Upgraded Antares Rolls Out to Virginia Launch Pad, High Stakes Engine Test Looms

Orbital ATK’s Antares first stage with the new engines is rolled from NASA Wallops Flight Facility’s Horizontal Integration Facility to Virginia Space’s Mid-Atlantic Regional Spaceport Pad-0A on May 12, 2016, in preparation for the upcoming stage test in the next few weeks.   Credit: NASA's Wallops Flight Facility/Allison Stancil
Orbital ATK’s Antares first stage with the new engines is rolled from NASA Wallops Flight Facility’s Horizontal Integration Facility to Virginia Space’s Mid-Atlantic Regional Spaceport Pad-0A on May 12, 2016, in preparation for the upcoming stage test in the next few weeks. Credit: NASA’s Wallops Flight Facility/Allison Stancil

An upgraded version of Orbital ATK’s commercially developed Antares rocket has at last rolled out to its launch pad on the Virginia shore – thus paving the path for a high stakes first stage engine test looming “in the next few weeks,” according to the aerospace firm.

“This stage test paradigm is a design verification test, said Kurt Eberly, Orbital ATK Antares deputy program manager, in an interview with Universe Today.

The rocket will be erected at the pad during the full power hot fire test which is scheduled to last approximately 30 seconds. Hold down restraints will keep the rocket firmly anchored at the pad.

“After the 30 second test is done we will shut it down and have a pile of data to look at,” Eberly told Universe Today.

“Hopefully it will confirm all our environments and all our models and give us the confidence so we can proceed with the return to flight.”

Indeed the significance of the hot fire engine test cannot be overstated because the entire future of Antares as a viable launch vehicle and resuming delivery of NASA cargo to the International Space Station (ISS) depends on a successful outcome of the crucial test firing – following a devastating launch failure 19 months ago.

Orbital ATK hopes to restart resupply missions to the crews living aboard the space station as soon as July – less than two months from today.

The now revamped launch vehicle dubbed Antares 230 has been re-engined and upgraded with a pair of modern new first stage engines, the Russian-built RD-181 fueled by LOX/kerosene.

The new RD-181 engines are installed on the Orbital ATK Antares first stage core ready to support a full power hot fire test at the NASA Wallops Island launch pad in March 2016.  Credit: Ken Kremer/kenkremer.com
The new RD-181 engines are installed on the Orbital ATK Antares first stage core ready to support a full power hot fire test at the NASA Wallops Island launch pad in May 2016. Credit: Ken Kremer/kenkremer.com

To prepare for the upcoming stage test, workers carefully assembled and thoroughly tested an Antares first stage equipped with the new RD-181 engines.

On May 12, 2016, they moved the vehicle on a dedicated multi-wheeled transporter from the Horizontal Integration Facility at NASA’s Wallops Flight Facility to Virginia Space’s Mid-Atlantic Regional Spaceport Pad-0A about a mile away.

Orbital ATK’s Antares first stage with the new engines is rolled from NASA Wallops Flight Facility’s Horizontal Integration Facility to Virginia Space’s Mid-Atlantic Regional Spaceport Pad-0A on May 12, 2016, in preparation for the upcoming stage test in the next few weeks.   Credit: Orbital ATK
Orbital ATK’s Antares first stage with the new engines is rolled from NASA Wallops Flight Facility’s Horizontal Integration Facility to Virginia Space’s Mid-Atlantic Regional Spaceport Pad-0A on May 12, 2016, in preparation for the upcoming stage test in the next few weeks. Credit: Orbital ATK

The team has about 3 weeks of check out work to complete before the live firing, including a wet dress rehearsal (WDR).

“The team will continue to work meticulously as they begin final integration and check outs on the pad and several readiness reviews prior to the test. The window for the stage test will be over multiple days to ensure technical and weather conditions are acceptable,” noted Orbital ATK in a statement.

The ‘Return to Flight’ blastoff – currently planned for as soon as July 2016 – will be the first for the private Antares rocket since a catastrophic launch failure on Oct. 28, 2014, just seconds after liftoff from Wallops. That flight was carrying Orbital ATK’s Cygnus cargo freighter on the critical Orb-3 resupply mission for NASA to the space station.

The launch mishap was traced to a failure in the AJ26 first stage engine turbopump and caused Antares launches to immediately grind to a halt.

Top Orbital ATK management soon decided to ditch the AJ26s, which were 40 year old refurbished engines, originally built during the Soviet era and originally known as the NK-33.

They sought a replacement and eventually decided to upgrade Antares by powering it with a pair of new Russian-made RD-181 main stage engines and modifying the first stage core structure to accommodate the new engines.

The RD-181 flight engines are built by Energomash in Russia.

“They are a good drop in replacement for the AJ26. And they offer 13% higher thrust compared to the AJ26,” Eberly noted.

As a result of switching to the new RD-181 engines, the first stage also had to be modified to incorporate new thrust adapter structures, actuators, and propellant feed lines between the engines and core stage structure.

