Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket on Dec. 6, 2015. Credit: Ken Kremer/kenkremer.com
Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
Story/photos updated
KENNEDY SPACE CENTER, FL – Today’s spectacular blastoff of a United Launch Alliance Atlas V rocket carrying an Orbital ATK Cygnus commercial resupply spacecraft ignited the restart of critically needed American cargo mission to the International Space Station (ISS) following a pair of launch failures over the past year.
Reflection view of Orbital ATK Cygnus CRS-4 spacecraft poised for blastoff to ISS on ULA Atlas V on Dec. 5, 2015 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com
Reflection view of Orbital ATK Cygnus CRS-4 spacecraft poised for blastoff to ISS on ULA Atlas V on Dec. 5, 2015 from Cape Canaveral Air Force Station, Florida. Credit: Ken Kremer/kenkremer.com
KENNEDY SPACE CENTER, FL – The unplanned ‘Happy Marriage’ of United Launch Alliance (ULA) and Orbital ATK is set to give birth Sunday, Dec. 6, to a Cygnus cargo freighter bound for the International Space Station (ISS).
Following two scrubs and a three day due to intense and wide spread rain squalls and excessive blustery winds, the third time is hopefully the charm for the Orbital ATK Cygnus resupply ship set for blastoff atop the venerable ULA Atlas V booster.
United Launch Alliance Atlas V rocket – powered by Russian made RD-180 engines – and Super Secret NROL-67 intelligence gathering payload poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station, FL, in March 2014. Credit: Ken Kremer – kenkremer.com
File photo of Atlas V rocket – powered by Russian made RD-180 engines – and Super Secret NROL-67 intelligence gathering payload following rollout to Space Launch Complex 41 at Cape Canaveral Air Force Station, FL, on March 24, 2014. Credit: Ken Kremer/kenkremer.com
First enhanced Orbital ATK Cygnus commercial cargo ship is fully assembled and being processed for blastoff to the ISS on Dec. 3, 2015 on an ULA Atlas V rocket. This view shows the Cygnus, named the SS Deke Slayton II, and twin payload enclosure fairings inside the Kennedy Space Center clean room. Credit: Ken Kremer/kenkremer.com
First enhanced Orbital ATK Cygnus commercial cargo ship is fully assembled and being processed for blastoff to the ISS on Dec. 3, 2015 on a ULA Atlas V rocket. This view shows the Cygnus, named the SS Deke Slayton II, and twin payload enclosure fairings inside the Kennedy Space Center clean room. Credit: Ken Kremer/kenkremer.com
KENNEDY SPACE CENTER, FL – The largest and most advanced version of the privately developed Cygnus cargo freighter ever built by Orbital ATK is fueled, loaded and ready to go to orbit – signifying a critical turning point towards resuming American commercial cargo launches to the space station for NASA that are critical to keep it functioning.
The enhanced and fully assembled commercial Cygnus was unveiled to the media, including Universe Today, during an exclusive tour inside the clean room facility on Friday, Nov. 13, where it is undergoing final prelaunch processing at the Kennedy Space Center (KSC).
The high gain antenna and solar arrays were installed on the OSIRIS-REx spacecraft prior to it moving to environmental testing. Credits: Lockheed Martin Corporation
OSIRIS-Rex, the first American spacecraft ever aimed at snatching pristine samples from the surface of an asteroid and returning them to Earth for exquisite analysis by researchers world-wide with the most advanced science instruments has successfully completed its assembly phase and moved into the “test drive” phase – just ten months before blastoff, following installation of all its science instruments at Lockheed Martin Space Systems facilities, near Denver, Colorado.
The launch window for OSIRIS-REx opens next fall on September 3, 2016 on a seven-year journey to asteroid Bennu and back. Bennu is a carbon-rich asteroid. OSIRIS-Rex will eventually return the largest sample from space since the American and Soviet Union’s moon landing missions of the 1970s.
The science payload installation was recently completed with attachment of the vehicles three camera instrument suite of cameras and spectrometers known as OCAMS (OSIRIS-REx Camera Suite), which was was designed and built by the University of Arizona’s Lunar and Planetary Laboratory.
OCAMS trio of instruments, PolyCam, MapCam and SamCam, will survey and globally map the surface of Bennu up close at a distance ranging from approximately 5 km to 0.7 km.
