How the Air Force and SpaceX Saved Dragon from Doom

This grappling of the SpaceX Dragon capsule on March 3, 2013 by the space station robotic arm nearly didn’t happen when a thruster failure just minutes after the March 1 liftoff nearly doomed the mission. Credit: NASA

The picture perfect docking of the SpaceX Dragon capsule to the International Space Station (ISS) on March 3 and the triumphant ocean splashdown last week on March 26 nearly weren’t to be – and it all goes back to a microscopic manufacturing mistake in the oxidizer tank check valves that no one noticed long before the vessel ever took flight.

Barely 11 minutes after I witnessed the spectacular March 1 blastoff of the Dragon atop the SpaceX Falcon 9 rocket from Cape Canaveral, Florida, everyone’s glee suddenly turned to disbelief and gloom with the alarming news from SpaceX Mission Control that contact had been lost.

I asked SpaceX CEO and founder Elon Musk to explain what caused the failure and how they saved the drifting, uncontrolled Dragon capsule from doom – just in the nick of time.

Applying the space version of the Heimlich maneuver turned out to be the key. But if you can’t talk to the patient – all is lost.

dragonRight after spacecraft separation in low Earth orbit , a sudden and unexpected failure of the Dragon’s critical thrust pods had prevented three out of four from initializing and firing. The oxidizer pressure was low in three tanks. And the propulsion system is required to orient the craft for two way communication and to propel the Dragon to the orbiting lab complex.

So at first the outlook for the $133 million Dragon CRS-2 cargo resupply mission to the ISS appeared dire.

Then, SpaceX engineers and the U.S Air Force sprang into action and staged an amazing turnaround.

“The problem was a very tiny change to the check valves that serve the oxidizer tanks on Dragon.” Musk told Universe Today

“Three of the check valves were actually different from the prior check valves that had flown – in a very tiny way. Because of the tiny change they got stuck.”

Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com

SpaceX engineers worked frantically to troubleshoot the thruster issues in an urgent bid to overcome the serious glitch and bring the crucial propulsion systems back on line.

“What we did was we were able to write some new software in real time and upload that to Dragon to build pressure upstream of the check valves and then released that pressure- to give it a kind of a kick,” Musk told me at a NASA media briefing.

“For the spacecraft you could call it kind of a Heimlich maneuver. Basically that got the valves unstuck and then they worked well”

“But we had difficulty communicating with the spacecraft because it was in free drift in orbit.”

“So we worked closely with the Air Force to get higher intensity, more powerful dishes to communicate with the spacecraft and upload the software to do the Heimlich pressure maneuver.”

Schematic of SpaceX Dragon. Credit: SpaceX
Schematic of SpaceX Dragon. Credit: SpaceX

Just how concerned was Musk?

“Yes, definitely it was a worrying time,” Musk elaborated.

“It was a little frightening,” Musk had said right after the March 1 launch.

Later in the briefing Musk explained that there had been a small design change to the check valves by the supplier.

“The supplier had made mistakes that we didn’t catch,” said Musk. “You would need a magnifying glass to see the difference.”

SpaceX had run the new check valves through a series of low pressurization systems tests and they worked well and didn’t get stuck. But SpaceX had failed to run the functional tests at higher pressures.

“We’ll make sure we don’t repeat that error in the future,” Musk stated.

Musk added that SpaceX will revert to the old check valves and run tests to make sure this failure doesn’t happen again.

SpaceX, along with Orbital Sciences Corp, are both partnered with NASA’s Commercial Resupply Services program to replace the cargo up mass capability the US lost following the retirement of NASA’s space shuttle orbiters in 2011.

Orbital’s Antares rocket could blast off on its first test mission as early as April 17.

Of course the Dragon CRS-2 flight isn’t the first inflight space emergency, and surely won’t be the last either.

So, for some additional perspective on the history of reacting to unexpected emergencies in space on both human spaceflight and robotic science probes, Universe Today contacted noted space historian Roger Launius, of the Smithsonian National Air & Space Museum (NASM).