Independent review teams have also been brought in to ensure that no stone is left unturned and everything is being done to achieve success.

The new RD-181 engines are installed on the Orbital ATK Antares first stage core ready to support a full power hot fire test at the NASA Wallops Island launch pad in March 2016.  New thrust adapter structures, actuators, and propellant feed lines are incorporated between the engines and core stage.   Credit: Ken Kremer/kenkremer.com
The new RD-181 engines are installed on the Orbital ATK Antares first stage core ready to support a full power hot fire test at the NASA Wallops Island launch pad in May 2016. New thrust adapter structures, actuators, and propellant feed lines are incorporated between the engines and core stage. Credit: Ken Kremer/kenkremer.com

Now it’s time for the real deal. After all the hard work Antares is now at the pad.

“We place it on the pad about 3 weeks prior to the engine test,” Eberly told me. “Then we and do a series of integrated checks, and electrical checks and pressure checks on the feed lines.”

“Then we will do a wet dress rehearsal where we will load the tanks with propellants. We will load the pressure bottles, pressurize the tanks and then count down just like we would for the real stage test. And right before we ignite the engines we will call a halt to the sequencer.”

“Then we will detank and pick through all that data and do a readiness review.”

If the WDR goes well, the full up engine test will follow.

“Then we will do the stage test,” Eberly explained.

“It is a 30 second test. We will fire up both engines and hit all 3 power levels that we plan to use in flight.”

“We will use the thrust vector controls. So we will move the nozzles and sweep them through sinusoidal sweeps at different frequencies and excite various resonances and look for any adverse interaction between fluid modes and structural modes.”

Orbital Sciences Antares rocket and Launch Complex 0-A at the edge of Virginia’s shore at NASA Wallops are crucial to resupply the International Space Station (ISS). .   Credit: Ken Kremer (kenkremer.com)
Orbital Sciences Antares rocket first stage stands erect at Launch Complex 0-A at the edge of Virginia’s shore at NASA Wallops, in this file photo. Credit: Ken Kremer/kenkremer.com

The vehicle and pad will be outfitted with lots of special instrumentation to gather as much test data as possible.

“We will have a lot of accelerometers and extra instrumentation and extra microphones on the test article and around the pad.

“After the 30 second test is done we will shut it down and have a pile of data to look at.”

“That will hopefully confirm all our environments and all our models and give us the confidence so we can proceed with the return to flight on the OA-5 mission.”

The test uses the first stage core planned to launch the OA-7 mission late this year.

After the engine test is completed, the stage will be rolled back to the HIF and a new stage fully integrated with the Cygnus will be rolled out to the pad for the OA-5 ‘Return to Flight’ mission as soon as July.

In the past 6 months, Orbital ATK has successfully resumed launches of their Cygnus cargo freighters to the ISS – as an interim measure until Antares is returned to flight status

They utilized the United Launch Alliance (ULA) Atlas V rocket to deliver two Cygnus resupply vessels to the ISS on the OA-4 flight in Dec. 2015 and OA-6 flight in March 2016.

A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com
A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com

Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.

Ken Kremer

A Cygnus cargo spacecraft named the SS Rick Husband  is being prepared inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016.  Credit: Ken Kremer/kenkremer.com
A Cygnus cargo spacecraft named the SS Rick Husband is being prepared inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Full Moon Offers Spectacular Nighttime Launch Outlook for Orbital ATK Cygnus Resupply to ISS on Atlas V on March 22 – Watch Live

The Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com
The Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – Clear skies and a nearly full Moon offer the distinct possibility to witness an astronomical launch spectacular for all those who have traveled near and far to witness the nighttime liftoff of an Orbital ATK Cygnus commercial cargo mission for NASA to the space station on Tuesday night, March 22.

With the heaviest Cygnus ever bolted atop and packed to the gills with science and supplies for the six person crew living and working aboard the International Space Station (ISS), a venerable United Launch Alliance Atlas V rocket is due to blastoff on March 22, at 11:05 p.m. EDT from Cape Canaveral Air Force Station in Florida.

The nighttime liftoff is targeted for 11:05 PM EDT March 22, at the opening of a 30 minute launch window from Space Launch Complex 41 at Cape Canaveral Air Force Station in Florida.

The ULA Atlas V rocket will liftoff on the CRS-6 resupply mission with the private Orbital ATK Cygnus spacecraft under a commercial resupply services (CRS) contract to NASA.

The Atlas V/Cygnus CRS-6 launch coverage will be broadcast on NASA TV and the NASA launch blog beginning at 10 PM, Tuesday night.

You can watch the launch live at – http://www.nasa.gov/multimedia/nasatv/index.html

NASA will also provide additional live coverage overnight of the critical solar array deployment at 12:45 a.m. March 23 followed be a post-launch briefing will be approximately two hours after launch.

The weather forecast has been upgraded and currently calls for an unusually favorable 90 percent chance of acceptable conditions at launch time.

