.

[T]he new “Assessments of Major NASA Projects” report released on Wednesday contains what seems to be an entirely new bit of information about the Space Launch System rocket NASA is developing for deep space exploration. The report asserts that engineers at NASA and the SLS rocket’s core-stage contractor, Boeing, are concerned about fuel leaks.

Earlier this year, NASA moved the big rocket’s core stage to a test site at Stennis Space Center in southern Mississippi. Before the COVID-19 pandemic temporarily halted work, NASA and Boeing teams were working toward a critical summer exercise. During this “green run” test, the clamped-down rocket will ignite its engines and burn for about eight minutes to simulate an ascent into orbit.

“Program officials indicated that one of the top remaining technical risks to the green run test is that the core stage may develop leaks when it is filled with fuel,” the report states on page 82. “According to these officials, they have conducted extensive scaled testing of the gaskets and seals used in the core stage; however, it is difficult to precisely predict how this large volume of liquid hydrogen will affect the stage.”

My god, for them to think that the core stage might leak when it is filled with fuel for the first time illustrates the entire bankrupt nature of this entire project. This is why you do tank tests early in the process (as SpaceX has been doing with Starship), so that you don’t get surprised late in the game.

The report also notes further issues with the Orion capsule.

The Orion program plans to reduce the 7-month-long pre-launch processing period by 1.5 months. The program plans to use a mass simulator—instead of the Orion spacecraft—to conduct some prelaunch tests that would otherwise be done after integrating Orion with SLS—providing the program with extra time to complete work before delivering Orion for integration and further testing according to officials. With this shortened process, the program has only 1 week of schedule reserve remaining to the November 2020 launch date, and program officials have said this date will likely be delayed

I must remind everyone that Lockheed Martin got the contract to build Orion in 2005. They have had fifteen years to build this one capsule, and will still deliver it late.

Personally, I hope SLS leaks. If it does, it will force a very long new delay to the program, and very well might finally force Congress and the Trump administration to face reality and cancel it.

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Boeing’s fall from grace at NASA

9:26 am

Eric Berger at Ars Technica yesterday uncovered a NASA report that outlined its selection process for awarding a contract for providing cargo to the agency’s proposed Lunar Gateway space station — eventually won by SpaceX — that gave Boeing’s proposal a terrible ranking.

Of the four contenders, [Boeing] had the lowest overall technical and mission suitability scores. In addition, Boeing’s proposal was characterized as “inaccurate” and possessing no “significant strengths.” Boeing also was cited with a “significant weakness” in its proposal for pushing back on providing its software source code.

Due to its high price and ill-suited proposal for the lunar cargo contract, NASA didn’t even consider the proposal among the final bidders. In his assessment late last year, NASA’s acting chief of human spaceflight, Ken Bowersox, wrote, “Since Boeing’s proposal was the highest priced and the lowest rated under the Mission Suitability factor, while additionally providing a conditional fixed price, I have decided to eliminate Boeing from further award consideration.” [emphasis mine]

The highlighted words could possibly be a death sentence for Boeing. The company has numerous other serious problems, including its commercial 737-Max airplane, its KC-46 Pegasus tanker for the Air Force, and of course its SLS rocket for NASA. For NASA to say that it will no longer consider Boeing in future contract bidding, especially since NASA has been one of Boeing’s biggest customers for decades, cannot be good for the company’s already badly suffering bottom line.

Berger also notes how much NASA’s attitude toward Boeing has changed since the agency removed Bill Gerstenmaier as head of its manned space operations. Gerstenmaier had apparently given Boeing the highest marks routinely, and appeared to have lost his ability to look at the company objectively. Moreover, his (and NASA’s) kid-glove treatment of Boeing for decades probably contributed to that company’s sloppy bid on the Lunar Gateway cargo contract. They were likely not used to tough questioning, and didn’t put the proper effort into writing their bid.

For the taxpayer and the American space effort, however, this report is wonderful news. It appears that NASA is breaking its tight and blind partnership with the big space contractors that has for decades handicapped the nation’s ability to get things built in space. These contractors have not been able to deliver, but because of their powerful allies on Congress, NASA has for years kowtowed to them in contract awards.

Now however it appears NASA’s management has become quite willing to reject these powerful companies, despite Congressional backing, in order to get the best deal and the best product, for the nation.

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Boeing to do second unmanned test flight of Starliner

12:59 am

Capitalism in space: Boeing officials said yesterday that they now plan a second unmanned demo mission to ISS of their Starliner manned capsule in order to make sure they have cleared up all the issues that plagued the first unmanned flight in December.

The company on Monday confirmed a report in the Washington Post that it will fly a second uncrewed demonstration mission — which Boeing calls an Orbital Flight Test — before astronauts ride a Starliner into orbit.

“We have chosen to refly our Orbital Flight Test to demonstrate the quality of the Starliner system,” Boeing said in a statement Monay. “Flying another uncrewed flight will allow us to complete all flight test objectives and evaluate the performance of the second Starliner vehicle at no cost to the taxpayer. We will then proceed to the tremendous responsibility and privilege of flying astronauts to the International Space Station.”

