Tag: Superheavy

SpaceX raises another $337 million in investment capital

9:45 am

Capitalism in space: In an SEC filing yesterday SpaceX revealed that it has raised another $337 million in investment capital.

The company raised in 2021 a total of $1.85 billion, and over the last six years has raised close to $7 billion total. While some of that capital is being used to finance its Starlink internet constellation of satellites, most is being funneled into the development of its totally reusable heavy lift Starship/Superheavy rocket.

The eagerness of investors to put money behind SpaceX is a strong vote of confidence in the company, coming from totally independent sources.

Adding in the $2.9 billion dollar contract from NASA for building a lunar lander version of Starship, SpaceX has raised about $10 billion total for building this rocket.

Whether that will be enough of course is not yet known. Based on SpaceX’s past work it should be. That however assumes the federal government’s bureaucracy doesn’t throw a serious wrench in the process, something it right now appears to be doing by stalling the orbital test flight of Starship/Superheavy.

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Starship prototype #20 completes another static fire launchpad test

9:40 am

Capitalism in space: Despite being blocked by the federal government bureauceacy from launching its Starship/Superheavy rocket on its first orbital flight, SpaceX yesterday successfully completed another static fire launchpad test of the 20th prototype of Starship.

It appears that this was the second static fire test that used all six of prototypes’s Raptor engines.

Meanwhile, Superheavy prototype #4 sits on the orbital launchpad, where similar static fire tests were expected but have not yet occurred. Either SpaceX engineers found they needed to additional revisions of the prototype before attempted such a test, which could fire as many as 29 Raptor engines at once, or the company has decided to hold back its testing because the FAA has not yet approved the environmental reassessment for the Boca Chica launch site. Firing the engines on Superheavy before that approval could be used by SpaceX’s environmental enemies as a public relations weapon to help kill the approval entirely.

Personally I think the answer is the former. It is not Elon Musk’s way to cower in fear of others. In fact, he is more likely to push forward, knowing that the publicity from a successful Superheavy static fire test will almost certainly be mostly positive and enthusiastic, thus helping to force politicians to force the bureaucracy to sign off its approval.

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FAA delays final approval of Starship environmental reassessment till Feb 28th

11:42 am

The FAA has now made it official and announced that the final approval of Starship environmental reassessment will not occur before the end of February, thus preventing any Starship orbital test flights until the spring, at the earliest.

As previously announced, the FAA had planned to release the Final PEA in on December 31, 2021. However, due to the high volume of comments submitted on the Draft PEA, discussions and consultation efforts with consulting parties, the FAA is announcing an update to the schedule. The FAA now plans to release the Final PEA on February 28, 2022.

When the rumors of a delay were first noted last week, I predicted that “Starship’s first orbital flight will not happen until the latter half of ’22, if then.” That prediction is now almost certainly confirmed.

Nor I am not confident the FAA’s environmental reassessment of SpaceX’s launch facility in Boca Chica will be ready even in February. The problem appears to be that the FAA needs to also get the approval of both NOAA and the U.S. Fish & Wildlife agencies, and both appear to be very hostile to SpaceX’s efforts.

In fact, this is beginning to look like the situation in Hawaii with the Thirty Meter Telescope. There protesters blocked the start of construction, and the government, controlled by Democrats, worked with those protesters to step by step keep that obstruction active and working. If so, SpaceX faces a very dangerous situation, as it appears the Biden administration is about to do the same thing to it.

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FAA’s approval of SpaceX’s Starship operations delayed at least a month

9:45 am

The FAA has now had to delay the final approval of its environmental reassessment of SpaceX’s Starship facility and operations at Boca Chica for at least one month because NOAA has refused to approve the plan.

That puts NOAA’s generic review of Rocket Landing and Launches back to at least the end of January, with the much more complex and contentious USFWS [Fish and Wildlife] review also pending (this one is habitat and species review of impacts to bird and wildlife populations specific to Boca Chica).

The earliest approval by the FAA (which again, is far from a sure thing) should be projected into February. And the actual launch license process can’t be started until then. March is absolutely the earliest even the giddiest optimist could expect for Starship’s Maiden Orbital Flight.

It appears that the bureaucrats in NOAA are hostile to the launch site, and are looking for reasons, mostly environmental, to either block it or slow it down.

It also appears that a second Department of the Interior agency must sign off, and it is also hostile.

Based on this story, it looks like Starship’s first orbital flight will not happen until the latter half of ’22, if then. Nor can we expect any help from the Biden administration. Unlike Trump, the Democrats now running the executive branch of government do not like private enterprise and business, and generally look for excuses to regulate and even block it, especially if they think there is the slightest chance it might harm some formerly unknown species somewhere.

This is America today, no longer free. Rather than you making the decision freely, as an American citizen, un-elected federal government officials now decide whether you can do anything, or not.

