Foam crack examined as NASA readies for launch (Launch on for 7/4)

CNN ^ | Monday, July 3, 2006 | Miles O'Brien, Kate Tobin, Marsha Walton and Jason Meucci

[MinorityRepublican]

KENNEDY SPACE CENTER, Florida (CNN) -- Engineers on Monday are closely scrutinizing a small crack in insulation on space shuttle's fuel tank as NASA continues to prepare for a Tuesday launch.

NASA deputy manager John Shannon said foam that cracked covers a bracket that connects the liquid oxygen feedline to shuttle Discovery's external fuel tank.

When engineers went to inspect it, they pinched off a .0057-pound, 3- inch piece of foam.

Even so, Shannon said, had that piece fallen off during launch it wouldn't have damaged the orbiter.

The crack was discovered during an inspection Sunday evening, and is 4- to 5-inches- long and eighth- to a quarter-inch wide, NASA said. (Watch CNN's space expert explain when and why the crack could have appeared -- 1:27)

The Mission Management Team met Monday morning to go over possible scenarios -- including a possible fix.

Team members will meet again Monday evening to decide whether it must be fixed and whether the shuttle can launch Tuesday at 2:38 p.m. ET.

"We're going to meet back again at 6:30 p.m. ET tonight and summarize where we are with the analysis, summarize where we are with the inspection, try and and clear all our concerns and go launch tomorrow," Shannon said.

NASA has until July 19 to attempt a launch.

If a repair is needed, NASA would have to build a platform that would reach out to the bracket, which would allow engineers to make the fix, according to NASA spokesman Bruce Buckingham.

That would take more than a day, and delay Tuesday's launch.

But Buckingham says there's no fear the July 19 window would be in jeopardy.

There are two concerns with the cracked foam -- it could fall off during launch, and the piece is close to the belly of the orbiter.

[MinorityRepublican]

The crack covers a bracket that connects the liquid oxygen feedline to Discovery's external fuel tank.

[MinorityRepublican]

When engineers went to inspect the crack, they pinched off a .0057-pound, 3- inch piece of foam.

[SE Mom]

Absolutely beautiful afternoon here today...would have been perfect.

[hoagy62]

In actuality, the decision to fly/not fly tomorrow will be AFTER the 6:30PM EDT meeting of the Mission Management Team. FOR NOW, the launch is still on, but this may change.

[MinorityRepublican]

In actuality, the decision to fly/not fly tomorrow will be AFTER the 6:30PM EDT meeting of the Mission Management Team. FOR NOW, the launch is still on, but this may change.

NASA sure can't make up their own mind.

[hoagy62]

Tell me about it. Everyone's got such a "CYA" mentality that it's no wonder nothing gets done around there!

I tell you, even though I love what NASA does, space exploration HAS to be put in the hands of private enterprise so we can get the ball rolling ahead again!

[MaDeuce]

Is this that EPA approved foam or is this the same good old foam from years gone by used on the tanks?

Wasn't there dammage during the last launch due to the EPA approved junk foam?

I think the head of the EPA and his family should be part of this mission if they believe their PC Enviro friendly stuff is so great.

[oxcart]

In the olden days test flights of experimental aircraft were conducted at dawn when the wind was light and weather best. Is there a reason they need to launch in the afternoon? Is it so they reach the Space Station at the right moment?

[Knute]

A piece of duct tape will take care of that pesky little crack!

[burzum]

Wasn't there dammage during the last launch due to the EPA approved junk foam?

No. This comment appears on almost all Shuttle threads. The foam that was on the bipod mount (from which foam shedding impacted the wing), had a EPA waiver and was of the old design.

[burzum]

Actually, now that I have read your comment again, I think you were referring to the Discovery launch last year. I can't tell you the answer to that. I do know that the CAIB report noted that 80% of shuttle flights observed had shed foam, and 10% had shed foam from the bipod mount. This occurred throughout 2 separate changes in foam design (one of which was for the EPA regulations, of which certain areas got waivers).

[rocksblues]

NASA deputy manager John Shannon

John should now be aboard the shuttle when it launches!

[AVNevis]

Off topic question - Why the July 19th deadline? What happens then?

[burzum]

In the olden days test flights of experimental aircraft were conducted at dawn when the wind was light and weather best. Is there a reason they need to launch in the afternoon? Is it so they reach the Space Station at the right moment?

Yes. They are trying to hit a moving target.

[burzum]

Why the July 19th deadline?

The shuttle has to launch during the day for this second test flight. That is so that the cameras on the ground and in the air can observe if the corrections to the foam have been successful. I think that's the reason.

[RightWhale]

There are orbital constraints.

[cabojoe]

Alot of the launch timing constraints have to do with the lighting conditions available for tank photography, as well as the before mentioned orbital constraints.

[mwyounce]

The shuttle has to launch at the moment that the launch pad is in the plane of the orbit of the space station (imagine slicing the Earth in half along the path the ISS takes) because the ISS will be a rescue craft if the Discovery is damaged.