Right now they are aiming for an October/November launch date.

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NASA selects full crew for first operational Dragon mission

10:23 am

Even though SpaceX’s first demonstration manned mission to ISS has not yet occurred, NASA yesterday announced the selection of the full four person crew for the second flight, set for later this year and intended as the first operational mission to ISS, lasting six months.

This announcement tells us several things, all good. First, it appears NASA has now definitely decided that the demo mission, presently scheduled for mid-May, will be a short-term mission. They had considered making it a six-month mission, but it now appears they have concluded doing so will delay the demo launch too much.

Second, that NASA is solidifying its plans for that operational flight, the second for Dragon, including a tentative launch date later in 2020, is further evidence that they intend to go through with the demo mission in mid-May.

Finally, it appears that NASA has decided that it will not buy more seats on Russian Soyuz capsules, something that they had previously hinted they needed to do because the agency was worried the American capsules would not be ready this year. The article describes the negotiations on-going with the Russians about the use of Dragon, as well as the future use by Americans of Soyuz. NASA wishes to have astronauts from both countries fly on both spacecraft (Starliner too, once operational), but Russia is as yet reluctant to fly its astronauts on Dragon. They want to see that spacecraft complete more missions successfully.

Regardless, future flights of Americans on Soyuz will cost NASA nothing, as the agency wishes to trade the seats on the U.S. capsules one-for-one for the seats on Soyuz. It also means that NASA has decided it doesn’t need to buy Soyuz flights anymore, as it now expects Dragon to become operational this year.

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New inspector general report slams NASA’s SLS management

10:20 am

A new report [pdf] by NASA’s inspector general released today harshly slams the management of NASA for the never-ending cost overruns and scheduling delays that have plagued the agency’s effort to build and launch the Space Launch System (SLS).

From the report’s introduction:

Based on our review of SLS Program cost reporting, we found that the Program exceeded its Agency Baseline Commitment (ABC)—that is, the cost and schedule baselines committed to Congress against which a program is measured—by at least 33 percent at the end of fiscal year 2019, a figure that could reach 43 percent or higher if additional delays push the launch date for Artemis I beyond November 2020.

… [T]he SLS Program now projects the Artemis I launch will be delayed to at least spring 2021 or later. Further, we found NASA’s ABC cost reporting only tracks Artemis I-related activities and not total SLS Program costs. Overall, by the end of fiscal year 2020, NASA will have spent more than $17 billion on the SLS Program—including almost $6 billion not tracked or reported as part of the ABC.

The graph below, taken from page 45 of the report, illustrates the management failures here quite starkly.
» Read more

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NASA confirms seriousness of 2nd Starliner software issue

5:38 pm

At a press conference today, NASA and Boeing officials confirmed the rumors that there was a second software error during Starliner’s unmanned demo mission in December that might have caused a serious failure had it not been caught on time.

[After the first software error], engineers began reviewing other critical software sequences as a precaution and discovered yet another problem. Software used to control thruster firings needed to safely jettison the Starliner’s service module just before re-entry was mis-configured, set for the wrong phase of flight.

Had the problem not been found and corrected, the cylindrical service module’s thrusters could have fired in the wrong sequence, driving it back into the crew module and possibly triggering a tumble or even damaging the ship’s protective heat shield.

While a detailed analysis was not carried out at the time, “nothing good can come from those two spacecraft bumping back into one another,” said Jim Chilton, a senior vice president for Boeing Space and Launch.

That two different software errors were not caught prior to flight has NASA demanding a complete review of Boeing’s quality control systems. And NASA here is correct. Boeing as a company appears to have fundamental quality control issues up and down the line, in all its projects. A complete review appears warranted.

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NASA safety panel raises more questions about Boeing and Starliner

10:05 am

In its quarterly meeting yesterday, NASA’s safety panel raised more questions about the software problems during the unmanned demo mission of Boeing’s Starliner manned capsule in December.

NASA’s Aerospace Safety Advisory Panel (ASAP) revealed today that a second software error was discovered during the uncrewed Boeing Starliner flight test in December. Had it gone undetected during the flight, it had the potential to cause “catastrophic spacecraft failure” during reentry. The panel wants a complete review of Boeing’s software verification processes before NASA decides whether a second uncrewed flight test is needed. In an email this evening, Boeing said it appreciates the input and is working on a plan with NASA to address all the issues and decide what comes next.

In that Boeing email it noted that it was “unclear” what the consequences would have been if this second software issue had not been fixed.

The safety panel also called for an overall organizational review of the entire Boeing company, similar to the review done to SpaceX after Elon Musk was videoed taking a toke on a joint during a podcast interview.

The decision on whether Boeing will be required to fly another unmanned demo mission is targeted for before the end of February.