Roger provided these insights to Universe Today editor Nancy Atkinson – included here:

“There are many instances in the history of spaceflight in which the mission had difficulties that were overcome and it proved successful,” said Launius.

“Let’s start with Hubble Space Telescope which had a spherical aberration on its mirror and the first reports in 1990 were that it would be a total loss, but the engineers found workarounds that allowed it to be successful even before the December 1993 servicing mission by a shuttle crew that really turned it into a superb scientific instrument.”

“Then what about Galileo, the Jupiter probe, which had a problem with its high gain antenna. It never did fully deploy but the engineers found ways to overcome that problem with the communication system and the spacecraft turned into a stunning success.”

“If you want to feature human spaceflight let’s start with the 1999 shuttle flight with Eileen Collins as commander that had a shutdown of the SSMEs prematurely and it failed to reach its optimum orbit. It still completed virtually all of the mission requirements.”

“That says nothing about Apollo 13,… I could go on and on. In virtually every mission there has been something potentially damaging to the mission that has happened. Mostly the folks working the mission have planned for contingencies and implement them and the public rarely hears about it as it looks from the outside like a flawless operation.”

“Bottom line, the recovery of the Dragon capsule was not all that amazing. It was engineers in the space business doing what they do best,” said Launius.

Ken Kremer

…………….

Learn more about SpaceX, Antares, Curiosity and NASA missions at Ken’s upcoming lecture presentations:

April 20/21 : “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus Orion, SpaceX, Antares, the Space Shuttle and more! NEAF Astronomy Forum, Suffern, NY

April 28: “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus the Space Shuttle, SpaceX, Antares, Orion and more. Washington Crossing State Park, Titusville, NJ, 130 PM

SpaceX Falcon 9 rocket and Dragon capsule poised to blast off from Cape Canaveral Air Force Station, Florida on a commercial resupply mission to the ISS. Credit: Ken Kremer/www.kenkremer.com

‘Alien Spaceship’ looking Dragon set for Unveiling by SpaceX this Year!

Future Dragon spacecraft will one day touch down propulsively on the ground with ‘Alien looking’ landing legs instead of an ocean splashdown. Credit: SpaceX

Later this year SpaceX will unveil the design of a new and upgraded version of the firm’s Dragon spacecraft that will look like “an Alien spaceship,” said Elon Musk, the CEO and Chief Designer of SpaceX, at a NASA media teleconference on Thursday, March 28.

Musk announced the SpaceX plans at the briefing to mark the successful conclusion of the latest unmanned Dragon cargo carrying flight, known as CRS-2, to the International Space Station (ISS) earlier this week with a Pacific Ocean splashdown on Tuesday, March 26.

Dubbed ‘Dragon 2’, the futuristic capsule will eventually boast the ability to propulsively land on Earth’s surfaceperhaps back at the Kennedy Space Center – instead of splashing down in the Pacific Ocean beneath a trio of parachutes.

At the moment, imagery of ‘Dragon 2’ is SpaceX Top Secret ! I asked.

How is the ‘Dragon 2’ different from the current ‘cargo Dragon’?

“It’s going to be cool,” gushes Musk.

“There are side-mounted thruster pods and quite big windows for astronauts to see out,” SpaceX founder Musk explained. “There are also landing legs that pop out at the bottom. So It looks like a real alien spaceship.”

One day, Musk hopes that an advanced Dragon will ferry humans on an interplanetary journey to the alien surface of Mars. Perhaps the lucky astronauts will even visit our Curiosity.

SpaceX Grasshopper test flight successfully demonstrates touchdown on land as a prelude to future demonstration missions to recover Falcon 9 1st stages.  Credit: SpaceX
SpaceX Grasshopper test flight successfully demonstrates touchdown on land as a prelude to future demonstration missions to recover Falcon 9 1st stages. Credit: SpaceX

Dragon 2 will also enable a transition to maximize use of the capsule by significantly increasing the quantity of cargo hauled up to the ISS, Musk stated.