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SpaceX begins testing of launch procedures for Superheavy prototype #4

8:50 am

Capitalism in space: SpaceX began this week the testing of the fueling and launch procedures it will follow for launching the first orbital Superheavy, prototype #4, presently mounted on the orbital launchpad at Boca Chica.

On December 17th, SpaceX subjected Super Heavy B4 to a cryogenic proof test about twice as ambitious as B3’s, filling the booster maybe a sixth of the way with a few hundred tons of liquid nitrogen (LN2). What isn’t clear is if that test also raised the booster’s propellant tanks to flight pressures (6-8 bar or 90-115 psi). If Booster 4 did reach those pressures, the test is even more significant – partially proving that the rocket is ready for flight. On December 21st, SpaceX performed a similar series of cryogenic tests, again partially filling Booster 4 with about the same amount of liquid nitrogen but doing so two or three times in a row. Again, the Super Heavy survived the several-hour ordeal without any obvious issues. Still, a number of additional tests – some even more important – are still in front of SpaceX and Super Heavy B4.

The most obvious is simple enough: SpaceX needs to fully fill a Super Heavy booster for the first time. Depending on the storage situation, that process will likely begin by filling Booster 4 with about 2500 tons (5.5M lb) of liquid nitrogen (LN2) – about two-thirds full. If SpaceX also temporarily fills one of the orbital tank farm’s liquid oxygen (LOx) or methane (LCH4) tanks with nitrogen, it could fully load Booster 4 with around 3500 tons (7.7M lb) of nitrogen. At least according to SpaceX’s own website, that’s about the same weight as the propellant (3400t/7.5M lb) Super Heavy is designed to lift off with. If that full cryoproof goes well, SpaceX will then likely perform one or several wet dress rehearsals, ultimately filling Booster 4 with approximately 2900 tons (6.4M lb) of cryogenic oxygen and 500 tons (1.1M lb) of cryogenic methane.

At some point the company will need to not only fill the booster, it will need to do at least one static fire test of its 29 engines. If all goes well, SpaceX will then mount Starship on top, with the first orbital flight to follow. Musk has said they are aiming for a January launch, but no one should be surprised if it slips to February.

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Superheavy prototype #4 installed on orbital launchpad

9:06 am

Capitalism in space: SpaceX has now installed its fourth Superheavy prototype on the orbital launchpad at Boca Chica, with the possibility of the first static fire test of Superheavy possibly occurring in the next week or so.

Around 10am CST (UTC-6), SpaceX began retracting more than a dozen clamps that hold the 69m (~225 ft) tall Super Heavy – the largest booster ever built – to its transport and work stand. By 11:30am, Booster 4 was safely extracted from the stand and hovering above it as the lift team crossed their Ts and dotted their Is before proceeding. SpaceX’s newest Starbase crane then spun around and crawled a short distance to the orbital launch mount, where it lifted Booster 4 above the mount.

In a process that this particular Super Heavy prototype is thoroughly familiar with, SpaceX then very carefully lowered B4 down into the center of the donut-shaped orbital launch mount, where 20 separate clamps – each capable of deploying and retracting – form a support ring and giant hold-down clamp.

The booster has 29 Raptor engines total, with 20 in the outer ring, 8 in the inner ring, and 1 in the center. It will be quite amazing to watch all these engines finally fire and lift the entire rocket, with Starshp, off the launchpad.

As for the upcoming static fire tests, road closures have been announced starting today through the end of this week.

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SpaceX begins construction of Starship launchpad in Florida

9:48 am

Capitalism in space: Elon Musk yesterday announced that SpaceX has begun the construction of a Starship launchpad at its facility at Cape Canaveral, though no launch scheduled was revealed.

Musk implied that the Starship orbital launchpad is being built at Launch complex 39A. If so, it will pose some scheduling issues for SpaceX, as the company also uses that site for Falcon 9 and Falcon Heavy launches. In fact, it is the only one it uses for Falcon Heavy.

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Musk shakes up Raptor engine development

11:16 am

Capitalism in space: Based on all the reports I’ve read, Elon Musk this past weekend did a major shake-up of the management that was running the Raptor engine development, apparently focused on the need to be able to mass produce these engines at a very high rate to allow numerous test flights in the coming year.

More here, including this company email from Musk:

Unfortunately, the Raptor production crisis is much worse than it had seemed a few weeks ago. As we have dug into the issues following the exiting of prior senior management, they have unfortunately turned out to be far more severe than was reported. There is no way to sugarcoat this.

I was going to take this weekend off, as my first weekend off in a long time, but instead, I will be on the Raptor line all night and through the weekend.

The management shakeup was as follows:

This ‘senior management’ that left is likely referring to Will Heltsley, former SpaceX senior vice president of propulsion. As CNBC reported, he left Raptor production due to a lack of progress. In addition, former SpaceX vice president of mission and launch operation Lee Rosen and senior director of mission and launch operations Rick Lim have left the company. Raptor engine production is now being led by Jacob Mackenzie, who has been with the company for over six years.