Up close view of umbilical’s connecting to Atlas V rocket carrying Orbital ATK CRS-6 launch vehicle to the ISS at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com
Up close view of umbilical’s connecting to Atlas V rocket carrying Orbital ATK CRS-6 launch vehicle to the ISS at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com

In case of a delay for any reason due to weather or technical issues the back up launch opportunity is slight earlier at 10:40 p.m. Wednesday, March 23. NASA TV coverage would start at 9:45 p.m.

The spacecraft will arrive at the station on Saturday, March 26, at which time Expedition 47 Commander Tim Kopra of NASA and Flight Engineer Tim Peake of ESA (European Space Agency) will grapple Cygnus, using the space station’s robotic arm, at approximately 6:40 a.m. NASA TV coverage of rendezvous and grapple will begin at 5:30 a.m.

Inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center in Florida, a Cygnus cargo spacecraft is being prepared for the upcoming Orbital ATK Commercial Resupply Services-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus was named SS Rick Husband in honor of the commander of the STS-107 mission. On that flight, the crew of the space shuttle Columbia was lost during re-entry on Feb. 1, 2003. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22.  Credit: Ken Kremer/kenkremer.com
Inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center in Florida, a Cygnus cargo spacecraft is being prepared for the upcoming Orbital ATK Commercial Resupply Services-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus was named SS Rick Husband in honor of the commander of the STS-107 mission. On that flight, the crew of the space shuttle Columbia was lost during re-entry on Feb. 1, 2003. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22. Credit: Ken Kremer/kenkremer.com

The commercial Cygnus cargo freighter was built by Orbital ATK, based in Dulles, Virginia.

The Cygnus has been named the S.S. Rick Husband in honor of Col. Rick Husband, the late commander of Space Shuttle Columbia, which was tragically lost with its crew of seven NASA astronauts during re-entry on its final flight on Feb. 1, 2003.

This flight is also known as OA-6 and is being launched under terms of the firm’s Commercial Resupply Services (CRS) contract with NASA. It also counts as Orbital ATK’s fifth cargo delivery mission to the space station.

OA-6 is loaded with 3513 kg (7700 pounds) of science experiments and hardware, crew supplies, spare parts, gear and station hardware to the orbital laboratory in support over 250 research experiments being conducted on board by the Expedition 47 and 48 crews.

About a quarter of the cargo is devoted to science and research gear. The cargo includes 3279 kg of science investigations, 1139 kg of crew supplies, 1108 kg of vehicle hardware, 157 kg of spacewalk equipment, and 98 kg of computer resources.
Here a NASA description of a few of the scientific highlights:

– Gecko Gripper, testing a mechanism similar to the tiny hairs on geckos’ feet that lets them stick to surfaces using an adhesive that doesn’t wear off.

– Strata-1, designed to evaluate how soil on small, airless bodies such as asteroids behaves in microgravity.

– Meteor, an instrument to evaluate from space the chemical composition of meteors entering Earth’s atmosphere. The instrument is being re-flown following its loss on earlier supply missions.

– Saffire, which will set a large fire inside the Cygnus in an unprecedented study to see how large fires behave in space. The research is vital to selecting systems and designing procedures future crews of long-duration missions can use for fighting fires.

– Cygnus is carrying more than two dozen nanosatellites that will be ejected from either the spacecraft or the station at various times during the mission to evaluate a range of technology and science including Earth observations.

When the ISS Expedition 47 crew members open the hatch, they will be greeted with a sign noting the spacecraft was named ‘SS Rick Husband’ in honor of the STS-107 mission commander.

Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com
Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Cygnus will spend approximately two months docked at the ISS.

OA-6 is only the second Cygnus to be launched atop a ULA Atlas V rocket, following the OA-4 mission last December.

The CRS-6/OA-6 flight is also the second flight of the enhanced Cygnus variant, that is over 1 meter longer and sports 50% more volume capability.

Thus it is capable of carrying a much heavier payload of some 3500 kg (7700 lbs) vs. a maximum of 2300 kg (5070 lbs) for the standard version.

Watch for Ken’s onsite launch reports direct from the Kennedy Space Center in Florida.

Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.

Ken Kremer

The Cygnus spacecraft for the upcoming Orbital ATK Commercial Resupply Services-6 mission is encapsulated inside its payload fairing as it moves past the Vehicle Assembly Building at NASA's Kennedy Space Center in Florida. It is being moved to Space Launch Complex-41 at Cape Canaveral Air Force Station.  Credits: NASA/Dimitrios Gerondidakis
The Cygnus spacecraft for the upcoming Orbital ATK Commercial Resupply Services-6 mission is encapsulated inside its payload fairing as it moves past the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. It is being moved to Space Launch Complex-41 at Cape Canaveral Air Force Station. Credits: NASA/Dimitrios Gerondidakis

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Learn more about Orbital ATK Cygnus, ISS, ULA Atlas rocket, SpaceX, Boeing, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:

Mar 21/22: “Orbital ATK Atlas/Cygnus launch to the ISS, ULA, SpaceX, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evening Mar 21 /late afternoon Mar 22