As well, after Columbia, two new guidelines were set: The shuttle must launch in daylight, and the the external tank needs to be examined in daylight after it is dropped, 8 minutes into the launch.

For this reason, the window for launch is only about 10 minutes long, and after July 19, the right time to launch, as determined by the ISS, would fall at the wrong time for the other requirements.

http://www.spaceflightnow.com/shuttle/sts121/fdf/sts121windows.html

[COBOL2Java]

Shuttle Foam Loss Linked to EPA Regs

As recently as last month, NASA had been warned that foam insulation on the space shuttle's external fuel tank could sheer off as it did in the 2003 Columbia disaster - a problem that has plagued space shuttle flights since NASA switched to a non-Freon-based type of foam insulation to comply with Clinton administration Environmental Protection Agency regulations.

Source: Newsmax

[tlj18]

NASA will have gone insane if they launch tomorrow. I mean, a piece of foam has come off, there's a crack in the foam... Couldn't that crack cause the foam to further deteriorate and crack more during launch? Yes, they want to get back into space, I can't blame them, but if we lose another orbiter, the program is OVER.

[RightWhale]

Maybe that's the idea.

[burzum]

Feel free to look up BX-250 foam. This is the original freon foam. It was mounted on the bipod and came off and caused the loss of the shuttle. Feel free to read the CAIB report.

The freon foam doomed the Columbia. Noone knows if the EPA regs will doom future shuttles, but it is known that they haven't doomed any so far (unless EPA regs affected the loss of the Challenger).

[tlj18]

Of course, we're also talking about people's lives here.

[my_pointy_head_is_sharp]

What is wrong with these people? The shuttle was due to launch days ago, and they're just discovering the crack NOW??

[burzum]

NASA will have gone insane if they launch tomorrow. I mean, a piece of foam has come off, there's a crack in the foam... Couldn't that crack cause the foam to further deteriorate and crack more during launch? Yes, they want to get back into space, I can't blame them, but if we lose another orbiter, the program is OVER.

Not to mention that the major purpose for launching this test flight is to see if the corrections made to the foam would prevent it from shedding. That obviously didn't work if it starts shedding on the ground! The secondary purpose for this mission is to see if repair technologies work. Perhaps they want to see if the repairs work in action.

[SC Swamp Fox]

they're just discovering the crack NOW?

They are speculating that the foam insulation was cracked due to the expansion and contraction of the tank caused by the multiple fueling and defueling operations over the last two days.

[The Great RJ]

This foam problem dates from the decision to make the foam with "earth friendly" CO2 rather that CFCs.

[forrestroche]

>>>>>What is wrong with these people?

Just calm down.

>>>>>The shuttle was due to launch days ago, and they're just discovering the crack NOW??

The crack did not exist days ago. It formed after pumping the cryo tanks empty, most likely due to expansion and contraction of a line articulation, and/or ice buildup under the foam at the articulation, that melting after pumping out the tanks.

[Chode]

make with the 200MPH tape already...

[forrestroche]

>>>>>They are speculating that the foam insulation was cracked due to the expansion and contraction of the tank caused by the multiple fueling and defueling operations over the last two days.

Not exactly.

[jetson]

[AVNevis]

Thanks

[fedupjohn]

In the olden days test flights of experimental aircraft were conducted at dawn when the wind was light and weather best. Is there a reason they need to launch in the afternoon? Is it so they reach the Space Station at the right moment?

Yea, the space stations orbit need to be over the launch site.

[UCANSEE2]

"The shuttle was due to launch days ago, and they're just discovering the crack NOW??":

You do realize that the shuttle, boosters, and primary are an immensely large structure?

That the craft and engines are not attached to very much in the way of structure that would allow viewing and access to the surface of the ship or engines?

That everyone is pulled back from the launch pad way before the actual launch?

[UCANSEE2]

Also, the fact that we are being told about it now, doesn't mean they just discovered it.

[oxcart]

Thank You! I understand but, one hour earlier on Saturday would of made a big difference.

[RightWhale]

It's the same problem when they have to rendezvous with the Hubble or another satellite. When they are going up on a Shuttle only mission they can launch anytime unless they are supposed to deploy a satellite from the cargo bay that needs to be in a specific orbit, which isn't often but has happened.

[tlj18]

REPORT: Launch will occur tomorrow, news conference set for 9 p.m. EDT (just a few minutes away)...

[tet68]

Time for the Superglue!

Tell ya'll what, If I go out there and squeeze Superglue in
the crack, do I get to ride it up tomorrow?

No problemo.

I'll be BACK!

I suppose that would be too simple, an engineer would want
to design a tool and test it first.

[tet68]

Thanks, got it running now.

[tet68]

Briefing on now, they are go for launch tomorrow.

[tet68]

We Fly Bump.

[tet68]

Ok, I take that back about the engineers, they
put a camera on a piece of PVC and viewed the "crack"!

GO NASA!

[Cyclopean Squid]

Let's hope they know what they're doing. I hope this decision hasn't been fueled by politics.

[Eastbound]

Is this the countdown thread?

[MinorityRepublican]

No, we talked about foam damage in this thread.