Tag: Orion

SLS dress rehearsal countdown ends at T-29 seconds

7:47 pm

NASA’s fourth attempt to complete a full dress rehearsal countdown of its giant SLS rocket today ended at T-29 seconds, just short of the complete countdown.

It appears the countdown had one issue — a hydrogen fuel leak at the point where the umbilical fuel line attaches to the rocket — that mission control decided to ignore (or “mask” to use their word) so that they could proceed into the count as far as possible. It was this decision however that caused the two-hour delay in the countdown. They then resumed the countdown at T-10 minutes, the beginning of terminal count.

During the terminal count, the teams performed several critical operations that must be accomplished for launch including switching control from the ground launch sequencer to the automated launch sequencer controlled by the rocket’s flight software, and important step that the team wanted to accomplish.

NASA will hold a press conference tomorrow at 11 am (Eastern) to discuss the results of this dress rehearsal. While the leak is concerning, I expect NASA to decide that this dress rehearsal was a success, that they will roll the rocket back to the vehicle assembly building where they will fix this problem, after which the agency will declare the rocket ready to launch by the end of August.

While risky, doing otherwise likely raises other risks. If they decide to do another dress rehearsal the launch faces more delays. And waiting much longer continues to increase the danger that the solid rocket side boosters will not function as intended because they have been stacked almost a year longer than their accepted use-by date.

If this turns out to be the plan, expect the actual launch countdown to be as plagued with issues and delays and scrubs. NASA has yet to demonstrate it can do this smoothly with no problems. Worse, this level of mediocre performance has been par for the course for this entire SLS program.

If that launch should go smoothly it will be a welcome and unprecedented event.

27 comments

SLS dress rehearsal countdown continues, though T-0 delayed two hours

9:33 am

The SLS dress rehearsal countdown is proceeding today as planned, though the countdown’s end at T-0 is now 4:38 pm (eastern), two hours later than previously announced.

Apparently they have delayed T-0 from the beginning of the two-hour simulated launch window to its end. This decision so early in the count suggests the launch team wants to give itself extra time either to deal with some issue that has come up that they haven’t told us about yet, or to give themselves more time in case some issue should come up.

2 comments

SLS dress rehearsal countdown begins

10:07 am

NASA engineers began their fourth attempt to complete a full dress rehearsal countdown of the SLS rocket yesterday, with everything proceeding so far as planned.

Overnight, engineers powered up the Orion spacecraft and the Space Launch System’s core stage. Teams also configured several systems on the ground, rocket, and spacecraft and performed activities to prepare umbilicals that connect the rocket and spacecraft to the mobile launcher and are used to provide power, communications, coolant, and propellant.

Actual fueling begins tomorrow, when the countdown is supposed to conclude at T-0 at 2:40 pm (Eastern).

NASA live stream is available here.

7 comments

SLS dress rehearsal countdown set for June 20th with launch delayed again

9:28 am

According to NASA officials, the next attempt to complete a dress rehearsal countdown for its SLS rocket will take place on June 20, 2022, with the earliest date an actual launch can occur delayed again, and now set at best for an August 23 to September 6 window.

The article also notes that during a different press conference, NASA administrator Bill Nelson hinted that “there could be slips” in the present target date of ‘2025 for landing humans on the Moon.

Ya think? I guarantee that NASA will not land humans on the Moon in ’25, at least not using SLS. Based on all the issues confronting SLS, as well as NASA’s normal way of doing things, this mission will certainly slip at least one to two more years. And I am being very very very very optimistic.

We must also note that when first proposed by Bush Jr. in 2004, he predicted a NASA manned lunar landing by 2015, which means this launch will be at least one decade behind schedule, with it more likely being later than that.

But then, I can hear our glorious president yelling at me for complaining. “C’mon man! What’s a decade or two when you’re scheduling something important?”

12 comments

SLS next dress rehearsal countdown scheduled for June 19th

8:44 am

NASA has now scheduled the next dress rehearsal countdown for its SLS rocket for around June 19th, with the rocket beginning its trip to the launch site on June 6th.

