SpaceX Engineers Race to Repair Engines for May 22 Launch

A team of SpaceX engineers diligently assess the cause of the May 19 launch abort for the Falcon 9 rocket poised at Pad 40 on Cape Canaveral Air Force Station. Repairs to a malfunctioning rocket engine are now underway. Credit: Ken Kremer

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Today’s (May 19) historic launch of the first ever privately developed rocket bound for the International Space Station (ISS) was very surprisingly aborted at the last second when an engine glitch forced a dramatic shutdown of the Falcon 9 rockets 1st stage firing already in progress and as the NASA launch commentator was in the middle of announcing liftoff.

SpaceX and NASA are now targeting liftoff of the mission dubbed COTS 2, for Tuesday, May 22 at 3:44 AM EDT from Space Launch Complex-40 on Cape Canaveral Air Force Station in Florida. There is another launch opportunity on May 23.

Later today, SpaceX engineers determined that a faulty valve caused the engine abort failure. They are now in a race against time to complete all the repair work and mandatory assurance testing required in order to be ready to achieve the new May 22 launch date.

The Falcon 9 rocket was designed and developed by SpaceX and the first stage is powered by nine Merlin 1 C engines. As the countdown clock ticked down to T-minus zero, all nine engines ignited. But engine #5 suddenly developed a “high chamber pressure” and computers instantaneously ordered a shutdown of thrust generation by all nine engines just 0.5 seconds from liftoff and the rocket therefore never left the pad, said SpaceX President Gwynne Shotwell at a briefing for reporters.

“We’ve had a cutoff,” announced NASA launch commentator George Diller. “Liftoff did not occur. We’ve had a launch abort. Standing by.”

After draining the explosive propellants, SpaceX engineers began inspecting the engines later today within hours of the aborted liftoff to determine the cause of the rocket engine malfunction.

“This is not a failure,” Shotwell told reporters at a post scrub media briefing. “We aborted with purpose. It would have been a failure if we lifted off with an engine trending in this direction.”

SpaceX may have caught a lucky break by being able to fix the rocket at the pad instead of a time consuming engine changout. Shotwell said that one possibility was to roll the Falcon 9 rocket back into the processing hangar and swap out the engine with a new one.

This evening SpaceX announced they had determined the cause of the engine failure.

“Today’s launch was aborted when the flight computer detected slightly high pressure in the engine 5 combustion chamber, said SpaceX spokeswoman Kirstin Grantham. “We have discovered root cause and repairs are underway.”

SpaceX Falcon 9 engines ignite and shutdown at T Minus 0.5 seconds during May 19, 2012 launch abort at Pad 40 at Cape Canaveral Air Force Station in Florida.
Credit: Ken Kremer/www.kenkremer.com

“During rigorous inspections of the engine, SpaceX engineers discovered a faulty check valve on the Merlin engine. We are now in the process of replacing the failed valve. Those repairs should be complete tonight. We will continue to review data on Sunday. If things look good, we will be ready to attempt to launch on Tuesday, May 22nd at 3:44 AM Eastern.”

The purpose of Dragon is to carry some 1200 pounds of supplies up to orbit and dock at the ISS and partially replace the capabilities of NASA’s now retired space shuttle.

SpaceX Falcon 9 launch abort on May 19, 2012 at Pad 40 at Cape Canaveral Air Force Station in Florida. Credit: Jeff Seibert

SpaceX is under contract with NASA to conduct twelve resupply missions to carry about 44,000 pounds of cargo to the ISS for a cost of some $1.6 Billion.

Ken Kremer

SpaceX says All Systems GO for Historic May 19 Blast Off to ISS

SpaceX Dragon approaches the ISS on COTS 2 test flight slated for May 19 liftoff and docking of Day 4. Astronauts will grapple it with the robotic arm and berth it at the Earth facing port of the Harmony node. Illustration: NASA /SpaceX

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In less than 48 hours, SpaceX is primed to make history and launch the first ever commercial rocket and spacecraft to the International Space Station (ISS) early Saturday morning on May 19.

Following today’s Launch Readiness Review (LRR), SpaceX was just given the official “GO” from NASA to proceed with the blastoff of the Falcon 9 at 4:55 a.m. EDT (0855 GMT) from Space Launch Complex-40 on Cape Canaveral Air Force Station in Florida. This also marks the first night time liftoff of the Falcon 9 rocket.

“Just passed final launch review with NASA”, SpaceX CEO Elon Musk tweeted this evening. “All systems go for liftoff on Sat morn”.

The SpaceX developed Dragon cargo resupply spacecraft is bolted on top of the two stage Falcon 9 rocket and stands 157 feet tall for the mission dubbed “COTS 2”. The Falcon 9 booster generates 1 million pounds of thrust

The official Air Force weather forecast gives a 70% chance of acceptable conditions for launch. The primary concern for launch day is a violation of the Cumulus Cloud Rule. On the heels of a significant drought, stormy weather has rolled into the Florida Space Coast and thunder is striking the area at the moment.

In the event of a launch scrub, the next launch opportunity comes in three days on May 22.

The launch will be broadcast live on NASA TV and via SpaceX Webcast at http://spacex.com

This SpaceX Falcon 9 rocket inside the processing hanger at Pad 40 is due for liftoff on May 19, 2012 to the ISS. Credit: Ken Kremer/www.kenkremer.com

Technicians plan to roll the Falcon 9/Dragon duo out to the seaside launch pad tonight. The rocket will be moved on rail tracks about 600 feet from the processing hanger to the pad and vertically erected.

The purpose of Dragon is to carry supplies up to orbit and dock at the ISS and partially replace the capabilities of NASA’s now retired space shuttle. Dragon is a commercial spacecraft designed and developed by SpaceX.

SpaceX is under contract with NASA to conduct twelve resupply missions to the ISS to carry cargo back and forth for a cost of some $1.6 Billion.

The Dragon spacecraft is loaded with nearly 1200 pounds of non-critical cargo such as food and clothing on this flight. A collection of student experiments, commemorative patches, pins and emblems will also be on board Dragon’s upcoming test flight.

On Friday, Ken will be reporting from Space Launch Complex-40 on Cape Canaveral.

Ken Kremer