Tag: Starliner

Starliner unmanned demo flight likely delayed until ’22

9:20 am

Capitalism in space: The second Starliner unmanned demo flight, repeatedly delayed throughout ’21 due to scheduling and technical problems, is now likely to be delayed until next year.

Apparently, Boeing engineers have been unable to figure out why 13 of 64 valves on Starliner failed to function properly just hours before the last planned launch, causing the launch to be scrubbed.

The quality control systems at Boeing during this entire program have not shined. The capsule is now years behind schedule, and has been dogged by design and construction flaws — from software to parachutes to valves — that in the 21st century should not be problems any longer in building a manned spacecraft.

Like SpaceX and its Dragon capsule, Boeing owns Starliner and will be able to offer private citizens and companies flights on it once it is operational. These failures, however, will not be good for that future business. They make this spacecraft a far less appealing product when compared to the high quality of the engineering at SpaceX. Why would anyone risk their life on Starliner when they can buy a ticket on the apparently much more reliable Dragon?

In other words, Boeing has been doing terrible harm to its brand name with these problems. It needs to get them fixed, and fast.

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Boeing to return Starliner to factory

11:11 am

Capitalism in space: According to a Wall Street Journal story today, Boeing and NASA have decided to remove the Starliner capsule from the Atlas-5 rocket and return it to Boeing’s factory in order to do a more thorough inverstigation into the capsule’s failing valves.

This decision means that the launch of the second unmanned demo test flight of Starliner will not occur in August, and will likely be delayed several more months. NASA and Boeing just held a press conference in which they made this decision official. During that conference they said they think the moist environment at Kennedy might have caused corrosion in the valves, which caused them to stick.

I once again wonder if Boeing has any quality control systems at all. For such a serious problem — the failure of 13 valves out of 24 — to suddenly pop up just hours before launch, when they have been developing this capsule for years, and even had an extra year and a half to check the capsule out after the failures during the first unmanned demo flight in December 2019, is somewhat astonishing, and very disturbing.

Others will argue that problems like this can always appear unexpectedly in space hardware. I say hogwash. Boeing is not inventing something new with Starliner. This is a capsule, using heritage engineering first invented in the late 1950s. It should not be so hard to get this right.

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Starliner launch scrub: 13 of 24 of the capsule’s propulsion valves failed to work

9:23 am

It now appears that the launch scrub last week of Boeing’s Starliner second unmanned demo flight to ISS occurred because thirteen valves in the capsule’s propulsion valves all failed to open during prelaunch testing.

Over the weekend, the team made “positive progress,” a spokesperson said Monday, allowing the company to continue to plan for a launch this month. The company has found “no signs of damage or external corrosion,” Boeing said in a statement Monday. “Test teams are now applying mechanical, electrical and thermal techniques to prompt the valves open.” As a result, more than half of the valves “are now operating as designed,” it said, and work would continue on the others “in the days ahead.”

In a blog post, NASA said that “if all valve functionality can be restored and root cause identified, NASA will work with Boeing to determine a path to flight for the important uncrewed mission to the space station.” The earliest opportunity would come in mid-August, it said.

But Boeing still does not know what caused the valves to remain closed when they needed to be in the open position, and it is unclear how long determining that would take. As a result, some in the aerospace industry are skeptical the company could launch this month.

They have managed to get seven of those thirteen valves working again.

That 13 of 24 failed to function correct strongly suggests the problem isn’t random but is instead a fundamental design problem that needs to be identified prior to launch.

That such a problem has only been discovered now, during the launch countdown, does not reflect well on Boeing or its capsule. That the problem was not noticed in the year and a half delay caused by the software problems during the first unmanned demo flight in December 2019 makes this problem even more disturbing.

In fact, it is downright shocking. It makes one wonder about Boeing’s entire operation, considering the disastrous problems the company has also had with its commercial and military airplane projects in recent years. Does the company have no quality control systems in place, at all?

I truly hope Boeing gets this fixed and Starliner flying, but right now they need to fly a number of times, including reusing a capsule a few times, before I’d recommend anyone buying a ticket.

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Starliner launch scrubbed; no launch date yet set

8:32 am

For reasons that have not yet been revealed, ULA scrubbed today’s unmanned demo test flight of Boeing’s Starliner capsule just prior to launch, rescheduling the launch for tomorrow.