One comment: While there is clear evidence here that Boeing had issues on that demo flight that must be resolved before humans fly on Starliner, we must also recognize that NASA’s safety panel has an unfortunate tendency to overstate risk, demanding margins of safety that are frequently unrealistic for an endeavor pushing the envelope of exploration. That panel has also exhibited an almost corrupt bias against private commercial space, while looking past much more serious safety issues in the NASA-built SLS and Orion programs.

At the same time, the larger corporate issues here with Boeing do appear far more systemic and concerning that those that occurred with SpaceX. A cold independent audit of the company by NASA could actually do Boeing a lot of good.

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Boeing budgets for extra unmanned Starliner test

9:30 am

Capitalism in space: Boeing has put aside $410 million in its next budget to pay for a possible second unmanned Starliner test, just in case NASA demands it.

The company said in its fourth quarter earnings release Jan. 29 that it was taking the charge “primarily to provision for an additional uncrewed mission for the Commercial Crew program, performance and mix.” It noted that NASA was still reviewing data from the Orbital Flight Test (OFT) mission in December that was cut short, without a docking at the International Space Station, by a timer problem.

“NASA is in the process of reviewing the data from our December 2019 mission,” Greg Smith, chief financial officer at Boeing, said in an earnings call. “NASA’s approval is required to proceed with a flight test with astronauts on board. Given this obligation, we are provisioned for another uncrewed mission.” Neither he nor Boeing’s new chief executive, David Calhoun, elaborated on that during the call, which was devoted primarily to issues related to the company’s 737 MAX airliner.

It might be too early to say, but my instincts are telling me that this decision, made very quickly, is a very good sign for Boeing. It suggests that Calhoun doesn’t fool around, that he takes very seriously the need for Boeing to serve its customers. In the past Boeing would have lobbied NASA, its customer, to pay for a possible additional flight (something NASA is not required to do according to the contract). Now Boeing instead makes it clear that it has accepted the responsibility of that additional flight, right off the bat, something that any good and healthy company should do.

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NASA picks Axiom to build three private commercial modules on ISS

10:05 am

Capitalism in space: NASA today picked the new space station company Axiom to build three modules to ISS, designed to operate as a private commercial operation.

The first segment launch is targeted for 2024. The three segments will include a node with multi-ports, a crew module, and a research module, and will be the “hotel” for private tourists that Axiom hopes to send to ISS two or three times per year. The entire section will also be designed to eventually separate from ISS when that station is retired and operate, with more additions, as an independent station.

This decision did not include the actual contract, only the choice of company to build this new section of ISS. Later negotiations will determine the fixed price amount that NASA will pay.

Why did NASA pick Axiom, which has not yet launched anything, and bypass Bigelow, which has launched two independent test modules and one that has been attached to ISS and working successfully now for several years? This quote explains:

Although Axiom is a relatively young company, having been formed only four years ago in 2016, there is no lack of experience within the company’s ranks.

Axiom’s Co-founder and CEO is Micheal Suffredini, who formerly worked at the Johnson Space Centre (JSC) as the program manager for the International Space Station project.

The Axiom team also includes Michael Lopez-Alegria, a former NASA astronaut who flew on the space shuttle three times and commanded the 14th Expedition to the ISS, as well as former shuttle commanders Brent Jett and Charles Bolden, the latter of whom served as NASA’s 12th administrator from 2009 to 2017.

Axiom is also working alongside several companies with extensive experience with the ISS program, this includes Boeing, who has made several of the modules that make up the US Segment, including Node 1 and the US Laboratory Module. Axiom is also working alongside Thales Alenia Space, Maxar Technologies and Intuitive Machines to get this project off the ground. [emphasis mine]

In other words, it appears it’s not what you know, it’s who you know. This is not to say that the individuals and companies listed above do not know much, but that the company’s real experience with building private modules is lacking. Boeing has built NASA’s modules, but those were for the government and were therefore costly. I have grave doubts they could do this inexpensively, though I could be wrong.

The key will be whether they aim to make their profits from their commercial customers, or use NASA (and the federal government) as their cash cow. The track record of most of Axiom’s partners suggests the latter. For example, Bigelow built and launched its BEAM module to ISS for $17 million, and got it done in three years. We don’t yet know the cost of Axiom’s modules, but their target build-time is already longer, at four to five years

Don’t get me wrong. I applaud NASA’s approach here. They are ceding ownership and construction to a private company, and allowing its work to be commercialized for profit, something that NASA routinely opposed for decades. I just worry that the company it has chosen will be not up to the task, and is not focused on making those profits.

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Boeing flies 777X for the first time

8:46 am

On January 25 Boeing successfully flew its new giant 777X commercial airplane for the first time.

Originally unveiled at the 2013 Dubai Airshow, the 777X is an advance on the engineering and interior innovations of the 777 and 787 Dreamliner. The twin-engine jetliner is available in the 777-8 and 777-9 variants with ranges of up to 8,700 nm (10,012 mi/16,110 km) and seating between 350 and 425 passengers.

The key innovation of the 777X is its lightweight wing design based on a composite spar made from over 400 miles (644 km) of carbon tape cured in a specially-built autoclave. This allows the aircraft to have a wingspan of 235 ft (72 m) – a span so long that the wings have folding sections at their tips so the plane can fit in conventional boarding gates.