It appears the issues that prevented the completion of the dress rehearsal in April have all been addressed:

While inside the Vehicle Assembly Building (VAB), teams completed several major objectives, including assessing the liquid hydrogen system leak at the tail service mast umbilical, replacing the interim cryogenic propulsion stage (ICPS) gaseous helium system check valve and support hardware, and modifying the ICPS umbilical purge boots. The addition of hazardous gas detectors above the upper stage allows for additional visibility into any potential leaks during cryogenic operations.

Other than the rollout on June 6th, all future dates remain flexible, depending on what happens step-by-step.

Leave a comment

NASA announces new possible launch dates for first SLS launch

10:13 am

NASA on May 16th announced the new possible launch dates for first SLS launch, outlining potential launch windows through the first half of 2023, with the first at the end of July 2022.

The calendar of launch windows through June of ’23 can be viewed here [pdf].

The July 26th to August 10th window is the one the agency is clearly targeting for that first launch, but it will not confirm this until after SLS successfully completes the next dress rehearsal countdown attempt in June. That the agency is now showing us potential launch dates in ’23 also suggests it is anticipating the possibility the launch could be delayed that much, especially if it determines it must replace the SLS’s two solid rocket boosters because they have been stacked unused for too long.

SLS was initially planned for a launch in 2015. It is now seven-plus years behind schedule, which is how long it took SpaceX to go from a blank sheet of paper to launching its Falcon Heavy for the first time.

3 comments

SLS launch delayed until August, at the earliest

9:34 am

In describing its plans for doing a second dress rehearsal countdown of its SLS rocket in June, NASA officials yesterday noted that they have delayed the actual launch until an August launch window so they will have time to do a third dress rehearsal before that launch.

But Free warned the issues are complex and it’s possible more than one tanking test will be required to thoroughly test the complex systems in the SLS rocket and their interaction with the ground systems that provide propellants, power and other critical elements. He said the August launch windows would “allow us to do two wet dress rehearsal attempts if we need them.”

“We are optimistic that we only need one more based on everything we’ve been able to do thus far to fine tune our tanking procedures,” he said. “But we also want to be realistic and upfront with you that it may take more than one attempt to get the procedures where we need them.”

According to this SpacePolicyOnline report, NASA has also mapped out additional launch windows for September through December.

In reviewing every news story about yesterday’s press conference, I could not find any that asked the agency about the status of SLS’s two solid rocket strap-on boosters. Both have now been stacked for more than seventeen months, and by August will have been stacked for twenty months, eight months past NASA’s use-by rule of one year. Either the past rules were too conservative, or NASA is simply ignoring the possibility that those boosters might no longer be viable. In either case, it is disappointing no reporter asked about this.

7 comments

NASA to conduct second SLS launch dress rehearsal in June

9:47 am

In announcing a press conference later today about the status of NASA’s SLS rocket, the agency revealed it now plans to conduct a second SLS launch dress rehearsal in June.

NASA’s SLS rocket and Orion spacecraft arrived back at Kennedy’s Vehicle Assembly Building April 26 after a 10-hour journey from launch pad 39B. Since their arrival, teams have worked to replace a faulty upper stage check valve and repair a small leak within the tail service mast umbilical ground plate housing. The teams also have been performing additional checkouts while the spaceport’s supplier of gaseous nitrogen makes upgrades to their pipeline configuration to support Artemis I activities.

We will likely find out NASA’s new launch schedule for the rocket today.

4 comments

SLS rocket rolled back to VAB

9:13 am

NASA’s SLS rocket has now been rolled back to the vehicle assembly building (VAB) so that engineers can assess the various problems that prevented the agency from completing a full dress rehearsal countdown last week.

Over the next several days, the team will extend the work platforms to allow access to SLS and Orion. In the coming weeks, teams will work on replacing a faulty upper stage check valve and a small leak within the tail service mast umbilical ground plate housing, and perform additional checkouts before returning to the launch pad for the next wet dress rehearsal attempt.

More details about these problems can be found here.

The bottom line is that these engineering fixes are certain to take at least two months to fix. Then NASA must decide what next to do. If it decides to redo the dress rehearsal countdown, then an actual launch cannot happen sooner than July, and only if they proceed directly to launch after completing the rehearsal. If the rocket is rolled back to the VAB after the next rehearsal the launch will be delayed further, into August or September.