The launch tomorrow wiill occur at 12:57 am (Eastern).

UPDATE: It appears the scrub occurred because of a valve issue in the propulsion system of Boeing’s Starliner capsule.

“During pre-launch preparations for the uncrewed test flight of the CST-100 Starliner spacecraft, Boeing engineers monitoring the health and status of the vehicle detected unexpected valve position indications in the propulsion system,” the company said in a statement. “The issue was initially detected during check outs following yesterday’s electrical storms in the region of Kennedy Space Center.”

…The propulsion system valves in question are inside the Starliner’s service module, which has an array of rocket thrusters designed to propel the spacecraft away from its launcher during an in-flight emergency. Other thrusters on the service module are used for in-orbit maneuvers and spacecraft pointing control.

Boeing cannot afford more failures during this second demo flight. The company has been plagued with numerous debilitating technical failures during the past four years, from Starliner to its airlines. Right now the failure to get Starliner operational is losing them business in the emerging orbital tourist market. They need to get it working, and working reliably.

UPDATE: They have decided to cancel the launch plans for tomorrow, to roll the rocket back into the assembly building so they can do more tests on the capsule’s service module where the troublesome valves are.

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Nauka engines fire unexpectedly after docking; forces cancellation of Starliner launch

1:20 pm

The soap opera of the Nauka module to ISS became even more dramatic today when its engines fired unexpectedly after its docking, causing the station to shift in orbit and forcing Russian mission controllers to shut it down and fire other engines to return the station to its proper orbit.

Russia’s Roscosmos space agency attributed the issue to Nauka’s engines having to work with residual fuel in the craft, TASS news agency reported. “The process of transferring the Nauka module from flight mode to ‘docked with ISS’ mode is underway. Work is being carried out on the remaining fuel in the module,” Roscosmos was cited by TASS as saying.

It appears that because they needed to improvise the rendezvous using different engines, there is more fuel left over in Nauka than expected once it docked, and this needs to be vented safely. Somehow, instead of venting the module ignited the engines.

NASA has subsequently postponed tomorrow’s second unmanned demo launch of Boeing’s manned Starliner capsule until the agency has a clear understanding of the issue and has confirmed that Nauka’s presence is not a serious safety issue.

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Boeing and NASA set July 30th for 2nd unmanned Starliner demo mission

5:40 pm

Capitalism in space: Boeing and NASA today announced that they have now scheduled the second unmanned Starliner demo mission to ISS for July 30th.

In separate statements, the agency and the company said they were planning to launch the Starliner on a United Launch Alliance Atlas 5 at 2:53 p.m. Eastern July 30 on the Orbital Flight Test (OFT) 2 mission. A launch that day would allow the spacecraft to dock with the International Space Station on the evening of July 31.

The new launch date comes after NASA and Boeing completed an “integrated mission dress rehearsal” for the mission using a simulator at a Boeing facility in Houston. The five-day simulation covered activities starting 26 hours before launch and going through landing, including docking and undocking from the station.

Both Boeing and NASA are still hopeful that the first manned flight of Starliner can still take place before the end of this year. Whether it does or not will largely depend on how well things go on this unmanned demo flight.

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Boeing confirms next Starliner unmanned demo flight delayed until August

9:25 am

Capitalism in space: Boeing on April 17th confirmed what had already been rumored, that the second unmanned demo flight to ISS of Starliner, its manned capsule, has been delayed until August.

In a statement, Boeing said that the company and NASA are projecting the uncrewed Orbital Flight Test (OFT) 2 mission will take place in August or September. That date is “supported by a space station docking opportunity and the availability of the United Launch Alliance Atlas V rocket and Eastern Range.”

Boeing had been working toward a launch of OFT-2 in late March or early April. However, by early March, NASA officials acknowledged that was no longer likely because of delays from the replacement of avionics units on the spacecraft that were damaged by a power surge during ground tests, as well as power outages in the Houston area caused by a winter storm in February that interrupted software testing.

They still hope to make the first manned demo flight before the end of the year, assuming the summer unmanned flight goes as planned.

For Boeing, the sooner they get this capsule operational, the sooner it can start earning money by flying commercial flights. At the moment the delays have meant that SpaceX is getting all that business, with two private flights already scheduled and rumors that it will win a flight from the UAE as well. Furthermore, other commercial competitors are on the horizon, including both China and India.

