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Engineers work to open Boeing Starliner's valves as schedule pressures mount

(2021/08/10)


Boeing's Starliner CST 100 – aka the Calamity Capsule – continues to remain firmly wedded to Earth as engineers [1]work to resolve a problem with valves in the spacecraft's thruster systems.

The valves, which connect to thrusters used for aborts and manoeuvring in orbit, didn't open as designed during the 3 August launch attempt, resulting in an unscheduled trip to United Launch Alliance's Vertical Integration Facility (VIF) near Space Launch Complex (SLC) 41 at Cape Canaveral Space Force Station.

The worst-case scenario would require the de-stacking of the Starliner from its Atlas V carrier rocket, effectively killing off any hope of launching Boeing's second crack at a demonstration mission of its crew capsule to the International Space Station (ISS) in the near future.

[2]

Its previous effort made [3]an early return to Earth in 2019 after a succession of failures meant the uncrewed capsule did not trouble the ISS and landed considerably earlier than planned. NASA had been a little too focused on making sure new kid SpaceX did everything right, [4]and assumed Boeing knew what it was doing .

[5]

[6]

There is, therefore, more than just the Calamity Capsule riding on this mission. Boeing's hopes of demonstrating its competence in such matters is up there too, which makes the valve problem all the more awkward.

In an update last night, NASA confirmed that Boeing had been able to command seven of the 13 valves open that were previously closed. Engineers have been able to connect to the Starliner to command the vehicle and have been "applying mechanical, electrical and thermal techniques to prompt the valves to open."

[7]Boeing and Rocket Lab hope for the best as both return to launchpad following failures

[8]Boeing Starliner commander Christopher Ferguson bows out of first crewed mission due to family commitments

[9]NASA trusted 'traditional' Boeing to program its Starliner without close supervision... It failed to dock due to bugs

[10]Two out of three parachutes... is just as planned for Boeing's Starliner this time around

No, we can't shake the image of an engineer with a hammer and blow torch either. The tweet below indicates that a desperate thwacking with a mallet is not, however, taking place.

[11]#Starliner teams restored functionality to more propulsion system valves this weekend. Work continues at the [12]@ulalaunch Vertical Integration Facility on the remaining affected valves.

Learn more and get updates on the team’s progress: [13]https://t.co/HsH3wz5Qfb [14]pic.twitter.com/WhRDiK8aCi — Boeing Space (@BoeingSpace) [15]August 9, 2021

The challenge now is to get the rest of the valves open and demonstrate the process can be repeated before sending the stack back to the pad for the uncrewed Orbital Flight Test-2 mission.

Sadly, there is not a tremendous amount of wiggle room in the schedule. Tory Bruno, CEO of ULA, [16]tweeted that the turnaround time for the Atlas V was 17 days. The next Atlas V launch from SLC-41 pad is a Space Test Program for the US Department of Defense in September followed by NASA's Lucy asteroid probe in October.

[17]

The latter has only a limited window for launch, and NASA confirmed that "any launch date options [for Starliner] would protect for the planetary window for the agency's Lucy mission – the first-ever mission to explore Trojan asteroids."

If the problem cannot be resolved in both a safe and timely fashion, there is every chance that the next flight of the Calamity Capsule could slip toward the end of the year, or even into 2022. ®

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[1] https://blogs.nasa.gov/oft-2/2021/08/09/nasa-boeing-make-progress-on-starliner-valve-issue/

[2] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/science&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=2&c=2YRL3H5-g3mp08uefu7BFngAAAIc&t=ct%3Dns%26unitnum%3D2%26raptor%3Dcondor%26pos%3Dtop%26test%3D0

[3] https://www.theregister.com/2019/12/23/cst_100_lands/

[4] https://www.theregister.com/2020/07/08/nasa_boeing_starliner/

[5] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/science&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=4&c=44YRL3H5-g3mp08uefu7BFngAAAIc&t=ct%3Dns%26unitnum%3D4%26raptor%3Dfalcon%26pos%3Dmid%26test%3D0

[6] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/science&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=3&c=33YRL3H5-g3mp08uefu7BFngAAAIc&t=ct%3Dns%26unitnum%3D3%26raptor%3Deagle%26pos%3Dmid%26test%3D0

