Tag: Orion

NASA sets target launch date for SLS in February ’22

2:51 pm

As expected, the first unmanned demo launch of NASA’s SLS rocket has now been scheduled for a February launch window.

The first launch window for NASA’s Artemis I mission opens on February 12 at 5:56 p.m. EDT – yes, we have dates and times for this long-awaited mission. The February window lasts two weeks, with the first half of that window allowing a six-week mission and a four-week mission on the back half.

If for some reason NASA cannot launch in that firs window, they have back up windows in March and April. These windows exist because the plan is to send the Orion capsule to orbit the Moon from four to six weeks, and then return to Earth.

The announcement came the day after NASA had finally stacked the Orion capsule on top of the SLS rocket, essentially completing the rocket’s assembly.

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NASA awards Aerojet Rocketdyne contract to build 20 Orion main engines

10:21 am

NASA announced yesterday that it has awarded Aerojet Rocketdyne the contract to build twenty Orion main engines for capsules on missions running through 2032, with the first to be used on the seventh Artemis launch..

This engine is the one that Orion will use to enter and leave lunar orbit.

Based on the pace that NASA expects to launch SLS, once per year, I expect the last engine in this contract will fly in 2048, not 2032, since it will take about 27 years to put that many Orions into space after SLS’s first launch, expected sometime in the next five months.

In other words, this is a contract to keep the jobs at Aerojet Rocketdyne in existence for the next three decades, even if that company’s engineers build little and accomplish less. Nice welfare work I must say.

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GAO finds more NASA cost overruns in Webb, SLS, and Orion

2:18 pm

GAO graph documenting NASA's big project delays and cost overruns

The annual Government Accountability Office’s (GAO) report on major NASA-led programs has found that the cost overruns and scheduling problems it has documented now for years continued in 2020.

You can obtain the report here. The graph to the left, from the report, summarizes the data quite succinctly.

The cumulative cost overrun of 20 major programs in development, defined as those with total costs of at least $250 million, grew to more than $9.6 billion in the report. Three programs — the James Webb Space Telescope, Orion spacecraft and Space Launch System — account for $8 billion of that total, including $4.4 billion for JWST alone.

SLS and the Exploration Ground Systems program accounted for effectively all of the $1.1 billion in overruns in 2020. … SLS alone accounted for nearly $990 million in cost increases. About two-thirds of that increase came from NASA adopting a GAO recommendation to lower the original baseline cost estimate for SLS to properly account for work that had been shifted to later phases of the program.

The report also documented almost 20 years of cumulative delays, with Webb leading the way with delays of more than seven years. The new report added 37 more months of delays during the last year.

The report, and NASA, laid the blame for many of the more recent delays and cost overruns on last year’s COVID epidemic, but if so those delays were imposed by choice, not necessity, considering how both China and SpaceX moved forward without any delays during the same time period. In reporting on NASA for the last three decades I have found it willing to initiate long delays at the drop of a hat, sometimes for reasons, such as a storm that causes some minor damage, that do not justify either the delay or its length. The COVID panic was just another example of this.

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ESA contracts Airbus to build three more Orion service modules

11:38 am

The European Space Agency (ESA) late last week announced that it has awarded Airbus a contract to build three more service modules for NASA’s Orion capsule.

This new contract supplements the existing contract that already has Airbus building three service modules. With six service modules in the pipeline, the ESA is signaling that it is very confident the Artemis program will continue.

The key question remains: Will it continue with SLS as the rocket of choice? Right now there simply aren’t the funds to build six SLS rockets. Congress has only funded two. Moreover, the pace of construction for SLS means that, if funded, it will likely take a decade at least for it to launch these six capsule/service modules. Since SpaceX’s Starship/Super Heavy will likely be operational in about half that time, and will also be capable of much more for far less, I suspect that if these additional Orion capsules get launched, they will do so on something other than SLS.

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NASA to do another static fire test of SLS’s core stage

10:52 pm

NASA has now scheduled a second static fire test of the core stage of its SLS rocket, tentatively scheduled for the fourth week in February.

The first test, planned to last eight minutes, shut down after only one minute when the stage’s computers decided the parameters on engine #2 were outside their conservative margins. That burn also had a sensor issue with its fourth engine.

Conducting a second hot fire test will allow the team to repeat operations from the first hot fire test and obtain data on how the core stage and the engines perform over a longer period that simulates more activities during the rocket’s launch and ascent. To prepare for the second hot fire test, the team is continuing to analyze data from the first test, drying and refurbishing the engines, and making minor thermal protection system repairs. They are also updating conservative control logic parameters that resulted in the flight computer ending the first hot fire test earlier than planned. The team has already repaired the faulty electrical harness which resulted in a notification of a Major Component Failure on Engine 4. This instrumentation issue did not affect the engine’s performance and did not contribute to ending the first test early.