The reports imply that the engine itself is in trouble, but I do not think that is the issue. Instead, as Musk has said many times, more important than developing new technology is developing the efficient manufacturing processes that will allow the company to take advantage of that technology. It appears the manufacturing part of Raptor had not been covered well by the now disposed management.

SpaceX not only needs a working reliable Raptor engine, it needs to be able to mass produce them in the hundreds, quickly. This is the challenge that apparently the previous management failed to face. Musk is now refocusing Raptor development around this need.

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Musk lays out Starship testing plan

12:27 am

Capitalism in space: In a meeting in Washington today, Elon Musk laid out SpaceX’s upcoming testing plan for developing its Starship/Superheavy heavy-lift reusable rocket.

“We’ve completed the first orbital booster and first orbital ship, and we’ll be complete with the launch pad and launch tower later this month, and then we’ll do a bunch of tests in December, and hopefully launch in January,” Musk said. “There’s a lot of risk associated with this first launch, so I would not say it is likely to be successful, but I think we’ll make a lot of progress,” musk said. “We’ve also built a factory for making a lot of these vehicles. So this is not a case for just one or two. We’re aiming to make a great many.

“We intend to do hopefully a dozen launches next year, maybe more,” Musk said. “And if we’re successful with it being fully reusable, that means we build up the fleet just as we are with the Falcon 9 booster, which is reused.”

Musk says the cost of a Starship launch will eventually fall below the cost of a Falcon 9 rocket flight, which a SpaceX manager said last year can fall below $30 million with reused parts.

“Basically, we intend to complete the test flight program next year, which means it’s probably ready for valuable payloads that are not for testing, but actual real payloads, in 2023.”

According to this schedule 2022 will be devoted to refining the rocket to make it dependable, and 2023 will be used to fly unmanned cargo flights to prove it out for later manned flights.

SpaceX will also likely develop in parallel the various expected versions of Starship, including the refueling ship, the manned lunar lander, and ships used for point-to-point transportation on Earth.

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SpaceX completes Starship static fire test with all six engines

2:30 pm

Capitalism in space: SpaceX today successfully completed a short static fire test of Starship prototype #20 using all six orbital engines.

Though this prototype has previously completed static fire tests, those used only two engines. This test was the first using all the engines that will fly on the spacecraft’s first orbital flight.

When that flight will occur remains uncertain. Elon Musk has said it could fly as early as this month. First however the FAA must give final approval of its environmental reassessment of SpaceX’s Boca Chica spaceport. The agency has released a preliminary draft approval, but that is not yet finalized, with no clear date on when an approval will be issued.

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SpaceX begins filling tanks at Starship orbital launchpad

9:03 am

Capitalism in space: SpaceX has begun the process of filling the many tanks at its Starship orbital launchpad in Boca Chica, requiring more than a hundred truck deliveries of nitrogen (for cleaning the interior of the tanks as well as cooling the propellants) and oxygen.

In mid-September, SpaceX began delivering cryogenic fluids to Starbase’s orbital tank farm for the first time ever. Instead of propellant, dozens of tanker trucks delivered liquid nitrogen to one or two of the farm’s tanks between mid-September and mid-October. Altogether, around 40-60 truckloads was delivered – only enough to partially fill one tank. That liquid nitrogen also appeared to be piped into two of the farm’s three liquid oxygen tanks, meaning that it may have only been used to clean and proof test them.

Combined, the farm’s seven main tanks should be able to store roughly 2400 tons (5.3M lb) of liquid methane (LCH4), 5400 tons (12M lb) of liquid oxygen (LOx), and 2600 tons (5.7M lb) of liquid nitrogen (LN2). LCH4 and LOx are Starship’s propellant, while LN2 is needed to ‘subcool’ that propellant below its boiling point, significantly increasing its density and the mass of propellant Starships can store.

It appears that while SpaceX has begun storing oxygen, it has not yet begun loading its methane tanks. When that fuel begins arriving we will know that an orbital launch of Starship is imminent.

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Musk: Starship orbital flight could happen as soon as next month

2:57 pm

Capitalism in space: Elon Musk today announced that SpaceX will be ready to launch the first orbital flight of Starship as soon as one month from now.

“If all goes well, Starship will be ready for its first orbital launch attempt next month, pending regulatory approval,” Musk tweeted today [emphasis mine]

Musk’s tweet came one day after the FAA completed its public hearings on its environment reassessment of SpaceX’s operations in Boca Chica. Before the agency can approve that reassessment it has to digest the comments, then to hold an “industry workshop” on this reassessment.

Thus, while SpaceX is ready to go, our lumbering, oppressive government is not. As I’ve written before, I fully expect there to be pressure from the Biden administration and NASA to slow walk that government approval so that Starship does not launch before February 2022, when SLS is now scheduled for its first launch. Having SpaceX get its heavy lift rocket into orbit before NASA would be very embarrassing, considering that SpaceX has spent about a third the time and about a tenth the money getting it done.