“PolyCam, MapCam and SamCam will be our mission’s eyes at Bennu,” said Dante Lauretta, principal investigator for OSIRIS-REx at the University of Arizona, Tucson, in a statement.
“OCAMS will provide the imagery we need to complete our mission while the spacecraft is at the asteroid.”
“All in all it was flawless installation, with the three cameras and the control electronics making it on the spacecraft well in advance of when we originally planned these activities. In general, the OSIRIS-REx ATLO (assembly, test and launch operations) flow has gone smoothly,” said Lauretta in a blog update.
The University of Arizona’s camera suite, OCAMS, sits on a test bench that mimics its arrangement on the OSIRIS-REx spacecraft. The three cameras that compose the instrument – MapCam (left), PolyCam and SamCam – are the eyes of NASA’s OSIRIS-REx mission. They will map the asteroid Bennu, help choose a sample site, and ensure that the sample is correctly stowed on the spacecraft. Credits: University of Arizona/Symeon Platts
For the next five months, NASA’s OSIRIS-REx which stands for Origins, Spectral Interpretation, Resource Identification, Security, Regolith Explorer will undergo a rigorous regime of critical environmental testing to ensure the probe will survive the unforgiving extremes of vacuum, vibration and extreme temperatures it will experience during launch and throughout the life of its planned eight year mission.
The asteroid sampling spacecraft is tracking on budget and ahead of schedule.
“OSIRIS-REx is entering environmental testing on schedule, on budget and with schedule reserves,” said Mike Donnelly, OSIRIS-REx project manager at NASA’s Goddard Space Flight Center in Greenbelt, Maryland, in a statement.
“This allows us to have flexibility if any concerns arise during final launch preparations.”
Bennu is a near-Earth asteroid and was selected for the sample return mission because it “could hold clues to the origin of the solar system and host organic molecules that may have seeded life on Earth,” says NASA.
The spacecraft is equipped with a suite of five science instruments to remotely study the 492 meter wide asteroid.
The instruments were all installed as planned on the spacecraft deck over the past few months so they can all be subjected to the environmental testing together with the spacecraft bus.
“This milestone marks the end of the design and assembly stage,” said Lauretta, in a statement.
“We now move on to test the entire flight system over the range of environmental conditions that will be experienced on the journey to Bennu and back. This phase is critical to mission success, and I am confident that we have built the right system for the job.”
The tests will “simulate the harsh environment of space, including acoustical, separation and deployment shock, vibration, and electromagnetic interference. The simulation concludes with a test in which the spacecraft and its instruments are placed in a vacuum chamber and cycled through the extreme hot and cold temperatures it will face during its journey to Bennu,” say NASA officials.
Video caption: Engineers at Lockheed Martin move the OSIRIS-REx spacecraft onto a rotation fixture. This fixture supports the full weight of the spacecraft and acts as a hinge, orienting the spacecraft at a 90 degree angle, which allows engineers to access the top of the spacecraft much more easily. Credits: Lockheed Martin Corporation
The testing is done to uncover any issues lurking prior next September’s planned liftoff.
“This is an exciting time for the program as we now have a completed spacecraft and the team gets to test drive it, in a sense, before we actually fly it to asteroid Bennu,” said Rich Kuhns, OSIRIS-REx program manager at Lockheed Martin Space Systems.
“The environmental test phase is an important time in the mission as it will reveal any issues with the spacecraft and instruments, while here on Earth, before we send it into deep space.”
After the testing is complete by next May, the spacecraft will ship from Lockheed Martin’s Denver facility to NASA’s Kennedy Space Center, where it will undergo final prelaunch preparations and transport to the launch pad at Cape Canaveral.
Artist concept of OSIRIS-REx, the first U.S. mission to return samples from an asteroid to Earth. Credit: NASA/Goddard
OSIRIS-REx is scheduled for launch in September 2016 from Cape Canaveral Air Force Station in Florida aboard a United Launch AllianceAtlas V 411 rocket, which includes a 4-meter diameter payload fairing and one solid rocket motor. Only three Atlas V’s have been launched in this configuration.
“This is an exciting time,” says Lauretta.
The spacecraft will reach Bennu in 2018. OSIRIS-REx will gather rocks and soil and bring at least a 60-gram (2.1-ounce) sample back to Earth in 2023 for study by researchers here with all the most sophisticated science instruments available.