The SpaceX Dragon CRS-2 capsule blasted off on March 1 atop a SpaceX Falcon 9 rocket from Cape Canaveral Air Force Station in Florida. It docked at the orbiting lab complex on March 3 and remained attached for 3 weeks until departing and returning to Earth on March 26.

Launching more mass to orbit will be a boon for the science research capability of the ISS, said NASA’s ISS Program scientist Julie Robinson. “We have over 200 investigations active.”

“The SpaceX flights are so important to our use of the International Space Station,” said Robinson.

Falcon 9 rocket is the launcher for both the cargo and human-rated Dragon spacecraft. Credit: SpaceX
Falcon 9 rocket is the launcher for both the cargo and human-rated Dragon spacecraft. Credit: SpaceX

With three successful Dragon docking flights to the ISS now under his belt, Musk said his goal now is to ‘push the envelope’.

Whereas initially SpaceX’s goal was to minimize risk in order to fulfil SpaceX’s $1.6 Billion commercial contract with NASA to fly 20,000 kg of sorely needed science experiments, equipment, gear, food and supplies to the ISS with a dozen Dragon cargo capsules.

SpaceX, along with Orbital Sciences Corp, are both partnered with NASA’s Commercial Resupply Services program to replace the cargo up mass capability the US lost following the retirement of NASA’s space shuttle orbiters in 2011.

NASA Administrator Charles Bolden said at the telecom that the Orbital Sciences Antares rocket is on schedule for a test flight from NASA Wallops in Virginia slated for mid-April.

Antares will launch the unmanned Cygnus cargo spacecraft to the ISS. Read my launch site update and visit to Antares – here.

Simultaneously, SpaceX will also debut a more powerful version of the Dragon’s Falcon 9 launch vehicle later this year that eventually will be both recoverable and reusable – long the Holy Grail in space exploration.

The new Falcon 9 version 1.1 “will be a meaningful upgrade” said Musk. “It will have 60-70% greater thrust capability, greater redundancy and more engine to engine protection. It will be more robust.”

Falcon 9 v 1.1 will incorporate the significantly more powerful Merlin 1-D first stage engines that will increase the liftoff thrust to about 1.5 million pounds – and serve as the launch vehicle for ‘Dragon 2’.

Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. The Dragon capsule splashed down safely in the Pacific Ocean on March 26, 2013. Credit: Ken Kremer/www.kenkremer.com

SpaceX will also start testing the capability to recover the spent Falcon 9 first stage from the Atlantic Ocean. Thereafter SpaceX will eventually try and have the first stage fly itself back to the Cape Canaveral, Florida launch complex using the so called “Grasshopper’ version of the Falcon 9.

But Musk strongly advised that will take several test flights to demonstrate such recovery technologies.

“I really want to emphasize that we don’t expect success on the first several attempts,” Musk emphasized. “Hopefully next year, with a lot more experience and data, we should be able to return the first stage to the launch site, deploy the landing legs and do a propulsive landing on land back at the launch site.”

The overarching goal is to dramatically cut costs and increase efficiency to make space more accessible, especially in these ultra lean budget times.

SpaceX is also developing a manned version of the Dragon capsule and aims for the first crewed test flight perhaps in 2015 depending on NASA’s budget.

If all of Musk’s dreams work out, they could spark a revolutionary change in spaceflight and the exploration and exploitation of the High Frontier.

Ken Kremer

…………….

Learn more about SpaceX, Antares, Curiosity and NASA missions at Ken’s upcoming lecture presentations:

April 20/21 : “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus Orion, SpaceX, Antares, the Space Shuttle and more! NEAF Astronomy Forum, Suffern, NY

April 28: “Curiosity and the Search for Life on Mars – (in 3-D)”. Plus the Space Shuttle, SpaceX, Antares, Orion and more. Washington Crossing State Park, Titusville, NJ, 130 PM

Gallery: Dragon Splashes Down Successfully

Dragon is slowed by three main parachutes prior to splashdown into the Pacific Ocean. Credit: SpaceX.