And all that assumes the next rehearsal goes perfect, something that seems unlikely based on what has happened so far.

The delays are a problem because the first stage’s two strap-on solid rocket boosters are already well past their “use-by” date of January ’22. The possibility that NASA will have to unstack this rocket and replace these boosters is growing. If that happens the launch cannot occur sooner than early ’23, if then.

Worse, these delays cause all other subsequent SLS launches to be delayed as well. Right now the manned mission to the Moon, presently scheduled for ’25, is likely going to be pushed back to ’26.

11 comments

SLS dress rehearsal begins, with press coverage limited by NASA

5:56 pm

NASA today began the two-day-long “wet dress rehearsal” countdown of its first SLS rocket, with T-0 expected to occur at 2:40 pm (Eastern) on April 3rd.

The article at the link provides all the information you could want about this rocket, which is now about seven years behind schedule and having a cost so far about $25 billion. This quote however tells us much about the mentality at NASA:

But much of the test will happen without independent press coverage. NASA plans to provide sanctioned updates on the two-day dress rehearsal via the agency’s website and social media accounts, but news media representatives are not being permitted to listen to the countdown activities.

NASA has cited security and export control restrictions for the move. Numerous media representatives requested access to the SLS countdown audio for the wet dress rehearsal. Launch countdown audio feeds for other U.S. rockets, including those developed by private companies and hauling sensitive U.S. military satellites into orbit, are widely available to the news media and the public.

…NASA plans to release only text updates through the weekend. NASA TV will not be airing any live commentary for the final hours of the practice countdown. The agency’s television channel has previously provided live coverage of similar events, such as space shuttle tanking tests. [emphasis mine]

NASA reasons for not allowing anyone to listen to its audio feed — “security and export control restrictions” — is an utter lie. The real reason is that NASA fears the public’s reaction should anything not go exactly as planned. By blocking access to the audio feed, they can hide any faux pas.

NASA’s fear of course is misplaced. This is a test. No one will be surprised or outraged if it doesn’t go perfectly. Better to be open and up front than try to hide problems, because eventually those problems will be revealed and the cover-up will do far more harm to NASA’s reputation than the problems themselves.

The many new private rocket companies, SpaceX, Rocket Lab, Astra, Virgin Orbit, understand this, which is why they all make their primary countdown audio feeds available, though of course they almost certainly have secondary private feeds where engineers can speak more freely. Similarly, NASA did the same in the 1960s, and then during the entire shuttle program.

Now however “export control restrictions” and “security” requires them to be secretive? It is to laugh.

10 comments

SLS arrives at launch site

8:43 am

NASA’s SLS rocket finally arrived at its launch site early this morning after an 11 hour journey on its mobile launcher from the Vehicle Assembly Building (VAB), in preparation for a dress rehearsal countdown on April 3, 2022.

The approximately two-day test will demonstrate the team’s ability to load cryogenic, or super-cold, propellants into the rocket, conduct a launch countdown, and practice safely removing propellants at the launch pad. After wet dress rehearsal, engineers will roll the rocket and spacecraft back to the Vehicle Assembly Building for final checkouts before launch.

The launch is presently scheduled for late May, but we must not be surprised if it is delayed to June, or July.

One comment

NASA IG: SLS/Orion cost per launch equals $4.1 billion and is “unsustainable”

12:40 am

The real cost of SLS and Orion

At a House hearing today the NASA Inspector General Paul Martin stated unequivocally that the cost of NASA’s SLS rocket, Orion capsule, and the associated ground systems is about $4.1 billion per launch, which made the entire program, in his words, “unsustainable.”

Appearing before a House Science Committee hearing on NASA’s Artemis program, Martin revealed the operational costs of the big rocket and spacecraft for the first time. Moreover, he took aim at NASA and particularly its large aerospace contractors for their “very poor” performance in developing these vehicles.

Martin said that the operational costs alone for a single Artemis launch—for just the rocket, Orion spacecraft, and ground systems—will total $4.1 billion. This is, he said, “a price tag that strikes us as unsustainable.” With this comment, Martin essentially threw down his gauntlet and said NASA cannot have a meaningful exploration program based around SLS and Orion at this cost.