Bennu is an unchanged remnant from the collapse of the solar nebula and birth of our solar system some 4.5 billion years ago, little altered over time.
OSIRIS-REx is the third mission in NASA’s New Frontiers Program, following New Horizons to Pluto and Juno to Jupiter, which also launched on Atlas V rockets.
NASA’s Goddard Space Flight Center in Greenbelt, Maryland, is responsible for overall mission management.
OSIRIS-REx complements NASA’s Asteroid Initiative – including the Asteroid Redirect Mission (ARM) which is a robotic spacecraft mission aimed at capturing a surface boulder from a different near-Earth asteroid and moving it into a stable lunar orbit for eventual up close sample collection by astronauts launched in NASA’s new Orion spacecraft. Orion will launch atop NASA’s new SLS heavy lift booster concurrently under development.
OSIRIS-REx logo
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Cygnus service module built by Orbital ATK in their Dulles, Virginia cleanroom is shown here with unfurled Ultraflex solar panels that will fly for the first time with mated pressurized module on the OA-4 ISS resupply mission on ULA Atlas V rocket on Dec. 3, 2015 from Cape Canaveral, Florida. Credit: Orbital ATK
Cygnus service module built by Orbital ATK in their Dulles, Virginia cleanroom is shown here with unfurled UltraFlex solar panels that will fly for the first time with mated pressurized module on the OA-4 ISS resupply mission on ULA Atlas V rocket on Dec. 3, 2015 from Cape Canaveral, Florida. Credit: Orbital ATK
See OA-4 mission patch and hardware photos below
The biggest and heaviest Cygnus commercial cargo craft ever built by Orbital ATK is coming together at the Kennedy Space Center as the launch pace picks up steam for its critical ‘Return to Flight’ resupply mission to the space station for NASA. Cygnus is on target for an early December blastoff from Florida and the Orbital ATK team is “anxious to get flying again.”
100th United Launch Alliance (ULA) rocket streaks to orbit with Atlas V booster carrying the Morelos-3 mission for Mexico from Space Launch Complex 41 on Cape Canaveral Air Force Station, Florida at 6:28 a.m. EDT, Oct. 2, 2015 as seen from Melbourne Beach pier, Florida. Credit: Julian Leek
100th United Launch Alliance (ULA) rocket streaks to orbit with Atlas V booster carrying the Morelos-3 mission for Mexico from Space Launch Complex 41 on Cape Canaveral Air Force Station, Florida at 6:28 a.m. EDT, Oct. 2, 2015 as seen from Melbourne Beach pier, Florida. Credit: Julian Leek See launch photo and video gallery below
United Launch Alliance (ULA) celebrated an incredible milestone today, Oct. 2, with the successful launch of the firms 100th mission on an Atlas V rocket carrying Mexico’s next generation Morelos-3 satellite to provide advanced telecommunications for education and health programs for rural communities and secure communications for Mexican national security needs.
NOAA's GOES-East satellite captured this visible image of Hurricane Joaquin affecting the Bahamas on Thursday, Oct. 1 at 1255 UTC. Credits: NASA/NOAA GOES Project
Video caption: This animation of images captured from September 29 to October 1, 2015 from NOAA’s GOES-East satellite shows Hurricane Joaquin become a major hurricane in the Bahamas. Credits: NASA/NOAA GOES Project
NEW JERSEY – A wide swath of the US East Coast is bracing for impact in the coming days as ‘Hurricane Joaquin’ strengthened to a major and dangerous Category 4 storm, today, Thursday, Oct. 1, as NASA and NOAA satellites keep constant watch as it barrels potentially towards tens of millions of coastal residents.
Joaquin is already packing winds exceeding 130 mph with even higher wind gusts as the storm continues to strengthen at this hour and the pressure is decreasing. See the latest Hurricane Joaquin animation and imagery from NASA and NOAA, above and below.
A ULA Atlas V is slated to lift off Friday from Cape Canaveral Air Force Station in Florida at 6:08 a.m. EDT with the Morelos-3 communications satellite for Mexico, before the hurricane gets closer to Florida.
The National Hurricane Center declared Joaquin had intensified into a massive Category 4 hurricane on the Saffir-Simpson Wind Scale, as of 2 PM EDT today, Oct. 1.