[7] https://www.theregister.com/2021/07/28/boeing_rocket_lab/

[8] https://www.theregister.com/2020/10/09/boeing_starliner_loses_commander/

[9] https://www.theregister.com/2020/07/08/nasa_boeing_starliner/

[10] https://www.theregister.com/2020/06/30/boeing_starliner_tests/

[11] https://twitter.com/hashtag/Starliner?src=hash&ref_src=twsrc%5Etfw

[12] https://twitter.com/ulalaunch?ref_src=twsrc%5Etfw

[13] https://t.co/HsH3wz5Qfb

[14] https://t.co/WhRDiK8aCi

[15] https://twitter.com/BoeingSpace/status/1424738066854522894?ref_src=twsrc%5Etfw

[16] https://twitter.com/torybruno/status/1422975444094181380

[17] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/science&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=4&c=44YRL3H5-g3mp08uefu7BFngAAAIc&t=ct%3Dns%26unitnum%3D4%26raptor%3Dfalcon%26pos%3Dmid%26test%3D0

[18] https://whitepapers.theregister.com/



"assumed Boeing knew what it was doing."

alain williams

Does anyone assume that these days ? Too many memories of the 737 max.

Re: "assumed Boeing knew what it was doing."

simonlb

Companies like Grumman and Rockwell have been doing this kind of work for over 50 years so it can't be that hard. Anyone would think this was rocket science...

Re: "assumed Boeing knew what it was doing."

NoneSuch

"Boeing's Starliner CST 100 – aka the Calamity Capsule"

This first line is why the Reg is always the first news site I check.

Re: "assumed Boeing knew what it was doing."

FIA

I have started to wonder what a SpaceX aeroplane would be like.

(Sure, you'd probably want to skip the first 10-15 flights, but after that.....)

Doesn't inspire confidence

Pete 2

> have been "applying mechanical, electrical and thermal techniques to prompt the valves to open."

When the acme of Boing's technical input is to whack them with a hammer.

Re: Doesn't inspire confidence

John Robson

Turn it off and on again, hit it, take a blowtorch/heat gun to it…

Re: Doesn't inspire confidence

skeptical i

If at first you don't succeed, get a bigger hammer.

Re: Doesn't inspire confidence

Imhotep

Yes, that would be the mechanical technique using what we fondly refer to as a BFH.

Unfortunately, for rocketry you don't have the option of the 7" drop like you do with stuck hard drives.

Re: Doesn't inspire confidence

Mark 85

Isn't Rule #1 "Beware of flying in something built by the lowest bidder"? Maybe they'll have to launch with a techie and his/her hammer strapped to the outside?

Icon.. the techie strapped to outside making sure there's no loose change in his/her pockets.

Best qualiy strategy

Doctor Syntax

The Board and C suite should be on the first crewed flights. Branson and Bezos have set a precedent for this.

Dum dee dum, dum dum dum

Bitsminer

NASA has form in using hammers.

Alan Bean applied the same technique to the color video camera on Apollo 12, when the picture went out after the camera was accidently pointed at the sun.

116:16:02 Bean: I hit it on the top with my hammer. I figured we didn't have a thing to lose.

https://www.hq.nasa.gov/office/pao/History/alsj/a12/a12.tvtrbls.html

Inventor of the Marmite Laser

Keeeeerist.

If it's a Boeing, there's no way I'm going.

Boeing knows best !!!

Anonymous Coward

Looks like Boeing has sneaked in an MCAS (Maneuvering Characteristics Augmentation System) equivalent into the Starliner !!!

No doubt to make the Starliner handle like a 'Space shuttle' when in orbit.

or

(from wikipedia article)

"In July 2018, a test anomaly was reported in which there was a hypergolic propellant leak due to several faulty abort system valves."

Seems that the issue was solved by 'welding the valves shut' !!!

Not sure how that helps when the abort system may be necessary (it is Boeing after all !!!)

:=)

"applying mechanical, electrical and thermal techniques to prompt the valves to open."

Mike Richards

Hitting it.

Turning it off and on again.

Setting fire to it.

"Besides, I think [Slackware] sounds better than 'Microsoft,' don't you?"
(By Patrick Volkerding)