I hope I am wrong, but this is what I expect from the corrupt federal government we now have.

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First FAA hearing on Starship environmental assessment dominated by supporters

8:48 am

Capitalism in space: The FAA yesterday conducted its first of two virtual public hearings to allow public comment on its proposed environmental assessment that would allow SpaceX to launch orbital Starship missions from Boca Chica, Texas>

According to the story at the link, the comments were dominated by supporters, interspersed with the typical small number of anti-development environmental activists.

Over the course of more than three hours on Monday, members of the public who had registered in advance were given three minutes each to deliver their oral public comments on Starship and the draft. Most were in favor of SpaceX, though many positive comments appeared to originate from outside of Texas. A smaller number of people also voiced concerns about impacts on local ecosystems and species near Boca Chica.

The second hearing is scheduled for tomorrow.

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NASA document: Starship orbital flight in March ’22

9:11 am

Starship orbital flight date?
Click for full image.

According to a NASA proposal to observe and measure the temperatures on Starship’s thermal protection during its return to Earth from orbit, that flight is now tentatively scheduled for March ’22.

The graphic to the right highlights the pertinent language in the poster presentation.

It must be noted that the poster might not be telling us when Starship will first launch, but when the designers of the camera system will be ready to film. The two are different. Still, the slowdown in flight testing at Boca Chica by SpaceX since July suggests there may be some truth to this date. That date also seems more reasonable now in connection with the FAA’s regulatory pace, which still needs to provide the final approval of SpaceX’s environmental reassessment of its Boca Chica launch site.

It also seems to me that the March ’22 date would be very convenient for NASA, as it almost certainly guarantees that Starship will reach orbit after SLS, thus avoiding for the agency a very big public relations embarrassment. I would not be surprised at all if the Biden administration and NASA’s top administrators, led by Bill Nelson, are purposely pressuring the FAA to make sure that Starship orbital flight is delayed until after the first SLS test flight, now expected in the January/February time frame.

There is also the possibility that SpaceX’s targeted launch dates were unrealistically optimistic. The company had a lot of work it needed to do prior to launch on its orbital launch facility at Boca Chica, and that work could not go forward while test flights and static fire tests were taking place. Pausing those tests has allowed the launch facility work to move forward aggressively.

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Starship/Superheavy update

8:43 am

Link here. SpaceX is moving on several fronts in preparation for the next Starship/Superheavy tests:

  • Engines have been installed in Starship prototype #20 which will be tested this week
  • A new Raptor engine factory is under construction
  • Launch tower construction continued
  • Future prototypes continue to be built

Lots of details and videos at the link. Based on road closures, the prototype #20 static fire test will occur today, and will be the first such test on a Starship using orbital Raptor engines.

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FAA extends comment period for SpaceX Starship/Superheavy environmental reassessment

11:11 am

Capitalism in space: The FAA today announced that it has extended the comment period for its environmental reassessment of SpaceX’s operations at Boca Chica, Texas two weeks until November 1st.

From the email announcement:

The Federal Aviation Administration (FAA) has received requests for an extension of the public comment period for the Draft Programmatic Environmental Assessment for the SpaceX Starship/Super Heavy Launch Vehicle Program at the SpaceX Boca Chica Launch Site in Cameron County, Texas (Draft PEA). In consideration of these requests, the FAA is extending the public comment period.

The agency has also changed the dates for the two public hearings it will hold to October 18 and October 20. It will announce more information on those hearings on October 15th.

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SpaceX schedules likely first static fire tests for orbital Starship and Superheavy

9:01 am

Capitalism in space: SpaceX has scheduled a weeklong series of road closures at Boca Chica, beginning next week, suggesting they are about to begin the first static fire tests for the orbital prototypes of both Starship (#20) and Superheavy (#4).

The company has been installing or replacing engines on both prototypes, with the installation apparently now complete on Starship #20.

Starship’s current design features three gimballing sea-level Raptors and three vacuum-optimized variants with much larger nozzles – all in close proximity inside a 9m-wide (30 ft) skirt. As such, the first Starship static fire with any combination of Raptor Center and Raptor Vacuum engines will be a significant milestone for SpaceX. Eventually, that will likely culminate in the first static fire(s) of a Starship (likely S20) with all six Raptors installed – a test that will effectively qualify that prototype for its first orbital launch attempt.

As for Superheavy #4, they have been replacing some of its 29 engines while it sits on the launchpad, for reasons that are not clear.

It appears the company is aiming to get all of its ground-testing completed while the FAA’s approval process for the permit for the orbital flight is ongoing. This will make it possible to launch as soon as approval is obtained.

This strategy carries some risk. As long as the testing proceeds smoothly it will provide positive coverage during the FAA’s public comment period, running until mid-October. Should a test fail dramatically, however, the explosion could generate the wrong response during that comment period. Not surprisingly, SpaceX is willing to accept that risk.