The test flight lasted just under four hours. The pictures at the link illustrate clearly emphasize the lightweight wings, which look tiny compared to the two engines.

Boeing desperately needs a success, considering the string of problems almost all of its major projects have been having recently.

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Boeing abruptly exits DARPA’s experimental spaceplane project

5:37 pm

Boeing today announced it is pulling out of DARPA’s Experimental Spaceplane Program, cancelling development of its Phantom Express-1 hyposonic plane.

The Pentagon’s Defense Advanced Research Projects Agency says Boeing is dropping out of its Experimental Spaceplane Program immediately, grounding the XS-1 Phantom Express, even though technical tests had shown the hypersonic space plane concept was feasible. “The detailed engineering activities conducted under the Experimental Spaceplane Program affirmed that no technical showstoppers stand in the way of achieving DARPA’s objectives, and that a system such as XSP would bolster national security,” DARPA said in a statement issued today.

Boeing has provided no clear explanation for this exit. I suspect it might have to do with their other problems related to the 737-Max airplane and the costs it is imposing on the company. Also, the program called for the first test flights in 2020, and it might also be that Boeing had doubts about meeting that goal.

Right now I wonder if Boeing will have to return any of the cash DARPA provided it for the work done so far, out of the total $146 million award. Moreover, at least two other companies had bid for this contract, Masten and Northrop Grumman. Will Boeing’s exit now allow them to pick up the pieces? Or has Boeing’s contract win and sudden exit mainly achieved the goal of stymieing their compeition?

Overall, this decision by Boeing is just another black mark on the company, just one of many that has occurred in the past few years.

UPDATE: It appears that Doug Messier at Parabolic Arc suspects the same Machiavellian maneuvers from Boeing as I.

A couple of years ago, a friend made the surprising predication that DARPA’s Experimental Spaceplane Program (XSP) — a R&D effort designed to produce a rocket capable of being launched 10 times in 10 days — would never see any hardware built.

The reasoning went like this: the winning bidder, Boeing, really wasn’t interested in the technology. The company was actually interested in government funding and keeping other companies from developing the system.

Messier isn’t sure either, noting that the pull out might also have occurred due to the arrival of Boeing’s new CEO, only a week earlier.

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Boeing looking to borrow up to $10 billion because of 737-Max problems

9:20 am

Boeing apparently is in discussions with several banks in an effort to secure a $10 billion loan to help it deal with the costs related to the suspension of production of the 737-Max airplane after two fatal crashes.

Boeing is in talks with banks to secure a loan of $10 billion or more, according to people familiar with the matter, as the company faces rising costs stemming from two fatal crashes of its 737 Max planes. The company has secured at least $6 billion from banks so far, the people said, and is talking to other lenders for more contributions. The total amount could rise if there is additional demand from banks, one person familiar with the matter said.

Liquidity isn’t an immediate concern, analysts have said, but the new debt shows Boeing is shoring up its finances amid the cash-sapping fallout of the two crashes — one in Indonesia in October 2018 and another in Ethiopia in March last year — that killed all 346 people aboard the two flights.

The amount Boeing is seeking to borrow is more than what some analysts were expecting. For example, Jefferies earlier this month forecast Boeing would issue $5 billion in debt this quarter.

I must emphasize that this story relies on anonymous sources, and is reported by CNBC, a division of NBC, one of today’s least reliable news sources.

More trustworthy information should become available on January 29, when Boeing makes its next earnings report.

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A detailed look at Boeing’s recent aircraft problems

2:33 pm

Link here. The article is entirely focused at reviewing only Boeing’s recent aircraft projects (Boeing 787, Boeing 747-8, Boeing KC-46A, Boeing 777X and Boeing 737 MAX), all of which appear to have had a lot of development issues.

The worst of the lot was the KC-46A, with many of the problems shared by our incompetent federal government. Initially proposed in 2001 (that is not a typo), the contract award did not occur until 2010, with delivery of the first 18 planes set for August 2017. The GAO predicted this delivery would be late, and the GAO was right.

Worse, Boeing has had cost overruns on the tanker totaling $3.4 billion above the initial fixed cost development contract of $4.9 billion (that is also not a typo).

The article also cites far too many examples of where Boeing requested waivers in order to meet schedule, even though the waiver allowed serious safety issues to linger, a behavior that reminded me strongly of NASA’s management during the shuttle program, resulting in the loss of two shuttles because the agency preferred to push its schedule rather than deal with serious engineering problems.

When you add the delays, cost overruns, and sometimes absurd mistakes that have occurred during Boeing’s development of SLS, this article is far more disturbing. It gets worse when you consider the issues that have delayed the launch of Starliner, some of which (the parachutes) should not have been an issue considering Boeing’s half century of experience.

All told, these problems portray a company that is akin to our federal government, badly managed and ripe for disaster. While the U.S. aerospace industry would take a deep hit if Boeing went under, that hit however would likely be temporary, especially considering the problems Boeing is having.