You can watch the launch on ULA’s live webcast starting at 5:48 a.m. Oct 2: http://www.ulalaunch.com
The governors of three states – New Jersey, Virginia and North Carolina – have already declared ‘States of Emergency’ in anticipation of potentially destructive winds, potentially life threatening drenching rains and floods, downed power lines and ocean rip currents with high waves in local areas.
Multiple NASA and NOAA satellites are intensively and continuously observing Joaquin, and are providing absolutely critical data to forecasters and government officials with the most current and best information available.
NASA’s GPM, Terra and NPP-Suomi satellites and NOAA’s GOES-East satellite are tracking Joaquin and have seen powerful thunderstorms today which indicates continued strengthening.
At this time we still don’t whether the US eastern seaboard will suffer a major hit but officials are taking no chances after suffering through Superstorm Sandy which caused many deaths, widespread power outages and billions and billions of dollars of damage – from which we are still recovering.
Joaquin is currently over The Bahamas in the Caribbean and is expected to make a sharp right turn on Friday Oct 2 and head northwards to the east coast and the Atlantic Ocean. It could start impacting the Carolinas and regions further north as soon as Sunday, Oct. 4, based on current forecasts, and drop double digits inches of torrential rainfall.
NASA-NOAA’s Suomi NPP satellite passed over Joaquin at 06:10 UTC (2:10 a.m. EDT) on Oct. 1 as it was strengthening from a Category 2 to a Category 3 hurricane. It’s now a Category 4. Imagery showed cloud top temperatures colder than -63F/-53C (yellow). Credits: NRL/NASA/NOAA
Its pounding the Bahamas right now and is creating a disaster with hurricane force winds and heavy rainfall, say weather forecasters, as it remains over the island for some 24 hours or more and may drop over 10 inches of rain.
But there is a very wide cone of uncertainly of where it could hit as the possible storm track extends from the Carolinas to Maine. It may or may not directly impact the eastern US. The storm may shift to the right and spare the east coast. But no one knows at this time.
Some areas on the US East coast stretching from Virginia to Maine have already suffered from torrential rains and severe flooding from an unrelated storm the past few days and also right now today, Thursday.
So the grounds are already saturated in parts of the Carolina’s, Virginia, Maine and elsewhere.
NASA/JAXA’s GPM satellite provided a 3-D side view of Tropical Storm Joaquin on Sept. 29 showing the internal precipitation structure. The areas in blue are frozen precipitation. Areas in green and red are liquid precipitation. Credits: Scientific Visualization Studio, NASA’s Goddard Space Flight Center
Coastal flood warnings and watches are already in effect in many areas along the eastern seaboard where local areas could be drenched by some 12 to 18 inches of additional rain which could fall even before the hurricane hits.
Significant beach erosion has already occurred in the Carolinas over the past few days and more is expected up and down the entire coast up to Maine.
And 10 foot high defense berms of sand are being constructed at this moment along miles and miles of the Jersey Shore – areas that suffered devastating damage from Superstorm Sandy.
There is a potential risk of deadly flooding, flash flooding and damage to houses, buildings, businesses, roadways and infrastructure.
“At 2 p.m. EDT (1800 UTC), the center of Hurricane Joaquin was located near latitude 23.0 North, longitude 74.2 West. Joaquin was moving generally southwestward at about 6 mph (9 kph), and the National Hurricane Center forecast a turn toward the northwest and north on Friday, Oct. 2. On the forecast track, the center of Joaquin will move near or over portions of the central Bahamas today and tonight and pass near or over portions of the northwestern Bahamas on Friday, Oct. 2,” according to NASAs Rob Gutro.
The weather forecast for Friday’s launch from Cape Canaveral , Florida is currently 70 percent GO for liftoff of the United Launch Alliance Atlas V rocket at 6:08 a.m. EDT. The Atlas V will launch with the Morelos-3 mission for Mexico’s Secretaria de Comunicaciones y Transportes (Ministry of Communications and Transportation).