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FAA now taking public comments on the licensing of SpaceX to launch Starship/Superheavy from Boca Chica

10:59 am

Capitalism in space: The FAA today announced by email that it is now taking public comments on the “Draft Programmatic Environmental Assessment (PEA)” it requires from SpaceX before it can issue a launch license at Boca Chica, Texas for Starship/Superheavy orbital launches.

From the email:

The FAA invites interested agencies, organizations, Native American tribes, and members of the public to submit comments on all aspects of the Draft PEA. Public comments are due on Monday, October 18, 2021. Comments or questions on the Draft PEA can be addressed to Ms. Stacey Zee, SpaceX PEA, c/o ICF, 9300 Lee Highway, Fairfax, VA 22031. Comments may also be submitted by email to SpaceXBocaChica@icf.com. Before including your address, phone number, e-mail address, or other personal identifying information in your comment, be advised that your entire comment – including your personal identifying information – may be made publicly available at any time. While you can ask us in your comment to withhold from public review your personal identifying information, we cannot guarantee that we will be able to do so.

The FAA will also hold two public hearings on October 6th and 7th, though it provided no information yet on where those hearings will be held.

This announcement means that the Starship/Superheavy orbital test flight cannot occur any earlier than October 18, 2021, and will actually occur at least several weeks or months later, based on the schedule outlined on slide 32 of this FAA presentation [pdf]. Once the 30-day public comment period ends the FAA must then hold “an industry workshop” reviewing the comments and then issue an update of the PEA, or a rejection of it.

Though the chances of the FAA rejecting SpaceX’s permit are practically nil, I fully expect this process to be slow-walked by the FAA under orders of the Biden administration in order to do whatever it can to prevent this orbital flight occurring before SLS’s first launch, now expected in early ’22.

I hope I am wrong, and that the FAA surprises me. We can only wait and see.

Update: If you think I am crazy thinking that the politics of the Biden administration will cause a slowdown in the FAA’s process, just read this story about the FAA suddenly imposing flight restrictions at the southern border to block drone flights by media outlets that show the illegal immigrant crisis there.

“We’ve learned that the FAA just implemented a two week TFR (Temporary Flight Restrictions) over the international bridge in Del Rio, TX, meaning we can no longer fly our FOX drone over it to show images of the thousands of migrants,” Fox News reporter Bill Melugin tweeted. “FAA says ‘special security reason.’”

Fox’s report resulted in a quick lifting of this flight restriction on their drone, but the action by the Biden administration shows that it is quite willing to interfere with normal aviation regulations for its own political reasons.

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Update on status of first orbital Starship/Superheavy

10:02 am

Capitalism in space: The first planned orbital Superheavy booster, prototype #4, has been moved back to the orbital launch site, this time with all of its 29 engines fully installed.

It appears SpaceX engineers are about to begin an extensive test campaign of this booster and its engines. They need to test the fueling of all 29 engines. They need to test fire the engines as a unit. And they need to do a full static fire of them all to see if they will work together as planned.

All these tests, which based on SpaceX’s past pace, will likely take about three to four weeks, which means that the orbital test flight cannot occurr before the end of September, as previously guessed. More likely they will not be ready to fly before the end of October, at the soonest.

That schedule is also impacted by the FAA’s bureaucracy, which still needs to approve the environmental assessment required before any Starship orbital flight. That approval process has been ongoing, but could still take several more months, especially if the effort by some fearful environmentalists to stop the flight gains political momentum.

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Musk’s Boring Co offers to dig tunnel for resident transportation during launch closures

1:49 pm

Capitalism in space: Elon Musk’s Boring Company has proposed digging a tunnel so that people can still access Boca Chica’s beaches even during periods when SpaceX is doing launch operations and needs to close the surface roads.

The Boring Company (TBC) met with Cameron County officials to discuss the possibility of a tunnel project running from South Padre Island (SPI) to Boca Chica Beach.

The Boring Company pitched the idea of an SPI-Boca Chica tunnel to Cameron County administrator Pete Sepulveda Jr. and county engineer Benjamin Worsham early this summer. Cameron County officials have been thinking of giving people access to part of Boca Chica Beach even during closures.

The county has said it likely cannot afford to pay for such a thing, but Musk’s company is still proposing to do an in-depth study to find out what will be necessary to make it happen.

It could very well be that Musk might find some cash to help pay for this himself. The public relations would be excellent, and it would I think be the right thing to do. It is also possible that the local communities will have more cash themselves because of the booming economy SpaceX is bringing them.

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Eric Berger: FAA regulators should get out of the way

10:16 am

In a essay today for Ars Technica, Eric Berger makes note of the progress that SpaceX is making on its Starship/Superheavy rocket, and points out that the one major obstacle that SpaceX cannot control and that stands in its way is the revised “environmental assessment” the FAA still must approve to permit the rocket to launch from Boca Chica.