Freedom must allow bad businesses to fail so that fresh faces not bogged down by old problems can come to the fore and replace them. If Boeing collapsed I suspect a host of new companies would quickly appear, all likely more capable of producing what the nation’s aerospace industry needs. Because right now, Boeing is certainly not doing the job.

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Boeing releases video of Starliner’s first orbital demo flight

9:25 am

Capitalism in space: Boeing has released a video showing what it was like to be on its Starliner capsule during its first orbital demo flight on December 20, 2019.

Flying alongside the uncrewed Starliner’s only official passenger — a spacesuit-clad, instrumented dummy (or anthropometric test device) named “Rosie” (after the World War II icon Rosie the Riveter), Snoopy, in plush doll form, served as the vehicle’s “zero-g indicator.” The video shows the doll floating weightless at the end of its “leash” after the Starliner entered Earth orbit.

The video is embedded below the fold. It is relatively boring, which actually is a good thing. The interior of the capsule does not seem much disturbed during each phase of the flight, from launch, separation from launch vehicle, and touchdown.
» Read more

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More problems at Boeing, this time with military aircraft

10:11 am

In this article about Israel’s desire to obtain the new KC-46A airplane tankers being built by Boeing for the Air Force, it is revealed that Boeing has had numerous disturbing manufacturing problems on this particular plane.

Earlier in 2019 the U.S. air force resumed, after a two-month delay, accepting new KC-46As. That two-month delay was because of FOD (Foreign Object Debris), including tools and other metal objects, still showing up in various parts of the aircraft. This indicated a serious lapse in the management of assembly and quality control while producing these aircraft. By March, after nearly a month of effort to check out aircraft nearly ready for delivery as well as factory inspection procedures, the air force agreed to begin accepting KC-46s once more. Deliveries continued despite the recently discovered cargo lock (unreliable cargo tie down latches) problem. The Americans are now concerned about Boeing, the manufacturer while also needing the KC-46As as soon as possible. This is the same firm that is having worse problems with its new 737 Max commercial airliner.

In mid-2019 Boeing planned to deliver 36 KC-46As by the end of 2019 and later expected to meet that goal even though only 19 had been delivered by early September. At the end of the year the goal of 36 was missed but Boeing did fix the cargo lock problem and this allowed cargo to again be carried. There is one problem left with the accuracy of the remote viewing system used by the 46A boom operator. That does not prevent operation of the aircraft, just slows down refueling in some cases.

Boeing has had problems with its 737-Max commercial jet (now grounded), with the construction of the Space Launch System (SLS) for NASA (a decade behind schedule and billions over budget), and with its manned Starliner space capsule. The list of issues above for the KC-46A is equally troubling, and indicates that the management and quality control problems indicated by the other projects might very well be systemic to the entire company. Not good, not good at all.

Hat tip to reader Norm Donovan.

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Boeing fires CEO

9:12 am

Boeing today fired its CEO Dennis Muilenburg, citing the need to “restore confidence in the company.”

The company has had a very bad year, with the grounding of its 737-Max airplane, the cost overruns and delays in its NASA Space Launch System (SLS) rocket, and the failure of its Starliner manned capsule to dock with ISS this past weekend.

Whether this change will accomplish anything is hard to say. The problems above appear very deeply embedded within the company’s culture, and might require the kind of wholesale changes that big bloated corporations like Boeing are generally loath to impose.

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Starliner lands safely after failed orbital insertion

9:29 pm

Capitalism in space:Boeing’s Starliner capsule successfully landed today in New Mexico, returning to Earth prematurely because of its failure to reach its proper orbit after launch two days ago.

The article quotes extensively from both NASA and Boeing officials touting the many successful achievements of this flight, while trying to minimize the failure that prevented the capsule from docking with ISS properly. And that failure?

The mission elapsed timer issue that cut short Starliner’s planned eight-day mission started before the spacecraft lifted off Friday from Cape Canaveral aboard a United Launch Alliance Atlas 5 rocket, according to Chilton. “Our spacecraft needs to reach down into the Atlas 5 and figure out what time it is, where the Atlas 5 is in its mission profile, and then we set the clock based on that,” Chilton said in a press conference Saturday. “Somehow we reached in there and grabbed the wrong (number). This doesn’t look like an Atlas problem. This looks like we reached in and grabbed the wrong coefficient.”

“As a result of starting the clock at the wrong time, the spacecraft upon reaching space, she thought she was later in the mission, and, being autonomous, started to behave that way,” Chilton said. “And so it wasn’t in the orbit we expected without the burn and it wasn’t in the attitude expected and was, in fact, adjusting that attitude.”

I read this and find myself appalled. While I agree that overall the mission proved the capsule capable of launching humans to ISS (which is why NASA is considering making the next Starliner mission manned despite this failure), this failure suggests a worrisome lack of quality control at Boeing. I can’t even imagine how the Starliner software could be mis-configured to “grab the wrong number.” This explanation makes no sense, and suggests they are spinning the failure to avoid telling us what they really did wrong.