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More delays to Boeing’s Starliner manned capsule schedule

9:52 am

Capitalism in space: Though no new launch date has been announced, both NASA and Boeing are now likely aiming for a summer launch of the second unmanned Starliner demo mission to ISS.

This is largely due to traffic at the International Space Station rather than the readiness of Starliner itself. Two NASA sources said the vehicle is “close” to being ready, with only a few small tests to certify the spacecraft for flight remaining. Starliner is therefore expected to be ready to fly by early summer.

The primary issue is the availability of space station docking ports fitted with an “international docking adapter,” which are used by SpaceX’s Crew Dragon, Cargo Dragon 2, and Starliner vehicles. There are presently two such ports on the station, and for NASA, the priority for access to these ports are crew rotations followed by supply missions. So the question becomes when the Starliner test flight can find an open slot on station.

It appears that they are now targeting the window of availability for either of those ports in the late July into August time period.

While this might be the main reason for this new delay, it also appears that there might be technical issues as well. In early March Boeing and NASA had announced that they were delaying this demo mission for the same scheduling reasons, but then they said they were targeting a May launch date, during a period after one manned Dragon mission had left in late April and before the next Dragon cargo mission arrived in June.

It now appears they cannot meet that window any longer, and are therefore aiming for the next, in July.

Meanwhile, the first manned Starliner demo mission appears to have also pushed back, from late this year to early next year.

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Scheduling conflicts at ISS delay Starliner unmanned demo flight till May

10:32 pm

NASA and Boeing have been forced to again delay the second unmanned Starliner demo mission to ISS due to scheduling conflicts with Soyuz and Dragon missions in April, forcing the flight to slip to May.

A Russian Soyuz capsule is set for launch April 9 from the Baikonur Cosmodrome in Kazakhstan with two Russian cosmonauts and a U.S. astronaut. The Soyuz MS-18 spacecraft will dock with the space station about three hours after launch, and an outgoing three-person crew will depart and return to Earth on April 17.

SpaceX’s next Crew Dragon flight to the space station is set for launch from NASA’s Kennedy Space Center in Florida around April 20 with astronauts Shane Kimbrough, Megan McArthur, Akihiko Hoshide, and Thomas Pesquet. Their mission, known as Crew-2, will last about six months.

The four astronauts who flew to the station last November on the Crew-1 mission — aboard the Crew Dragon “Resilience” spacecraft — will return to Earth in late April or early May. Both docking ports capable of receiving the Boeing Starliner capsule will be occupied during the crew handover in late April.

They had hoped to launch on April 2nd, but I suspect strongly that Boeing and NASA are glad to have this extra time.

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Texas power outages delay Starliner but not Starship

8:42 am

Boeing announced yesterday that due to the winter storms and power outages in Texas it has delayed the second unmanned demo flight of its Starliner manned capsule from March 25 to no earlier than April 2nd.

Meanwhile, SpaceX’s Starship operation in Boca Chica, Texas has been proceeding practically unaffected by the power outages.

At the southernmost fringes of Texas, SpaceX’s Boca Chica Starship factory hasn’t been insulated from the chaos, though a large Tesla Solar and Energy installation has almost certainly lessened the blow. Highly cognizant of Boca Chica’s shortcomings for industrial-grade power needs, SpaceX installed that solar array and Tesla-made Powerpacks almost three years ago and substantially expanded it in 2020.

As a result, despite major issues posed by freezing weather and power grid instability, SpaceX has managed to keep the lights on and continue work at its Starship factory, while also slowly but surely preparing Starship serial number 10 (SN10) for its first static fire and high-altitude launch.

The weather is clearly slowing the Starship test schedule, but at least the work seems insulated from loss of power.

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Boeing and NASA delay again the 2nd unmanned demo flight of Starliner

12:23 am

Boeing and NASA yesterday announced that they now plan to fly the second unmanned demo flight of Starliner in late March, rather in January as last scheduled.

Though there have been hints for awhile that a launch close to the start of the new year was no longer likely, this announcement confirms those hints. This means that it will have taken Boeing more than a year to fix the software issues that forced the first demo mission to abort its docking with ISS and come back early.