Perhaps the biggest hurdle of all will be clearance from the Federal Aviation Administration, which is working with SpaceX to conduct an environmental assessment of launching such a mammoth rocket from these South Texas wetlands. After a “draft” of this assessment is published, there will be an approximately 30-day period for public comments. This will be followed by other steps, including a determination by the FAA on whether SpaceX’s proposed environmental mitigations will be enough or if more work is required.

The stacking of the rocket late last week, and the photos released by Musk of that stacking, Berger sees as Musk’s effort to quietly apply pressure on those bureaucrats to get their work done already. As he writes, “Holding back Starship means holding back this progress, Musk wanted regulators to understand.”

Read the whole essay. In addition to illustrating the poltical games required by SpaceX to get past the stifling rules of our modern government, it very nicely shows how America has changed since the early 20th century. Then, no such regulators stood in the way, and Americans were thus about to build fast and with great skill, reshaping the cities of the world forever.

Though I expect the politics of the moment to favor SpaceX, forcing the FAA to get its work done quickly to allow the rocket to take off as planned, this is only going to happen because of the political clout SpaceX has with the public, and thus with politicians. For small companies no such clout exists, and thus expect U.S. innovation to continue to suffer in the coming years because we have given our govenrment too much power over our lives.

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The trials and tribulations of Blue Origin’s BE-4 engine

12:09 pm

Link here. The article tries to provide some explanations for the delays at Blue Origin that have put the BE-4 engine years behind schedule.

The first and most important fact gleaned from the article is that flightworthy versions of this engine will not be ready this summer as promised, and will likely not get delivered to ULA for its Vulcan rocket before the end of the year, causing its inaugural launch to be delayed to the second half of ’22. This also means that Blue Origin’s own orbital rocket, New Glenn, will likely not launch until late next year, at the earliest.

Moreover, the engines that Blue Origin will deliver to ULA will not be fully tested, and might require replacement if tests on other engines reveal more problems.

The article’s most important revelation about the delays however is this:

One of the most persistent problems, sources said, is that the BE-4 engine testing and development program has been relatively “hardware poor” in recent years. Effectively, this means that the factory in Washington has not had enough components to build development engines, and this has led to extended periods during which no testing has occurred on the stands in Texas.

It was surprising to hear this because back in the spring of 2017 Blue Origin stated publicly that its development program was hardware rich. After arriving as CEO in late 2017, however, [Bob] Smith appears to have focused more on a substantial reorganization of Blue Origin’s leadership rather than hardware development. Other programs were prioritized, too, so the BE-4 team did not get all the resources and freedom it needed to proceed at full throttle. [emphasis mine]

To put it more bluntly, Smith decided it was more important to rearrange the deck chairs rather than launch lifeboats into the water. As a result, Blue Origin has essentially wasted the last four-plus years.

There are signs that the company has changed course away from Smith’s focus, but we shall have to wait and see. The childish press release issued by Blue Origin yesterday, claiming its manned lunar lander was far better than SpaceX’s Starship and should have been chosen by NASA, suggests that the course change has not been as thorough as one would hope. The amount of intellectual dishonesty contained in that release is somewhat disturbing, especially coming from a rocket company:

Blue Origin appears to be, at minimum, cherry picking its comparisons. The graphic notes that the Starship-Super Heavy system hasn’t launched yet. Starship has launched six miles into the air on several occasions, but not with its Super Heavy booster. It also points out that SpaceX’s Starship facilities in Boca Chica, Texas have never accommodated an orbital launch. Blue Origin, though has never launched any rocket to orbit from anywhere.

The graphic doesn’t, however, note the cost of the Starship lunar lander. SpaceX’s proposal estimates that it will cost NASA $2.9 billion, while Blue Origin’s gave a price of $5.9 billion. [emphasis mine]

For the management of a rocket company to not recognize the fundamental facts indicated by the highlighted words above, or to make believe they are unimportant, does not bode well for that rocket company. Rather than focusing on getting its rocket finally off the ground, the management appears instead unwilling to face some hard facts, and fix them.

Meanwhile, SpaceX keeps barrelling along, focused not on petty managment issues or whiny complaints, but on actually building rockets that fly.

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SpaceX stacks Starship on top of Superheavy

11:19 am

Superheavy with Starship on top
Click for original image.

Capitalism in space: Only three days after the company had rolled Superheavy prototype #4 to the launchpad, SpaceX today stacked Starship prototype #20 on top, uniting for the first time the entire rocket.

All told, the rocket is 395 feet high, about 32 feet taller than the Saturn-5.

The photo to the right, reduced slightly to post here, was posted by Elon Musk earlier today. It also makes obvious several things that will be different for this Starship flight compared to the previous suborbital hops. Starship’s dark exterior is because it is covered with thermal tiles designed to protect it as it returns to Earth flying through the atmosphere at orbital speeds.

Note also the grid fins on Superheavy. Apparently they will be open during the entire flight, instead of unfurling shortly after stage separation as is done with Falcon 9.

I am not sure what the vertical attachments near the bottom of Superheavy are for. The plan is for the stage to land in the Gulf of Mexico, so it does not need landing legs. Could these be attachment points for holding the rocket to the launchpad?