Assuming this test is successful, they will then need a month to get the stage ready for shipment by barge to Cape Canaveral, where it will take several more months to get it assembled with its two strap-on solid rocket boosters, its upper stage, and the Orion capsule on top.

Right now the unmanned test flight into orbit of this entire rocket and Orion is set for November ’21. While NASA has not announced a delay, this additional static fire test puts significant pressure on that schedule.

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New Democrat head of House subcommittee covering NASA says he supports Artemis

9:32 am

The new Democrat head of the House appropriations subcommittee that covers NASA funding, Matt Cartwright (D-Pennsylvania), appears to support the Artemis program established during the Trump administration, though he has also indicated that he does not favor the timeline imposed by Trump to land a manned mission on the Moon by ’24.

Cartwright’s embrace of Artemis during [a] July 2020 webinar was a change from 2019 when he was one of several members reacting skeptically to a supplemental budget request from the Trump Administration after it unexpectedly accelerated the timeline for putting people back on the Moon from 2028 to 2024. He complained NASA did not even have a cost estimate for the entire effort, yet expected Congress to embrace it.

In 2018, he expressed concern about proposed cuts by the Trump Administration to NASA’s earth and space science activities especially climate programs and WFIRST (now the Roman Space Telescope). He urged NASA to follow the Decadal Surveys produced by the National Academies of Sciences, Engineering, and Medicine.

What his prior views presage now that he chairs the subcommittee remains to be seen. It is widely expected the 2024 deadline will be pushed back, perhaps to the 2028 date NASA originally planned, but Cartwright appears favorably disposed towards the agency overall.

Delaying the Moon landing by SLS forever is the real goal, so the jobs program can be extended without any risks. To actually fly might result in a failure, something that no politician wants.

In the end it will not be SLS anyway that gets Americans back to the Moon. It costs too much and is badly designed. It might fly once or twice, but after that Congress will drop it while keeping Artemis, albeit in a very different form. Instead of having NASA design and build things, the new Artemis will be built by the many companies who were awarded fixed priced contracts during the Trump administration to develop their own hardware as fast as possible and as inexpensively as possible.

The distinction is important, because the latter is more likely to succeed in a reasonable amount of time.

At the same time, with Congress on board and a Democrat in the White House, it is not surprising that the policy is immediately shifting to a slower timeline. Can’t get this done too fast! I must also add that 2028 was not NASA’s original date for its return to the Moon. Before the Trump administration took control of Artemis, NASA had wanted to complete Gateway first, which based on all of NASA’s previous schedules would have pushed a lunar landing into the 2030s. Do not be surprised if this sluggish schedule is reinstated.

In fact, with the present incompetents in charge in Washington, I fully expect China to own the Moon, while U.S. politicians brainlessly dither on how to spend pork.

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Another SLS core stage abort during dress rehearsal

1:33 pm

NASA today revealed that engineers were forced on December 20th to abort at about T-5 minutes their second attempt to do a fueled dress rehearsal countdown in preparation for the full core stage static fire test.

[S]ources said the terminal countdown started at T-10 minutes and counting and ran down to T-4 minutes and 40 seconds where an unplanned hold occurred. … The criteria for how long it should take for a liquid hydrogen replenish valve to close was violated at that point in the countdown when the valve was commanded to the close position as a part of the process to pressurize the liquid hydrogen tank for engine firing. After holding at the T-4:40 point for a few minutes, teams decided the terminal countdown test couldn’t continue.

Vehicle safing and recycle sequences were then executed.

Although the countdown ran for over half of its intended duration, the early cutoff left several major milestones untested. With the countdown aborted at that point, the stage’s propellant tanks weren’t fully pressurized, the hydraulic Core Stage Auxiliary Power Units (CAPUs) were never started, the final RS-25 engine purge sequence was never run, and the vehicle power transfer didn’t occur.

NASA management is debating now whether they can proceed directly to the full core stage static fire test, where the core stage engine will fire for the full duration of a normal launch. It could be that they will decide to waive testing what was not tested on this last dress rehearsal.

If they delay the full test to do another dress rehearsal, they risk causing a delay in the fall launch of SLS, as they need a lot of time to disassemble, ship, and reassembly the stage in Florida. If they don’t delay, they risk either a failure during the full static fire test, or (even worse) a failure during that first launch.