Martin’s testimony confirms what was contained in his November 2021 report, from which I took the graphic above. The article at the link details at length Martin’s testimony today, which was amazingly harsh. He also said that

NASA is obscuring costs that it is spending on the Artemis program and that, in aggregate, his office believes NASA will spend $93 billion from 2012 to 2025 on the Artemis program. “Without NASA fully accounting for and accurately reporting the overall costs of current and future Artemis missions, it will be much more difficult for Congress and the administration to make informed decisions about NASA’s long-term funding needs—a key to making Artemis a sustainable venture,” Martin said.

Martin has merely confirmed what I have been writing now for more than a decade, and documented at great length in my 2017 policy paper, Capitalism in Space. In fact, let me quote from one of my earliest essays on this subject on Behind the Black, from 2011:
» Read more

18 comments

SLS launch delayed again

8:54 am

As expected, NASA announced yesterday that it will be unable to launch its SLS rocket on its first unmanned test flight in April, as the agency had hoped, and is now evaluating a May launch date instead.

“April is not a possibility. We’re still evaluating the tail end of May,” said Tom Whitmeyer, NASA’s deputy associate administrator for exploration systems development. “But I want to be really careful once again, being straightforward with you. You know, we really need to get through this next few weeks here, see how we’re doing.”

The next possible windows for launch are from May 7-21, June 6-16 and June 29-July 12.

March 16th is still being targeted for the rocket’s full launch countdown dress rehearsal. Since the agency has said it will need about a month to assess the results of that dress rehearsal, the May launch window is exceedingly unlikely. Based on the slow pace NASA has set throughout this entire project, I predict that the launch will not occur before June, with the excellent chance it will be delayed to the summer. And this is assuming the dress rehearsal goes perfectly.

6 comments

Update on SLS: Still aiming for very unlikely March launch

9:20 am

A detailed update on the work being done by NASA and Boeing engineers to prepare SLS for its first unmanned test launch suggests that though a March launch is still the target, it is likely to be delayed.

The update at the link is very thorough, and outlines a large number of tests that need to be done to get this very cumbersome and complicated rocket ready for launch. They are just about done with the prep work for the core stage, and are now shifting to final testing of the upper stage, followed by some countdown sequence testing and a test of the flight termination system. In addition there are a number of other tests they wish to perform, all of which will take time.

Once these are done they will be ready to roll the rocket out to the launchpad for a final dress rehearsal countdown — dubbed the Wet Dress Rehearsal (WDR), now scheduled for mid- to late-February.

NASA will not set a launch date until after the WDR is completed and they can factor in any additional tasks with already-known work. “We’ve continually said that until we get through WDR we won’t set a launch date, so us getting out in mid-February for WDR allows them to look at March and April as opportunities,” Lanham said.

“I really can’t put my finger on it again until we come back from WDR and see if we have any issues there that we’ve got to go correct.” After the WDR test, the vehicle and Mobile Launcher will be rolled back to the VAB for final pre-launch maintenance and servicing.

Some have said the earliest realistic launch date is May, with the mid-summer more likely. We shall have to wait and see.

5 comments

Engineers replace engine controller on SLS core; launch to be delayed

9:12 am

Engineers have successfully replaced the failed engine controller on the core stage of NASA’s SLS rocket.

Last week engineers and technicians successfully removed and replaced an engine controller from one of four RS-25 engines after the team identified an issue during a power-up test of the rocket’s core stage. Engineers are now performing standard engine controller diagnostic tests and check-outs, including controller power-up and flight software load. Subsequently, the team will work to complete all remaining SLS pre-flight diagnostic tests and hardware closeouts in advance of a mid-February rollout for a wet dress rehearsal in late February. NASA will set a target launch date after a successful wet dress rehearsal test.

The official schedule still lists the launch for February, but NASA has already admitted this is now impossible. Once they complete the wet dress rehearsal on the launchpad they will have to roll the rocket back into the Vehicle Assembly Building to do further tests. While it remains possible for NASA to meet an April launch window, more likely the agency will push back to windows during the summer.

Thus, the race between SLS and Starship for completing the first orbital flight remains neck-and-neck. Starship could launch this spring, but it faces an uncertain schedule determined not by SpaceX but by the bureaucracy in the federal government, which is reviewing the FAA’s environment reassessment for the Boca Chica launch site and really has no requirement to meet any schedule at all. The FAA says it plans to approve the reassessment by the end of February, but that is simply made up deadline. It could revise it at will at any time.