Morelos-3 will be part of the Mexsat constellation of satellites that delivers advanced telecommunications throughout Mexico. United Launch Alliance Atlas V rocket after rollout to Pad 41 at Cape Canaveral Air Force Station, Florida for planned Oct. 2 launch at 6:08 a.m. EDT with the Morelos-3 mission for Mexico’s Ministry of Communications and Transportation. In progress assembly of the commercial crew access tower is seen at right, now under construction for the Boeing Starliner space taxi for astronaut crews launching to the ISS. Credit: Julian Leek
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
United Launch Alliance Atlas V rocket during rollout to Space Launch Complex-41 at Cape Canaveral Air Force Station, Florida on Oct. 1 for planned Oct. 2 launch at 6:08 a.m. EDT with the Morelos-3 mission for Mexico’s Ministry of Communications and Transportation. Credit: Julian Leek
Rendering of the ULA Vulcan rocket blasting off. United Launch Alliance (ULA) next generation rocket is set to make its debut flight in 2019. Credit: ULA
Aerojet Rocketdyne, which supplies critical rocket engines powering ULA’s fleet of Atlas and Delta rockets, recently made an unsolicited offer to buy ULA for approximately $2 Billion in cash, as Universe Today reported last week.
The Vulcan is planned to replace all of ULA’s existing rockets – which are significantly more costly than those from rival launch provider SpaceX, founded by billionaire entrepreneur Elon Musk.
Boeing never “seriously entertained” the Aerojet-Rocketdyne buyout offer, Universe Today confirmed with Boeing spokesperson Cindy Anderson.
Meanwhile in stark contrast to Boeing, Lockheed Martin has “no comment” regarding the Aerojet-Rocketdyne offer to buy ULA, Universe Today confirmed with Lockheed Martin Director External Communications Matt Kramer.
Furthermore Lockheed Martin is not only noncommittal about the future of ULA but is also “currently assessing our options” concerning the development of ULA’s Vulcan rocket, Kramer told me.
“With regard to reports of an unsolicited proposal for ULA, it is not something we seriously entertained for a number of reasons,” Boeing spokesperson Anderson told Universe Today.
“Regarding Aerojet and ULA, as a matter of policy Lockheed Martin does not have a comment,” Lockheed Martin spokesman Kramer told Universe Today.
Vulcan – United Launch Alliance (ULA) next generation rocket is set to make its debut flight in 2019. Credit: ULA
ULA was formed in 2006 as a 50:50 joint venture between Lockheed Martin and Boeing that combined their existing expendable rocket fleet families – the Atlas V and Delta IV – under one roof.
Who owns ULA is indeed of significance to all Americans – although most have never head of the company – because ULA holds a virtual monopoly on launches of vital US government national security payloads and the nation’s most critical super secret spy satellites that safeguard our national defense 24/7. ULA’s rocket fleet also launched scores of NASA’s most valuable science satellites including the Curiosity Mars rover, Dawn and New Horizons Pluto planetary probe.
Since 2006 ULA has enjoyed phenomenal launch success with its venerable fleet of Atlas V and Delta IV rockets.
“ULA is a huge part of our strategic portfolio going forward along with our satellites and manned space business. This bid we’ve really not spent much time on it at all because we’re focusing on a totally different direction,” said Chris Chadwick, president and chief executive of Boeing Defense, Space & Security, on Sept. 16 at the Air Force Association’s annual technology expo in National Harbor, Maryland – according to a report by Space News.
Boeing offered strong support for ULA and the Vulcan rocket.
Vulcan is ULA’s next generation rocket to space that can propel payloads to low Earth orbit as well as throughout the solar system – including Pluto. It is slated for an inaugural liftoff in 2019.
Vulcan’s continued development is being funded by Lockheed Martin and Boeing, but only on a quarterly basis.
The key selling point of Vulcan is that it will be an all American built rocket and it will dramatically reduce launch costs to compete toe to toe with the SpaceX Falcon rocket family.
And there is a heated competition on which of two companies will provide the new American built first stage engine that will replace the Russian-built RD-180 that currently powers the ULA Atlas V.
Vulcan’s first stage will most likely be powered by the BE-4 engine being developed by the secretive Blue Origin aerospace firm owned by billionaire Jeff Bezos.
This week ULA announced an expanded research agreement with Blue Origin about using the BE-4.
But ULA is also evaluating the AR-1 liquid fueled engine being developed by Aerojet-Rocketdyne – the company that wants to buy ULA.
The Atlas V dependence on Russia’s RD-180’s landed at the center of controversy after Russia invaded Crimea in the spring of 2014, raising the ire of Congress and enactment of a ban on their use several years in the future.