Considering the number of nagging problems that have plagued this test program, it seems foolish to me to bypass any testing. They not only do not have enough data to really understand how to fuel the core stage reliably, they don’t even have a lot of practice doing the countdown itself. All this bodes ill when they try to launch later this year, especially if they decide to not work the kinks out now.

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NASA budget passed by Congress rejects ’24 lunar landing

9:09 am

No surprise: The NASA budget that was passed by Congress this week as part of a giant omnibus bill only gave NASA 25% of the requested funds the agency says it needs to develop a human lander required for an Artemis manned mission to the Moon by ’24.

Overall, NASA will receive $23.271 billion, almost $2 billion less than requested. Importantly for the Trump Administration’s Artemis program to return astronauts to the Moon by 2024, it provides only $850 million instead of $3.4 billion for Human Landing Systems.

…The Trump Administration requested a 12 percent increase for NASA in order to fund the Artemis program: $25.2 billion for FY2021 compared to the $22.9 billion it received in FY2020. While the goal of returning astronauts to the Moon has broad bipartisan support in Congress, the Trump deadline of 2024 — set because it would have been the end of his second term if he had been reelected — won lukewarm support at best from Republicans and none from Democrats who pointed to both budgetary and technical hurdles.

It was always clear that the Democrats were not going to cooperate with Trump to could get that lunar landing during his second term. Moreover, the real goal of Artemis is not space exploration, but distributing pork. Stretching out these missions so that they take many many years achieves that goal far better than a tight competitive schedule that gets things done. This is why SLS and Orion have been under construction, with no flights, for decades, even as SpaceX moves forward with Starship/Super Heavy in only a few years.

A Biden presidency actually increases the changes that Artemis will get better funding, but that funding will always be designed to stretch out the program for as long as possible. Our policymakers in Washington really do not care much for the interest of the nation. What they care about is their own power and aggrandizement.

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NASA decides to fly Orion with failed power unit

1:59 pm

Because a repair would delay the first SLS launch for months if not a year, NASA has decided to fly Orion on that November ’21 mission with failed electronics power unit.

In a Dec. 17 statement, NASA said it had decided to “use as is” one of eight power and data units (PDU) on the Orion spacecraft, which provide communications between the spacecraft’s computers and other components. One of two redundant channels in one of two communications cards in that PDU is not working.

…NASA, in its statement about deciding not to replace the PDU, did not go into details about the repair options, but said that the risks of damaging the spacecraft during the PDU repair outweighed any loss of data should the unit completely malfunction.

Engineers, the agency stated, “determined that due to the limited accessibility to this particular box, the degree of intrusiveness to the overall spacecraft systems, and other factors, the risk of collateral damage outweighed the risk associated with the loss of one leg of redundancy in a highly redundant system.”

“NASA has confidence in the health of the overall power and data system, which has been through thousands of hours of powered operations and testing,” the agency added, noting that the PDU in question was still “fully functional.”

Let’s then assess Orion. The contract was issued to Lockheed Martin in 2006. In the fourteen years since Congress has spent about $17 billion on this manned capsule. In that time it has flown once, during a test flight that was intended to test its heat shield, even though when that flight happened NASA had already decided that it was not going to use the heat shield design it was testing.

Orion’s second flight in November ’21 will be unmanned, but it will be flying with this failed unit. The next time it is supposed to fly will be in ’24, when NASA is hoping to send astronauts on a lunar landing missions. By that time NASA will have spent about $20 billion on Orion, and gotten two test capsules (both unrepresentative of the flight model) plus one manned mission.

Would you fly on this capsule under these circumstances? I wouldn’t, especially considering the non-track record of its rocket, SLS.

As the taxpayer, do you think you’ve gotten your money’s worth from this capsule? I don’t. I think it has been an ungodly waste of money, and a demonstration of the incapability of NASA and the big space contractors Boeing and Lockheed Martin of getting anything accomplished. Depend on them, and you will never go anywhere.

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An update on the testing of SLS’s core stage

9:38 am

Link here. The article provides more information on the temperature issue that caused the seventh of eight fueling tests of the core stage to abort early.

The temperature issue arose when NASA transferred superchilled liquid oxygen, to fuel the rocket, from a holding facility to the core stage of the SLS. This procedure has been modeled and verified before, Julie Bassler, SLS stages manager at Marshall, told reporters during the same teleconference. But this was the first time the transfer actually took place.

“We were actually just a few degrees different than what we wanted to see coming in,” she continued, but said the temperature must be precise during the initial phases of filling the tank. The requirement is minus 290.57 degrees Fahrenheit (minus 179.21 degrees Celsius.) But the liquid oxygen was slightly cooler, at minus 296.67 degrees Fahrenheit (minus 182.59 degrees Celsius).