I have been predicting a late September/early October date for this rocket’s first orbital launch test. SpaceX is sure working hard to beat that timeline. They still need to do tank tests and static fire tests of the whole assembly, but based on past schedules, they might get this done in only a few weeks. If so, it means they might be able to launch before the end of August.

My god, if only other American rocket companies worked in this manner. Imagine what wonders they all could accomplish.

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Superheavy prototype #4 rolls to orbital launchpad

2:51 pm

Superheavy #20 on the way to launchpad

Superheavy on launchpad
Click for live stream.

Capitalism in space: SpaceX today rolled its 4th Superheavy prototype from its assembly building in Boca Chica, Texas, moving it to the orbital launchpad in preparation for having the 20th Starship prototype stacked on top and assembled for the rocket’s first orbital test flight.

The first image to the right is a screen capture taken from a short movie posted in an Elon Musk tweet. It shows the base of this Superheavy, with its 29 Raptor engines. The engines appear surrounded by the support structure that holds the stage to the truck mover.

The second image to the right is a screen capture from Labpadre’s live stream Saphire camera, captured shortly before this post was published. Superheavy is 230 feet tall. Starship is 165 feet tall. Combined that equals just under 400 feet, which is still about 30 feet taller than the Saturn-5.

Yet, Superheavy is easily dwarfed by the launch tower behind it, and when they stack Starship on top the combined rocket will still be only three quarters as tall as the tower. They are using that tower not only for launches, but for stacking of Starship as well as a capture devise for when later Superheavies return to Earth. Instead of having landing legs, Superheavy will eventually lower itself into position next to the tower and hover there so that the tower can grab it.

All this means the tower needs to be taller than the combined rocket. I would also expect that a second tower will be necessary eventually for that landing grab.

Before they stack Starship #20 on top they will likely do pressure and tank tests of Superheavy, and maybe a few dress rehearsal countdowns leading to short static fire tests.

It still appears to me that we are looking for an orbital test flight sometime in late September, early October.

21 comments

SpaceX installs 29 Raptor engines on Superheavy #4

8:45 am

Capitalism in space: SpaceX has now installed 29 Raptor engines on the fourth Superheavy prototype, intended to be the first to attempt an orbital launch, even as the company also prepares Starship prototype #20 for that flight.

In a marked increase to the already-impressive production cadence at SpaceX Starbase, it’s all hands on deck with Booster 4 and Ship 20 preparations ahead of the duo being sent to the launch site. Booster 4 was stacked on Sunday, with all 29 Raptors installed by Monday morning. While the orbital launch attempt is not imminent, the duo is expected to undergo a series of ground testing objectives, including multiple Static Fire tests for the booster. This will also provide time to complete the final elements of the Orbital Launch Site (OLS), from which the duo will conduct the milestone test flight.

Following a short ground testing campaign with Booster 3, which included cryo proofing and a three-engine Static Fire test, the focus is now on what will become the first integrated stack of a Super Heavy booster and a Starship vehicle. This is set to be achieved in double-quick time, following a call to arms from SpaceX to its workforce. This included the transportation of hundreds of workers from other sites in the country, as per a memo leaked on Facebook.

As predicted, SpaceX did not succeed in launching Superheavy/Starship on its first orbital test flight in August. However, as predicted the company is clearly pushing to attempt that flight before the end of the summer. Right now, based on the pace of operations, what has been accomplished, and what needs to be accomplished, I estimate that flight will likely occur sometime around late September to early October.

It also seems very obvious that SpaceX is trying very hard to beat SLS into orbit. If successful, it will underline most starkly the difference between free enterprise and government operations. The former got it done in about four years, for less than $6 billion. The latter has taken seventeen years, and about $60 billion, and has still not launched.

And even if SLS launches first, that contrast remains.

12 comments

SpaceX completes first static fire test of Superheavy prototype #3

9:37 am

Superheavy booster #3 fires
Superheavy booster #3 fires.

Capitalism in space: SpaceX yesterday successfully completed the first static fire test of the third Superheavy prototype, firing up three Raptor engines for about two seconds.

I have embedded the live stream from NASASpaceflight.com below the fold, cued to just before the engines fire. Because there was a delay of a few minutes from when the static fire was expected and when it actually happened, the announcers had began talking and were caught off guard by the burn.

Next up:

Booster 3 provides a first-time operation for fueling the huge booster with Liquid Oxygen (LOX) and Liquid Methane (CH4) during the test. How much propellant will be loaded, and the schedule for the sequence was unknown. However, NSF’s Adrian Beil wrote a feature on the expectations based on previous experiences with Starship being applied to Super Heavy.

Based on those evaluations, it was expected that Super Heavy would also undergo a Starship-like countdown of 45-60 minutes, with fueling beginning in the 30-40 minute range. Engine chill would then follow at T-12 minutes, ahead of the firing. As with previous Static Fires, the T-10 minute siren sounded, as per the alert notice to local residents. However, as with Starship, mini-holds can be expected, pushing the ignition time to the right. This proved to be the case on Monday.