Either way, I suspect that NASA will approve a manned launch for Starliner’s next orbital flight, but will do so only after dwelling on the problem for at least six months.

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Starliner launch fails, spacecraft to return to Earth

9:44 am

After being successfully placed in a preliminary orbit by ULA’s Atlas 5 rocket early this morning, Boeing’s Starliner capsule failed to reach its required orbit for docking with ISS when its own rocket engines did not fire properly at the right time.

The orbit it is in is stable, and the spacecraft is undamaged. Engineers now plan to bring it back to Earth on Sunday, landing at White Sands, New Mexico.

It appears some software issue had the capsule fire its own rockets either at the wrong time or for too short a time. The spacecraft was then in the wrong orbit, and needed to use too much fuel to correct this issue, making it impossible to dock with ISS.

More information here:

However, for reasons Boeing engineers do not yet understand, Starliner’s Mission Event Timer clock malfunctioned, causing the vehicle to think it was at a different point in the mission and at a different time in its mission that it actually was.

…This resulted in Starliner’s Reaction Control System thinking the Orbit Insertion Burn was underway and executing a series of burns to keep the vehicle oriented in the insertion burn attitude; however, the Orbit Insertion Burn was not actually occurring.

When mission controllers realized the issue, they sent manual commands to Starliner to perform an Orbit Insertion Burn in a backup window that came roughly eight minutes after the planned maneuver. However, a known and brief gap in NASA satellite communications caused a further delay.

By the time Starliner was finally able to burn its engines and get into a stable orbit, it had burned 25% more propellant than anticipated.

Boeing is certainly not having a good year. First it has had to shut down production on its new 737-Max airplane due to several crashes caused by software issues. Next its SLS rocket for NASA has had endless cost overruns and delays. Now Starliner fails during its first launch.

For ULA, however, the Atlas 5 rocket performed exactly as planned, so this launch gets listed as a success. They have now completed 5 launches this year.

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Inspector general slams NASA’s management for bonus payments to Boeing

10:11 am

In a report [pdf] issued yesterday, NASA’s inspector general blasted the agency’s manned commercial space management for issuing a $287 million bonus payment to Boeing to help it avoid delays in developing its Starliner capsule — which would have caused gaps in future American flights to ISS — even though the cost to use Russian Soyuz capsules would have been far less.

Worse, the agency never even allowed SpaceX to make its own competitive offer.

NASA agreed to pay Boeing Co (BA.N) a $287 million premium for “additional flexibilities” to accelerate production of the company’s Starliner crew vehicle and avoid an 18-month gap in flights to the International Space Station. NASA’s inspector general called it an “unreasonable” boost to Boeing’s fixed-priced $4.2 billion dollar contract.

Instead, the inspector general said the space agency could have saved $144 million by making “simple changes” to Starliner’s planned launch schedule, including buying additional seats from Russia’s space agency, which the United States has been reliant on since the 2011 retirement of its space shuttle program.

…NASA justified the additional funds to avoid a gap in space station operations. But SpaceX, the other provider, “was not provided an opportunity to propose a solution, even though the company previously offered shorter production lead times than Boeing,” the report said. [emphasis mine]

I’ve read the report, and from it the impression is clear that when NASA management discovered that Boeing was facing delays in Starliner and needed extra cash, it decided to funnel that cash to it, irrespective of cost. While it is likely that the agency did so because it did not wish to buy more Russian Soyuz seats, it makes no sense that it didn’t ask SpaceX for its own competitive bid. By not doing so the management’s foolish bias towards Boeing is starkly illustrated

Eric Berger at Ars Technica also notes that the report makes clear how Boeing’s prices for Starliner are 60% higher than SpaceX’s Crew Dragon prices, further illustrating how the agency favors Boeing over SpaceX.

Boeing’s per-seat price already seemed like it would cost more than SpaceX. The company has received a total of $4.82 billion from NASA over the lifetime of the commercial crew program, compared to $3.14 billion for SpaceX. However, for the first time the government has published a per-seat price: $90 million for Starliner and $55 million for Dragon. Each capsule is expected to carry four astronauts to the space station during a nominal mission.

What is notable about Boeing’s price is that it is also higher than what NASA has paid the Russian space corporation, Roscosmos, for Soyuz spacecraft seats to fly US and partner-nation astronauts to the space station. Overall, NASA paid Russia an average cost per seat of $55.4 million for the 70 completed and planned missions from 2006 through 2020. Since 2017, NASA has paid an average of $79.7 million.

I don’t have a problem with NASA favoring Boeing over Russia, considering the national priorities. I can also understand the agency’s willingness to keep buying some Starliner seats in order to guarantee an American launch redundancy. However, giving Boeing even more money to keep its schedule going, when SpaceX is available to fill the gaps, demonstrates the corruption in the agency’s management. They haven’t the slightest understanding of how private enterprise and competition works.