“We filled up [the tank] just enough to pass the phase where we knew we weren’t going to be able to get the temperature to a level that was going to be acceptable to meet the requirement, and that’s when they caught us … in the testing,” Bassler continued.

Despite this issue, NASA still hopes to do the last core stage test, dubbed the Green Run, in the last week in December. During that static fire test they will fuel the core stage entirely and then fire its engines for the full duration of an actual launch — almost ten minutes. If all goes well they will then pack up the stage and ship it to Florida for the planned November unmanned test mission sending Orion around the Moon.

They have no schedule margins, however, because all the components of this very expensive and complex rocket need a lot of time to get anything done. The two solid rocket boosters that will be attached to the sides of the core stage only have a twelve month lifespan once assembled, and they are holding off assembling them pending this test. The core stage itself needs two months to be disassembled, and then two months to be reassembled in Florida. And there remain the issue of a failed power unit in the Orion capsule that could take four to twelve months to repair.

The article however had this telling quote, based on comments from a NASA official, about future launch procedures, that sent a chill up my spine:
» Read more

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New problem found on Orion that could delay its launch by a year

12:11 am

The failure of a power unit on the Orion capsule slated to fly on SLS’s first test flight late in ’21 could delay that test flight by as much as an additional year.

Replacing the PDU isn’t easy. The component is difficult to reach: it’s located inside an adapter that connects Orion to its service module — a cylindrical trunk that provides support, propulsion, and power for the capsule during its trip through space. To get to the PDU, Lockheed Martin could remove the Orion crew capsule from its service module, but it’s a lengthy process that could take up to a year. As many as nine months would be needed to take the vehicle apart and put it back together again, in addition to three months for subsequent testing, according to the presentation.

Lockheed has another option, but it’s never been done before and may carry extra risks, Lockheed Martin engineers acknowledge in their presentation. To do it, engineers would have to tunnel through the adapter’s exterior by removing some of the outer panels of the adapter to get to the PDU. The panels weren’t designed to be removed this way, but this scenario may only take up to four months to complete if engineers figure out a way to do it.

A third option is that Lockheed Martin and NASA could fly the Orion capsule as is. The PDU failed in such a way that it lost redundancy within the unit, so it can still function. But at a risk-averse agency like NASA, flying a vehicle without a backup plan is not exactly an attractive option. It’s still not clear what went wrong inside the unit, which was tested before it was installed on the spacecraft, according to a person familiar with the matter.

None of these options are good. The first two will certainly delay the planned November 2021 launch, which by the way is already four years behind schedule. The third will risk a failure of the mission, which though unmanned would certainly lead to further delays in the manned mission expected one or two years later.

That they don’t know why the unit failed and cannot fix it easily speaks very badly to the design of Orion and SLS. Compare this with SpaceX, which in the past month has demonstrated it can in only days switch out engines on both its commercial Falcon 9 rocket and its new next generation Starship rocket. Moreover, SpaceX has demonstrated repeatedly that once they identify an issue they move immediately to understand it and fix it.

With NASA, Orion, and Orion’s contractor Lockheed Martin, such flexibility and agility appears all but impossible. They have designed a monster that cannot be fixed easily, cannot launched quickly, and costs an ungodly amount of money.

I increasingly believe that Starship will reach orbit before SLS/Orion, even though the latter has been in development for almost three times longer, and will cost 25 times more.

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Senate fails to fully fund manned lander for Trump’s 2024 lunar mission

10:30 am

The Senate appropriations committee’s budget recommendations for NASA, released yesterday, has refused to fully fund the development of the manned lander needed for Trump’s 2024 lunar mission.

The Senate Appropriations Committee released its recommendations for all 12 FY2021 appropriations bills today. The Commerce-Justice-Science (CJS) bill provides NASA with $23.5 billion, $1.75 billion less than requested. The House-passed bill keeps the agency at its current level of $22.6 billion, so the final compromise likely will be somewhere in that range. NASA’s request for Human Landing Systems (HLS) for the Artemis program was particularly hard hit on both sides of Capitol Hill.

NASA had requested $3.4 billion for building the lunar lander in time for 2024. The House appropriated $628 million. Today’s Senate recommendation budgeted $1 billion. This practically guarantees that no manned lunar mission will happen by 2024.

None of this is a surprise. The politicians in Congress from both parties don’t really want to rush this program. For them it is better to stretch it out for as long as possible, spending mucho bucks in their states and districts. Nothing will be accomplished, but they will be able to tell their constituents they brought the jobs home.

Useless and empty jobs, but jobs nonetheless.

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