Splashdown! The SpaceX Dragon has returned home safely, splashing down in the Pacific Ocean at 16:36 UTC (12:36 p.m. EDT) on Tuesday, March 26, 2013. “Recovery ship has secured Dragon,” Tweeted SpaceX CEO Elon Musk. “Powering down all secondary systems. Cargo looks A-OK.”

A team of SpaceX engineers, technicians and divers will recover the vehicle off the coast of Baja, California, for the journey back to shore, which NASA said will take 30-48 hours.

The big job will be unloading the 3,000- plus pounds (1,360 kg) of ISS cargo and packaging inside the spacecraft. The Dragon is currently the only vehicle capable of returning cargo and important scientific experiments back to Earth.

“The scientific research delivered and being returned by Dragon enables advances in every aspect of NASA’s diverse space station science portfolio, including human research, biology and physical sciences,” said Julie Robinson, International Space Station Program
scientist. “There are more than 200 active investigations underway aboard our orbiting laboratory in space. The scientific community has
eagerly awaited the return of today’s Dragon to see what new insights the returned samples and investigations it carries will unveil.”

See more images below of Dragon’s return and mission to the ISS; we’ll be adding more as the SpaceX team supplies them!

Here’s a gif image of the splashdown:

A series of images shows the Dragon splashdown. Credit: SpaceX.
A series of images shows the Dragon splashdown. Credit: SpaceX.
This picture captures the Dragon just as it hits the water in the Pacific Ocean. Credit: SpaceX.
This picture captures the Dragon just as it hits the water in the Pacific Ocean. Credit: SpaceX.
Dragon was released from the International Space Station on March 26, 2013 during the CRS-2 mission. Credit: SpaceX.
Dragon was released from the International Space Station on March 26, 2013 during the CRS-2 mission. Credit: SpaceX.

Dragon’s release from Canadarm2 occurred earlier today at 10:56 UTC. The Expedition 35 crew commanded the spacecraft to slowly depart from the International Space Station

Dragon attached to the International Space Station during the CRS-2 mission. Credit: NASA.
Dragon attached to the International Space Station during the CRS-2 mission. Credit: NASA.
Dragon in orbit during the CRS-2 mission. Credit: NASA/CSA/Chris Hadfield
Dragon in orbit during the CRS-2 mission. Credit: NASA/CSA/Chris Hadfield

Among the the scientific experiment returned on Dragon was the Coarsening in Solid-Liquid Mixtures (CSLM-3) experiment, which also launched to space aboard this Dragon. CLSM-3 studies how crystals known as dendrites form as a metal alloy becomes solid. The research could help engineers develop stronger materials for use in automobile, aircraft and spacecraft parts.

Dragon also is returning several human research samples that will help scientists continue to examine how the human body reacts to long-term spaceflight. The results will have implications for future space exploration and direct benefits here on Earth.

The mission was the second of at least 12 cargo resupply trips SpaceX plans to make to the space station through 2016 under NASA’s
Commercial Resupply Services contract.

SpaceX Dragon Departs Station for Pacific Splashdown with Valuable Science Cargo

SpaceX Dragon was released from ISS at 6:56am ET and now begins its return trip to Earth. Credit: NASA

The SpaceX Dragon commercially developed cargo craft loaded with thousands of pounds of precious science samples has departed from the International Space Station at 6:56 a.m EDT this morning (March 26) and is heading back to Earth today for a splashdown in the Pacific Ocean at around 12:34 p.m EDT.

The ISS crew commanded the Dragon’s release by a trigger at the robotic work station inside the Cupola as they were soaring some 250 miles over the northeast coast of Australia after Mission Control gave the “GO for release”.
A video of the unberthing is below:

Cameras aboard both the ISS and Dragon transmitted breathtaking views of the departure maneuver. The entire ISS filled the video screen as Dragon slowly pulled away.