The report is also filled with the same tiresome complaints about the on-going delays to the manned commercial program, focusing greatly on past technical issues (now mostly solved) while hiding in obscure language how it is NASA’s paperwork that is likely to cause all further delays.

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More detail on pad abort test parachute issue

10:22 am

At a press telecon yesterday Boeing outlined in more detail the cause of the failure of one main parachute to deploy during its November 4 Starliner pad abort test.

In a call with reporters, John Mulholland, vice president and program manager for commercial crew at Boeing, said an investigation after the Nov. 4 test at White Sands Missile Range in New Mexico led the company to conclude that a “lack of secure connection” between a pilot parachute and the main parachute prevented that main parachute, one of three, from deploying.

The pilot parachute is designed to deploy first, and pull out the main parachute. However, Mulholland said that hardware inspections and photographs taken during “closeout” of the vehicle prior to the test showed that a pin that links the pilot and main parachutes was not inserted properly.

“It’s very difficult, when you’re connecting that, to verify visually that it’s secured properly,” he said, in part because that portion of the parachute system is enclosed in a “protective sheath” intended to limit abrasion but which also makes it difficult to visually confirm the pin is in place. “In this particular case that pin wasn’t through the loop, but it wasn’t discovered in initial visual inspections because of that protective sheath.”

Mulholland said Boeing is modifying assembly procedures through what he called “fairly easy steps,” such as pull tests, to ensure those pins are properly installed. Technicians have already confirmed that the same parachute linkages are properly installed on the three parachutes on the Starliner that will launch in December on an orbital flight test to the International Space Station. [emphasis mine]

That a hardware inspection and photos taken before launch revealed this issue and resulted in nothing being done should rise serious questions at Boeing about its quality control processes. Based on the press telecon, however, it does not appear that Boeing is asking those questions. From a different report:

[John Mulholland, Boeing’s Starliner program manager] praised the rigging team, saying “even before we got eyes on the hardware, that team on their own initiative (was) reviewing the close-out photos and the processes, and they identified the potential issue that was subsequently validated by hardware inspection.”

“Most importantly, they raised their hand and and let us know what they believe the problem was,” he said. “It’s really a testament to the transparency of that team. The speak-up culture that we have, that is what we need on this program.”

While it is good that the rigging team was willing to speak up afterward, it is very bad that their procedures allowed the launch to go forward. The company says it has now changed its rigging procedures, but I don’t sense any effort on Boeing’s part to find out why its so-called “speak-up culture” failed to have these engineers speak-up, before launch.

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New video of Starliner pad abort test

3:19 pm

Boeing has released a new video of the Starliner pad abort test on November 4th, showing the full flight.

I have embedded the footage below the fold. The one aspect of this test that I have as yet not seen any explanation for is the red cloud to the left of the capsule’s touch down spot. It surely looks like the kind of smoke one sees from the release of certain toxic fuels. It was also something that the live stream video focused on, suggesting the possibility that its existence was important and needed to be recorded for engineering reasons.

Regardless, the fact that any onboard astronauts would have been safely returned to Earth, based on this test, should mean Boeing’s abort system is functioning properly. They note that they have pinpointed the reason one parachute did not deploy (“attributed to the lack of a secure connection between the pilot chute and one of the main chutes”), a problem that is probably quite simple to fix. Hopefully that one failure will not cause any significant delays in their future flights, including the first manned flight next year.
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NASA rejects Blue Origin’s proposed SLS upper stage

9:21 am

After considering an alternative bid by Blue Origin to build a less expensive upper stage for NASA’s SLS rocket, replacing the stage that Boeing is building, NASA has decided to reject that bid and stick with Boeing.

NASA sets out three reasons for not opening the competition to Blue Origin. In the document, signed by various agency officials including the acting director for human spaceflight, Ken Bowersox, NASA says Blue Origin’s “alternate” stage cannot fly 10 tons of cargo along with the Orion spacecraft.

Moreover, NASA says, the total height of the SLS rocket’s core stage with Blue Origin’s upper stage exceeds the height of the Vertical Assembly Building’s door, resulting in “modifications to the VAB building height and substantial cost and schedule delays.” Finally, the agency says the BE-3U engine’s higher stage thrust would result in an increase to the end-of-life acceleration of the Orion spacecraft and a significant impact to the Orion solar array design.

The article notes that there were also significant political reasons as well that pushed NASA to favor Boeing.

The article also states that SLS’s cost per launch will be about $2 billion. Though I think that number is probably low because it does not include any of the $25 billion spent for development, it does compare badly with SpaceX’s Falcon Heavy, which costs about $100 million per launch.

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Boeing proposes manned lunar lander that bypasses Gateway

8:47 am

Capitalism in space: Boeing today announced its bid to build a manned lunar lander for NASA’s Artemis program, with its lander launched to go directly to the Moon rather than stopping at the proposed Lunar Gateway lunar space station.