NASA meanwhile is still pushing to launch SLS in April, but this launch date is entirely unrealistic. Expect NASA to announce a new target date sometime in the summer in the coming weeks.

Leave a comment

A detailed review of SLS’s present launch status

10:28 am

Link here. The article provides a detailed look at the engine controllers in the former shuttle engines that SLS is using on its core first stage, including some details about the failed unit and the issues involved in replacing it.

I found this historical data in the article most interesting:

The first attempt to launch Orbiter Atlantis and the STS-43 Shuttle vehicle was scrubbed before dawn on July 24, 1991, when the primary computer, DCU A, failed while propellants were being used loaded into the External Tank. … As a result, the launch was scrubbed to allow replacement of the controller, and the launch was rescheduled for August 1, 1991. The failure analysis of the controller revealed a broken blind lap solder joint connection of the bit jumper to the half stack, which is not a generic design problem.”

According to contemporaneous Shuttle Status Reports issued by NASA Public Affairs at KSC in late July, 1991, after the launch was scrubbed and the External Tank was drained and inerted, access to the engine area for maintenance was established on July 26. The broken engine controller was removed, and a new one was installed on July 27, followed by testing to verify the new controller on July 28; the three-day countdown was started over from the top on July 29 for the next launch attempt on the morning of August 1.

It took NASA less than a week to replace an engine controller in 1991. Now, it appears it might take NASA several months, including testing, to do the same thing on SLS. Moreover, the article suggests that there are other subcontractors and organizations (such as the range safety) that are also having trouble being ready for the presently scheduled mid-February launch.

All in all, this report suggests that SLS will not launch in February, will be delayed until April, with a strong chance that even that April date might not be met.

The report also illustrates the sluggish manner in which NASA operates today. Nothing is done with any speed. No task is done in one day if it can take a week. This is bad management, and also a very dangerous way to operate, as it actually encourages sloppiness because no one is under any pressure to work hard. The result has been endless niggling failures, each of which delays things interminably.

10 comments

SLS likely facing another launch delay

9:45 am

Engineers for NASA’s SLS rocket have determined that they need to replace the flight controller on one of the engines in the rocket’s core stage, an action that will likely force a delay from the presently scheduled February launch date.

After performing a series of inspections and troubleshooting, engineers determined the best course of action is to replace the engine controller, returning the rocket to full functionality and redundancy while continuing to investigate and identify a root cause. NASA is developing a plan and updated schedule to replace the engine controller while continuing integrated testing and reviewing launch opportunities in March and April.

It appears they hope to make this change-out quickly and only have to delay one or two months, though at the moment it is also unclear this will be possible.

15 comments

More delays for SLS?

8:32 am

According to a report today at Ars Technica, there is an engine issue with the SLS rocket presently being prepared for a February unmanned test flight that could delay the launch for months.

The info is buried at the very bottom of the article:

There’s an issue with an SLS engine controller. This past weekend, rumors emerged about a problem with the controller for one of the four RS-25 engines that power the Space Launch System. NASA has not officially commented, but Aviation Week’s Irene Klotz spoke with Aerojet’s RS-25 program manager, Jeff Zotti. Troubleshooting the problem began on November 22, Aviation Week reported.

Schedule impacts yet to be determined … If necessary, “replacing a line or a component … we’re probably talking about multiple days. Replacing an engine, we’re probably talking about multiple weeks,” Zotti told the publication. “On top of that, we have to assess what that does and how that affects the vehicle and the integration activities that are going on,” he added. All of that must be factored into a potential delay of the launch, presently scheduled for February 12. A summer launch for the SLS now seems far more likely than spring.

Any delay beyond March poses a very serious and complex problem. The solid rocket strap-ons have a one year life expectancy once stacked, and both were initially stacked about a year ago. The February launch pushes that life span somewhat. A longer delay is more than can be waived.