ULA is expected to make a final decision on which first stage engine to use between Blue Origin and Aerojet-Rocketdyne, sometime in 2016.
The engine choice would clearly be impacted if Aerojet-Rocketdyne buys ULA.
Boeing for its part says they strongly support ULA and continued development of the Vulcan.
“Boeing is committed to ULA and its business, and to continued leadership in all aspects of space, as evidenced by the recent announcement of an agreement with Blue Origin,” Boeing spokesperson Anderson told me.
Lockheed Martin in complete contrast did not express any long term commitment to Vulcan and just remarked they were merely “actively evaluating continued investment,” as is their right as a stakeholder.
“We have made no long-term commitments on the funding of a new rocket, and are currently assessing our options. The board is actively evaluating continued investment in the new rocket program and will continue to do so,” Lockheed Director, External Communications Matt Kramer told Universe Today.
Another factor is that Aerojet-Rocketdyne has also sought to buy the rights to manufacture the Atlas V from ULA, which is currently planned to be retired several years after Vulcan is introduced, officials have told me.
Aerojet-Rocketdyne made a bid to buy ULA, manufacturer of the Atlas V, for approximately $2 Billion. MUOS-4 US Navy communications satellite and Atlas V rocket at pad 41 at Cape Canaveral Air Force Station, FL for launch on Sept. 2, 2015 at 5:59 a.m. EDT. Credit: Ken Kremer/kenkremer.com
The Atlas V enjoys unparalleled success. Earlier this month on Sept. 2, ULA conducted its 99th launch with the successful blastoff of an Atlas V with the MUOS-4 military communications satellite from Cape Canaveral Air Force Station for the U.S. Navy.
Starliner will eventually blastoff atop Vulcan after the Atlas V is retired in the next decade.
Lockheed provided me this update on Vulcan and ULA on Sept 21:
“Lockheed Martin is proud of ULA’s unparalleled track record of mission success, with 99 consecutive successful launches to date. We support the important role ULA plays in providing the nation with assured access to space. ULA’s Vulcan rocket takes the best performance elements of Atlas and Delta and combines them in a new system that will be superior in reliability, cost, weight, and capability. The government is working to determine its strategy for an American-made engine and future launch services. As they make those determinations we’ll adjust our strategy to make sure we’re aligned with the government’s objectives and goals.”
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
First view of upper half of the Boeing CST-100 ‘Starliner’ crewed space taxi unveiled at the Sept. 4, 2015 Grand Opening ceremony held in the totally refurbished C3PF manufacturing facility at NASA’s Kennedy Space Center. This will be part of the first Starliner crew module known as the Structural Test Article (STA) being built at Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at KSC. Credit: Ken Kremer /kenkremer.com
The first tier of seven tiers for Crew Access Tower is moved from its construction yard to Space Launch Complex-41 at Cape Canaveral Air Force Station in Florida. The tower will provide access at the pad for astronauts and ground support teams to the Boeing CST-100 Starliner launching atop a United Launch Alliance Atlas V rocket. Photo credit: NASA/Dmitrios Gerondidakis
The first tier of seven tiers for Crew Access Tower is moved from its construction yard to Space Launch Complex-41 at Cape Canaveral Air Force Station in Florida on Sept 9, 2015. The tower will provide access at the pad for astronauts and ground support teams to the Boeing CST-100 Starliner launching atop a United Launch Alliance Atlas V rocket. Photo credit: NASA/Dmitrios Gerondidakis Story/photos updated[/caption]
“Everything is on schedule,” Howard Biegler, ULA’s Human Launch Services Lead, told Universe Today during an exclusive interview. “The new 200-foot-tall tower structure goes up rather quickly at launch pad 41.”
The access tower essentially functions as the astronauts walkway to the stars.
“We start stacking the crew access tower [CAT] after the MUOS-4 launch and prior to the next launch after that of Morelos-3,” Beigler said in a wide ranging interview describing the intricately planned pad modifications and tower construction at the Atlas V Space Launch Complex 41 facility at Cape Canaveral.
Depending on the always tricky weather at the Cape, more than half the tower should be “installed prior to MORELOS-3’s launch on Oct. 2. The balance of the CAT will take form after the launch.”