The company said its “Fewest Steps to the Moon” proposal, submitted for NASA’s Human Landing Services program, minimized the number of launches and other “mission critical events” needed to get astronauts to the surface of the moon. “Using the lift capability of NASA’s Space Launch System Block 1B, we have developed a ‘Fewest Steps to the Moon’ approach that minimizes mission complexity, while offering the safest and most direct path to the lunar surface,” Jim Chilton, senior vice president for space and launch at Boeing Defense, Space and Security, said in a company statement.

The two-stage launched would launch on the enhanced Block 1B version of the rocket, which uses the more powerful Exploration Upper Stage (EUS), and go into lunar orbit. It would either rendezvous with the lunar Gateway or directly with an Orion spacecraft, where astronauts would board it for a trip to the lunar surface. The lander is designed to be launched as a single unit, rather than in separate modules that would be aggregated at the Gateway. The lander also doesn’t require a separate transfer stage to maneuver from a near-rectilinear halo orbit to low lunar orbit, as some other designs have proposed.

This approach, the company said in a statement, reduces the number of mission critical events, such as launches and dockings, to as few as five. Alternative approaches, Boeing claims, require 11 or more such events. [emphasis mine]

Boeing is essentially proposing a plan that makes Gateway unnecessary, a bidding ploy that very well might work with the Trump administration, which has already reduced Gateway’s initial construction to speed up its attempt to get to the Moon by 2024.

More important, Boeing’s proposal makes it very clear how unnecessary Gateway is, and how that boondoggle actually slows down our effort to return to the Moon. This is great news, for several reasons. First it shows that Boeing, one of the old big contractors that historically has depended on government dollars, is now publicly stating that it is not in favor of Gateway. This in turn makes it more politically acceptable for politicians to take this position. Expect more public advocacy against building Gateway.

Second, it shows that Boeing is trying to sell SLS. It wants Congress to appropriate more launches, and by showing Congress a cheaper way to use it the company is hoping legislators will buy into their proposal. SLS might be an exceedingly expensive rocket, but Gateway only makes it worse. Boeing is showing the world that there is a better and cheaper way to do things.

This also suggests that Boeing is recognizing the competition coming from SpaceX and others that might kill SLS, and is now trying to make SLS more competitive. While I am not a fan of SLS, if this proposal indicates an effort by Boeing is finally to make SLS more efficient and affordable I can only celebrate. The rocket has capabilities that are unique, and if its cost can be reduced in any way that can only benefit the U.S. effort to compete in the exploration and settlement of the solar system.

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Boeing & NASA declare pad abort test a success

8:44 am

According to the NASA press release for yesterday pad abort test of Boeing’s Starliner capsule, the test was a success even though one of three main parachutes did not deploy successfully.

A pitcharound maneuver rotated the spacecraft into position for landing as it neared its peak altitude of approximately 4,500 feet. Two of three Starliner’s main parachutes deployed just under half a minute into the test, and the service module separated from the crew module a few seconds later. Although designed with three parachutes, two opening successfully is acceptable for the test parameters and crew safety. After one minute, the heat shield was released and airbags inflated, and the Starliner eased to the ground beneath its parachutes.

All reports say that this parachute issue will not effect the December 17 planned launch of the first unmanned orbital flight to ISS.

I find NASA’s reaction to this anomaly fascinating. Previously the agency repeatedly made a very big deal about the slightest anomaly by both Boeing and SpaceX on any test or procedure. While the agency’s response to these problems could have been reasonably justified, the caution it sometimes exhibited, often causing significant delays that might have been avoidable, was somewhat disturbing, especially when contrasted with the agency’s willingness to accept far more serious issues in connection with SLS and Orion.

Now however, the agency has no problem with the failure of one parachute to deploy during this test. While I actually agree with this response, the contrast is interesting and suggests to me that politics and deadlines (with the Russian Soyuz contract running out) are finally exerting some influence over NASA’s safety people. I suspect it has been made clear to them that unless something really seriously goes wrong, as long as the tests would have resulted in living astronauts, the safety bureaucrats had better not stand in the way of progress.

If so, this is very good news. It means that, assuming nothing really goes wrong with the remaining tests, the first manned missions are finally going to occur next year, relatively early in the year.

Posted at the Hayabusa-2/OSIRIS-REx asteroid conference in Tucson this week.

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Boeing completes Starliner pad abort test

8:32 am

Embedded below the fold is the video of today’s Starliner pad abort test, cued up to just before launch. While the capsule landed safely, it appears that one of it’s parachutes deploy improperly. If so, this probably means Boeing will not be able to launch the unmanned demo flight to ISS on December 17.

No one during the podcast mentioned this fact, so it could mean that they considered the landing a success regardless. It is even possible that they planned it with only two chutes. Or it could be the corporate culture at Boeing, similar to the culture in the Soviet Union, to avoid mentioning non-obvious problems to the public in order to make believe all is well. We will have to wait and see.

UPDATE: More information here on the failure of one chute:

Video of the test appeared to show all three chutes deploy, but only two remained attached to Starliner – a significant issue that will have to be investigated and evaluated.

Hat tip to reader Col. Beausabre for the link to the video.
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