14 comments

NASA IG: Artemis manned lunar landing will likely not happen in ’25

11:01 am

IG's estimate of SLS's per launch cost

According to a new NASA inspector general report released today [pdf], because of numerous technical, budgetary, and management issues, the planned Artemis manned lunar landing now set for 2025 is likely to be delayed several years beyond that date. From the report’s summary:

NASA’s three initial Artemis missions, designed to culminate in a crewed lunar landing, face varying degrees of technical difficulties and delays heightened by the COVID-19 pandemic and weather events that will push launch schedules from months to years past the Agency’s current goals. With Artemis I mission elements now being integrated and tested at Kennedy Space Center, we estimate NASA will be ready to launch by summer 2022 rather than November 2021 as planned. Although Artemis II is scheduled to launch in late 2023, we project that it will be delayed until at least mid-2024 due to the mission’s reuse of Orion components from Artemis I. … Given the time needed to develop and fully test [SpaceX’s Starship lunar lander] and new spacesuits, we project NASA will exceed its current timetable for landing humans on the Moon in late 2024 by several years. [emphasis mine]

Gosh, it sure didn’t long for my prediction from last week — that the new target date of ’25 was garbage — to come true.

Today’s report also states that it does not expect the first test launch of SLS to occur in February ’22, as NASA presently predicts, but later, in the summer of ’22. It then notes that the next SLS launch, meant to be the first manned launch of SLS and Orion and presently scheduled for late ’23, will almost certainly be delayed to mid-’24. And that’s assuming all goes well on the first unmanned test flight.

While the report lauds SpaceX’s fast development pace, it also does not have strong confidence in SpaceX’s ability to get its Starship lunar lander ready on time, and believes that NASA could see its completion occurring from three to four years later than planned.

The report also confirms an August 2021 inspector general report about NASA’s failed program to develop lunar spacesuits, stating that its delays make a ’24 lunar landing impossible.

The report states that Gateway is well behind schedule, and will likely not be operational until ’26, at the earliest. While the present plan for that first manned lunar landing does not require Gateway, Gateway’s delays and cost overruns impact the overall program.

Finally, the report firmly states that the per launch cost of SLS is $4.1 billion, a price that will make any robust lunar exploration program utterly unsustainable.

Before the arrival of Trump, NASA’s original plan for SLS and Gateway called for a manned lunar landing in 2028. The Trump administration attempted to push NASA to get it done by ’24. This inspector general report suggests to me that this push effort was largely wasted, that NASA’s Artemis program will likely continue to have repeated delays, announced piecemeal in small chunks. This has been the public relations strategy of NASA throughout its entire SLS program. They announce a target date and then slowly over time delay it in small amounts to hide the fact that the real delay is many years.

Expect this same pattern with the manned lunar landing mission. They announce a delay of one year from ’24 to ’25. After a year they will then announce another delay to ’26. A year later another delay to ’27. And so forth.

15 comments

NASA admits manned lunar landing can’t happen before ’25

3:37 pm

NASA administrator Bill Nelson admitted today that the goal of landing Americans back on the Moon by 2024 was impossible, and that the agency has now delayed that target date one year to 2025.

Nelson attempted to blame the delay on Blue Origin’s lawsuit against NASA for its award of the manned lunar lander contract to SpaceX.

He blamed the shifting timeline on a lawsuit over the agency’s moon lander, to be built by SpaceX, and delays with NASA’s Orion capsule, which is to fly astronauts to lunar orbit. “We’ve lost nearly seven months in litigation, and that likely has pushed the first human landing likely to no earlier than 2025,” Mr. Nelson said, adding that NASA will need to have more detailed discussions with SpaceX to set a more specific timeline.

This however is a bald-faced lie. The Trump 2024 deadline was never realistic. Moreover, delays in SLS and Orion have been continuous and ongoing for years, all of which made a ’24 landing quite difficult and if attempted extremely unsafe. Even as it is, trying this mission by ’25 is risky, especially if it depends on SLS. Moreover, as the article notes, how SLS, Orion, and SpaceX’s Starship will team up to get this mission — designed by a committee — to and from the Moon remains exceedingly unclear.

With great confidence I predict that if the lunar mission depends on SLS in any manner, it will not launch in ’25 either.

9 comments

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.

11 comments

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.

One comment

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.

4 comments

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.

5 comments

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.

11 comments

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.

12 comments

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.

8 comments

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.

6 comments
1 2 3 4 5 … 9