The booster fired up all three engines for the expected duration, confirmed by Musk before he noted that “depending on progress with Booster 4, we might try a 9 engine firing on Booster 3.”

Booster #4 will be put on the orbital launchpad rather than the test pad, and is likely the booster to be used for the first orbital test flight of Starship, likely to be launched before the end of summer.
» Read more

8 comments

Maezawa reveals status of competition to join him on a private Starship mission to Moon

10:02 am

Capitalism in space: In a video released yesterday Japanese billionaire Yusaku Maezawa provided an update on his Dear Moon competition for choosing the eight individuals who will join him on his private Starship mission around the Moon.

The mission has changed a lot since it was first announced in 2018. Maezawa had planned to invite artists onboard the Starship and venture with them on a circuit around Earth’s only natural satellite. But earlier this year, he changed the process and opened up spots to practically everyone, calling on budding lunar explorers to register for a ticket aboard the Starship and then produce videos on why they want to go to space.

I have embedded the video below. In it Maezawa reveals that he received more than a million applications from every single country on Earth, with many sending short videos describing why they should be chosen. The video provides a sampling of clips from those videos.

What struck me most while watching the video is how completely confident all the applicants were that this private mission on Starship will fly. Even though this is a manned mission around the Moon, something that has only been done nine times, and not for a half century, all seemed entirely sure Maezawa’s mission would happen, and wanted to be on it. I was also struck by the variety of applicants from many places.

Capitalism and freedom is opening the heavens for all humans. And it is about time.

» Read more

5 comments

FAA threatens shutdown of SpaceX’s Starship program at Boca Chica

9:33 am

Banned by the FAA?
Starship banned by the FAA?

They’re coming for you next: An FAA official revealed yesterday that the agency has not approved the launch tower that SpaceX is building for its Starship/Superheavy rocket in Boca Chica, Texas, and threatened that if disapproved the government would force the company to tear it down.

The Federal Aviation Administration warned Elon Musk’s SpaceX in a letter two months ago that the company’s work on a launch tower for future Starship rocket launches is yet unapproved, and will be included in the agency’s ongoing environmental review of the facility in Boca Chica, Texas. “The company is building the tower at its own risk,” an FAA spokesperson told CNBC on Wednesday, noting that the environmental review could recommend taking down the launch tower.

The FAA last year began an environmental review of SpaceX’s Starship development facility, as Musk’s company said it planned to apply for licenses to launch the next-generation rocket prototypes from Boca Chica. While the FAA completed an environmental assessment of the area in 2014, that review was specific to SpaceX’s much-smaller Falcon series of rockets.

This revelation from FAA officials is most interestingly timed, coming on the same day as this garbage article about the terrible environmental damages some activists imagine SpaceX’s launch facility might someday cause. As is usual for a mainstream news source, the article makes no reference to the wildlife preserve that surrounds the Kennedy Space Center in Florida, where we have empirical proof for more than a half century that a spaceport does no harm to the environment and actually acts to protect it from development.

Nor was this the only such attack article in the past two days. Here is just a sampling:
» Read more

30 comments

Superheavy passes first tank test

9:17 am

Superheavy after tank test, July 12, 2021
Screen capture from NASASpaceflight.com live stream,
shortly after tank test of Superheavy

Capitalism in space: SpaceX’s first fullscale complete Superheavy prototype, dubbed #3, passed its first tank test yesterday.

Booster 3 was likely filled with a few hundred tons of liquid nitrogen relative to the more than 3000 tons its tanks could easily hold and the fraction of that total capacity SpaceX’s suborbital launch site can actually supply. Teams have been working around the clock for months to outfit Starship’s first orbital launch site with enough propellant storage for at least one or two back to back orbital launches – on the order of 10,000 tons (~22M lb) – but the nascent tank farm is far from even partially operational. That’s left SpaceX with its ground testing and suborbital Starship launch facilities, which appear to be able to store around 1200 tons of propellant.

Assuming the suborbital pad’s main liquid oxygen and methane tanks can also both store and distribute liquid nitrogen, which isn’t guaranteed, SpaceX thus has the ability to fill approximately 30-40% of Super Heavy B3’s usable volume. Frost lines aren’t always a guaranteed sign of fill level but if they’re close, SpaceX likely filled Booster 3’s tanks just 5-10% of the way during the rocket’s first cryoproof.

While the company still says it is aiming for a July orbital launch, that seems highly unlikely. They still have to do a Superheavy tank test with full tanks, plus static fire tests. They also need to get the orbital launchpad finished, with a full tank farm.

Nonetheless, SpaceX is moving fast towards flight of this heavy lift reusable rocket. I still think the odds are 50-50 it will complete its first orbital flight before SLS, even though its development began more than a decade later and has cost a tenth of the money ($6 billion vs $60 billion).

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