The first tier of the new Crew Access Tower for the Boeing CST-100 Starliner arrives at Space Launch Complex-41 at Cape Canaveral Air Force Station in Florida on Sept 9, 2015. The tower will provide access at the pad for astronauts and ground support teams to the Boeing CST-100 Starliner launching atop a United Launch Alliance Atlas V rocket. Photo credit: NASA/Dmitrios Gerondidakis
The crew access tower is a critical space infrastructure element and absolutely essential for getting Americans back to space on American rockets for the first time since NASA’s shuttles were retired in 2011. That action forced our total dependence on the Russian Soyuz capsule for astronaut ridesto the space station.
Boeing was awarded a $4.2 Billion contract in September 2014 by NASA Administrator Charles Bolden to complete development and manufacture of the CST-100 space taxi under the agency’s Commercial Crew Transportation Capability (CCtCap) program and NASA’s Launch America initiative. SpaceX also received a NASA award worth $2.6 Billion to build the Crew Dragon spacecraft for launch atop the firms man-rated Falcon 9 rocket.
Starliner is a key part of NASA’s overarching strategy to send Humans on a “Journey to Mars” in the 2030s.
The tower is of modular design for ease of assembly at the always busy Atlas launch pad.
“The crew tower is comprised of seven major tiers, or segments,” Beigler explained. “The building of the tiers went right on schedule. Each tier is about 20 feet square and 28 feet tall.”
Five of the seven tiers will be installed ahead of the next Atlas launch in early October, depending on the weather which has been difficult at the Cape.
“Our plan is to get 5 tiers and a temporary roof installed prior to MORELOS-3’s launch on October 2.”
“We have been hit hard with weather and are hopeful we can gain some schedule through the weekend. The balance of the CAT will take form after the 10/2 launch with the 7th tier planned to go up on 10/13 and roof on 10/15,” Biegler explained.
The first tier of the new Crew Access Tower for the Boeing CST-100 Starliner is installed at Space Launch Complex-41 at Cape Canaveral Air Force Station in Florida where United Launch Alliance Atlas V rockets will lift Boeing Starliners into orbit. Photo credit: NASA/Dmitrios Gerondidakis
The newly named ‘Starliner’ space taxi will launch atop a newly human-rated Atlas V booster as soon as mid-2017, say NASA, ULA and Boeing officials.
But before astronauts can even climb aboard Starliner atop the Atlas rocket, ULA and Boeing first had to design, build and install a brand new tower providing access to the capsule for the crews and technicians.
Pad 41 is currently a “clean pad” with no gantry and no walkway to ‘Starliner’ because the Atlas V has only been used for unmanned missions to date.
The CST-100 ‘Starliner’ is at the forefront of ushering in the new commercial era of space flight and will completely revolutionize how we access, explore and exploit space for the benefit of all mankind.
This is the first new Crew Access Tower to be built at the Cape in decades, going back to NASA’s heyday and the Apollo moon landing era.
The tier segments were assembled about four miles down the road at the Atlas Space Operations Center on Cape Canaveral – so as not to disrupt the chock full manifest of Atlas rockets launching on a breakneck schedule for the NASA, military and commercial customers who ultimately pay the bills to keep ULA afloat and launch groundbreaking science probes and the most critical national security payloads vital to national defense.
“Each segment was outfitted with additional steel work, as well as electrical, plumbing and the staircase. Then they will be transported 3.9 miles out to the pad, one at a time on a gold hoffer and then we start erecting.”
The first two tiers were just transported out to pad 41. Installation and stacking of one tier on top of another starts in a few days.
Artist’s concept of Boeing’s CST-100 space taxi atop a human rated ULA Atlas-V rocket showing new crew access tower and arm at Space Launch Complex 41, Cape Canaveral Air Force Station, Fl. Credit: ULA/Boeing
“We are very pleased with the progress so far,” Biegler told me. “Everything is on schedule and has gone remarkably well so far. No safety or workmanship issues. It’s all gone very well.”
“The first tier is obviously the most critical [and will take a bit longer than the others to insure that everything is being done correctly]. It has to be aligned precisely over the anchor bolts on the foundation at the pad. Then it gets bolted in place.”
“After that they can be installed every couple of days, maybe every three days or so. The pieces of the tower will go up quickly.”