SpaceX Dragon capsule grappled by ISS robotic arm prior to today’s  departure and  return to Earth and Pacific Ocean splashdown. Credit: NASA
SpaceX Dragon capsule grappled by ISS robotic arm prior to today’s departure and return to Earth and Pacific Ocean splashdown. Credit: NASA

The private Dragon was unberthed from a docking port on the Harmony node at 4:10 a.m. EDT in anticipation of today’s return to Earth.

The capsule had been docked at the orbiting outpost for three weeks since arriving on March 3.

NASA astronaut Tom Marshburn and station commander Chris Hadfield from Canada opened the snares on the stations Canadian built robotic arm – Canadarm2 – firmly grasping the Dragon.

ISS imaged be cameras on departing Dragon. Credit: SpaceX/NASA
ISS imaged by cameras on departing Dragon. Credit: SpaceX/NASA

A series of three short departure burns executed in rapid succession took Dragon safely away from the ISS and beyond the imaginary 656-foot (200-meter) “Keep Out Sphere” around the station for the journey back to Earth.

Everything with Dragon happened as expected said NASA.

“All looks beautiful and nominal as expected,” radioed the ISS crew.

The Dragon capsule is the first private ship ever to dock at the ISS.

Dragon conducts departure burns from the ISS on March 26, 2013. Credit: NASA
Dragon conducts departure burns from the ISS on March 26, 2013. Credit: NASA

Dragon will fire its engines for the last time for the 10 minute long deorbit burn at 11:42 a.m. EDT sending it through the Earth’s atmosphere for a fiery reentry and splashdown in the Pacific Ocean around 12:34 p.m.

“Sad to see the Dragon go,” said Marshburn. “She performed her job beautifully and is heading back to her lair. Wish her all the best for the splashdown today.”

A team of SpaceX engineers, technicians and divers will recover the vehicle after splashdown about 214 miles off the coast of Baja, California.

SpaceX recovery crews will pluck the capsule from the Pacific Ocean for the journey back to shore which will take about 30 hours.

Dragon had been scheduled to return yesterday on Monday, March 25, but was postponed due to inclement weather developing near its targeted splashdown site in the Pacific Ocean.

There was no affect on the return of the science samples and gear weighing a hefty 2668 pounds. Dragon is the only vehicle that can safely return significant amounts of science cargo and gear from the ISS following the retirement of NASA’s space shuttle orbiters.

The SpaceX Dragon CRS-2 capsule blasted off on March 1 atop a SpaceX Falcon 9 rocket from Cape Canaveral Air Force Station in Florida.

A thruster failure shortly after liftoff nearly doomed the mission. But fast acting SpaceX engineers saved the day and restarted the engines a few hours later – read my earlier story here.

Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com

The resupply mission carried aloft some 1200 pounds of food, water and science experiments for the station crew.

After a two day flight, Marshburn captured the Dragon just 32 feet away from the station with the Canadarm2 on March 3. Ground controllers then took over Canadarm2 operations and berthed Dragon to the Harmony node.

SpaceX is under contract to NASA to deliver about 44,000 pounds of cargo to the ISS during a dozen flights over the next few years at a cost of about $1.6 Billion.

SpaceX and Orbital Sciences Corp are partnered with NASA’s Commercial Resupply Services program to replace the cargo up mass capability the US lost following the retirement of NASA’s space shuttle orbiters in 2011.

The maiden launch of Orbital’s Antares/Cygnus ISS cargo resupply program is now slated to occur on April 16-18 from NASA Wallops Flight Facility in Virginia – read my onsite photo report here.

The inaugural Antares launch will be a test flight with a simulated Cygnus.

The next SpaceX Dragon flight – dubbed CRS-3 – is slated to blast off in late November 2013.