Whether this will delay the manned mission, which they are still targeting for as early as the summer of ’21, remains unclear. I think it will all depend on how well that the demo mission goes.

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Boeing hires former SpaceX software engineer

9:52 am

Capitalism in space: Boeing has hired a former SpaceX software engineer to head software development for the company.

Boeing on Friday announced it hired Jinnah Hosein as vice president of software engineering, a new role at the aerospace giant. The job will lead a centralized organization of engineers developing software across Boeing’s portfolio of products. Hosein will report to Greg Hyslop, Boeing chief engineer and senior vice president of engineering, test and technology.

…Hosein’s resume reads like a defense industry wish list of Silicon Valley stops. He worked as Google’s director of software engineering for cloud networking, helped design Tesla’s autopilot software and most recently worked as software lead for self-driving startup Aurora.

But it’s his experiences at SpaceX — where he was key to software development for the Falcon, Falcon Heavy, Dragon and Crew Dragon vehicles — that Boeing may look to draw from the most. Boeing and SpaceX have fiercely competed over NASA’s manned space programs, and SpaceX is a competitor for military space launches against the United Launch Alliance, which is co-owned by Boeing and Lockheed Martin.

Since software was the main issue that grounded Boeing’s 737-Max airplane as well as caused the serious problems on the first unmanned demo flight of the company’s Starliner capsule, this hire appears to be aimed at fixing these software issues. In both cases the management philosophy behind developing and testing software was very flawed, leaving the product saddled with software that either didn’t work properly or was not tested properly in development.

I imagine Boeing’s top management is hoping Hosein can bring to Boeing some of the agile, focused, and very successful management style found at SpaceX.

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Starliner Commander steps down from first manned mission

9:19 am

Capitalism in space: Boeing’s company astronaut chosen to command the first manned mission of its Starliner capsule has stepped down because the flight would prevent him from attending his daughter’s wedding next year.

In a video posted to his Twitter account, Ferguson said it was a difficult decision, but “next year is very important for my family.” He said he has several commitments “which I simply cannot risk missing.” A Boeing spokeswoman confirmed one is his daughter’s wedding. “I’m not going anywhere. I’m just not going into space next year,” Ferguson said. He stressed that he remains committed to the Starliner program and will continue to work for Boeing.

This is the second crew change for this mission. Earlier NASA astronaut Eric Boe had had to back out due to medical reasons.

Assuming the second unmanned Starliner demo mission scheduled for the December-January timeframe succeeds, the first manned mission will happen in June ’21, and last anywhere from two weeks to six months.

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Next Starship test flight to go to 60,000 feet

9:15 am

Capitalism in space: SpaceX has decided, after two successful 500 foot hops using its fifth and sixth Starship prototypes, to forego further hops with those prototypes and instead test fly prototype number eight to a height of 60,000 feet, about 11 miles.

Starship SN5 and SN6 were set to become a tag-team, flying 150-meter hops to refine the launch and landing techniques that SpaceX has pioneered with its Falcon 9 rocket. However, with SN5’s hop proving to be a success, followed by a notable improvement with SN6’s leap to 150 meters a few weeks later, it’s likely SpaceX is now confident of advancing to the next milestone.

The company has applied for an FCC license to do the flight anytime from Oct ’20 to April ’21, with October 11th being the first available date.

In the meantime the company plans a pressure tank test to failure of prototype #7, probably later this week.

In other related news at the second link, Boeing and Firefly have also applied for FCC licenses, the former for a Starliner demo mission from November ’20 to May ’21, the latter for its first launch of its smallsat Alpha rocket, also from November ’20 to May ’21.

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NASA/Boeing set summer ’21 for first manned Starliner mission

4:00 pm

Capitalism in space: NASA and Boeing have tentatively scheduled the launch of the first manned Starliner mission to ISS for the summer of 2021.

Boeing Co said on Tuesday it aims to redo its unmanned Starliner crew capsule flight test to the International Space Station (ISS) in December or January, depending on when it completes software and test hardware production development.

If the test mission is successful, Boeing and NASA will fly Starliner’s first crewed mission in summer 2021, with a post-certification mission roughly scheduled for the following winter, the company added.

Everything of course depends on the success of the unmanned demo flight. If the capsule has any further problems, as it did on its first unmanned demo flight, the manned flight will likely be delayed again.

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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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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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