Artist’s concept of Boeing’s CST-100 space taxi atop a human rated ULA Atlas-V rocket showing new crew access tower and arm. Credit: ULA/BoeingThe steel tiers and tower are being built by Hensel Phelps under contract to ULA.
“Construction by the Hensel Phelps team started in January 2015,” Biegler said.
Erecting the entire tower is the next step. After stacking the tiers is fully completed later this year then comes structure, testing and calibration work over the next year.
“After tower buildup comes extensive work to outfit the tower with over 400 pieces of outboard steel that have to be installed. That takes much longer,” Biegler said.
“Designed with modern data systems, communications and power networks integrated and protected from blast and vibration, plus an elevator, the Crew Access Tower has been built with several features only a fully suited astronaut could appreciate, such as wider walkways, snag-free railings and corners that are easy to navigate without running into someone,” according to NASA officials.
Just like the shuttle, “the tower will also be equipped with slide wire baskets for emergency evacuation to a staged blast-resistant vehicle.”
“At the very top is the area that protects the access arm and provides the exit location for the emergency egress system. It will all be stick built from steel out at the pad,” Biegler elaborated.
The access arm with the walkway that astronauts will traverse to the Starliner capsule is also under construction. It is about 180 feet above ground.
Astronauts will ride an elevator up the tower to the access arm, and walk through it to the white room at the end to board the Starliner capsule.
“The arm along with the white room and torque tube are being fabricated in Florida. It will all be delivered to the pad sometime around next June [2016],” Biegler stated.
“We built a test stand tower for the access arm at our Oak Hill facility to facilitate the installation process. We mount the arm and the hydraulic drive system and then run it through its paces prior to its delivery to the pad.”
“The access arm – including the torque tube out to the end – is just over 40 feet in length.”
“We will integrate it off line because we don’t have a lot of time to troubleshoot out at the pad. So we will hook up all its drive systems and electronics on the test structure stand.”
“Then we will spend about 3 months testing it and verifying that everything is right. We’ll use laser lining to know it all precisely where the arm is. So that when we bring it out to the pad we will know where it is to within fractions of an inch. Obviously there will be some minor adjustments up and down.”
“That way in the end we will know that everything in the arm and the hydraulic drive system are working within our design specs.”
When the arm is finally installed on the crew access tower it will be complete, with the white room and environmental seal already attached.
“It will stow under the crew access tower, which is located west and north of the launch vehicle. The arm will swing out about 120 degrees to the crew module to gain access and was strategically picked to best fit the features and foundation at the existing pad structure.”
Tower construction takes place in between Atlas launches and pauses in the days prior to launches. For example the construction team will stand down briefly just ahead of the next Atlas V launch currently slated for Oct. 2 with the Mexican governments Morelos-3 communications satellite.
The Crew Access Tower is now being erected at Pad 41 following MUOS-4 blastoff here. MUOS-4 US Navy communications satellite and Atlas V rocket at pad 41 at Cape Canaveral Air Force Station, FL for launch on Sept. 2, 2015 at 5:59 a.m. EDT. Credit: Ken Kremer/kenkremer.com
Starliners’ actual launch date totally depends on whether the US Congress provides full funding for NASA’s commercial crew program (CCP).
Thus far the Congress has totally failed at providing the requested CCP budget to adequately fund the program – already causing a 2 year delay of the first flight from 2015 to 2017.
Boeing is making great progress on manufacturing the first CST-100 Starliner.
Barely a week ago, Boeing staged the official ‘Grand Opening’ ceremony for the craft’s manufacturing facility held at the Kennedy Space Center on Friday, Sept 4. 2015 – attended by Universe Today as I reported here.
ULA has also already started assembly of the first two Atlas V rockets designated for Starliner at their rocket factory in Decatur, Alabama.
Read my earlier exclusive, in depth one-on-one interviews with Chris Ferguson – America’s last shuttle commander, who now leads Boeings’ CST-100 program; here and here.
First view of the Boeing CST-100 ‘Starliner’ crewed space taxi at the Sept. 4, 2015 Grand Opening ceremony held in the totally refurbished C3PF manufacturing facility at NASA’s Kennedy Space Center. These are the upper and lower segments of the first Starliner crew module known as the Structural Test Article (STA) being built at Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at KSC. Credit: Ken Kremer /kenkremer.com
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