Ken Kremer

Dragon and Earth from the ISS. Credit: NASA
Dragon and Earth from the ISS. Credit: NASA

Powerful Private Rocket Crucial to ISS Set for Maiden April Blast Off from Virginia – Launch Pad Gallery

The first stage of the privately developed Antares rocket stands on the pad at NASA's Wallops Flight Facility. Credit: Ken Kremer (kenkremer.com)

The first stage of the privately developed Antares rocket stands erect at newly constructed Launch Pad 0-A at NASA’s Wallops Flight Facility during exclusive launch complex tour by Universe Today. Maiden Antares test launch is scheduled for mid-April 2013. Later operational flights are critical to resupply the ISS.
Credit: Ken Kremer (kenkremer.com)
See Antares photo gallery below[/caption]

The most powerful rocket ever to ascend near major American East Coast population centers is slated to blast off soon from the eastern Virginia shore on its inaugural test flight in mid April.

And Universe Today took an exclusive inspection tour around the privately developed Antares rocket and NASA Wallops Island launch complex just days ago.

NASA announced that the maiden flight of the commercial Antares rocket from Orbital Sciences is slated to soar to space between April 16 to 18 from the newly constructed seaside launch pad dubbed 0-A at the Mid-Atlantic Regional Spaceport (MARS) at NASA’s Wallops Flight Facility in Virginia.

The two stage Antares rocket is absolutely pivotal to NASA’s plans to ship essential cargo to the International Space Station (ISS) in the wake of the shutdown of the Space Shuttle program in July 2011.

No admittance to the Orbital Sciences Corp. Antares rocket without permission from the pad manager! Credit: Ken Kremer (kenkremer.com)
No admittance to the Orbital Sciences Corp. Antares rocket without permission from the pad manager. Credit: Ken Kremer (kenkremer.com)

Antares stands 131 feet tall and serves as the launcher for the unmanned commercial Cygnus cargo spacecraft.

Both Antares and Cygnus were developed by Orbital Sciences Corp under NASA’s Commercial Orbital Transportation Services (COTS) program to replace the ISS cargo resupply capability previously tasked to NASA’s now retired Space Shuttle’s. The goal is to achieve safe, reliable and cost-effective transportation to and from the ISS and low-Earth orbit (LEO).

I visited NASA Wallops for an up close personal tour of the impressive Antares 1st stage rocket erected at the launch pad following the successful 29 second hot fire engine test that cleared the last hurdle to approve the maiden flight of Antares. Umbilical lines were still connected to the rocket.

Antares rocket 1st stage and umbilicals at NASA Wallops Flight Facility.  Credit: Ken Kremer (kenkremer.com)
Antares rocket 1st stage and umbilical lines at NASA Wallops Flight Facility. Credit: Ken Kremer (kenkremer.com)

The pads protective seawall was rebuilt following significant damage from Hurricane Sandy, NASA Wallops spokesman Keith Koehler told me.

Launch Complex 0-A sits just a few hundred yards (meters) from Virginia’s eastern shore line on the Atlantic Ocean. It’s hard to believe just how close the low lying pad complex is to the beach and potentially destructive tidal surges.

Barely 400 meters (1300 feet) away lies the adjacent Launch Pad 0-B – from which Orbital’s new and unflown solid fueled Minotaur 5 rocket will boost NASA’s LADEE lunar science probe to the Moon in August 2013 – see my upcoming article.

The maiden Antares test flight is called the A-One Test Launch Mission. It will validate the medium class rocket for the actual follow-on flights to the ISS topped with the Cygnus cargo carrier starting later this year with a demonstration docking mission to the orbiting lab complex.

The first stage of the privately developed Antares rocket stands on the pad at NASA's Wallops Flight Facility. Credit: Ken Kremer (kenkremer.com)
1st stage of private Antares rocket erect at new Launch Pad 0-A at NASA’s Wallops Flight Facility. This rocket will be rolled back to the hanger to make way for the complete Antares booster due to blast off in mid-April 2013. Credit: Ken Kremer (kenkremer.com)

The Antares first stage is powered by dual liquid fueled AJ26 first stage rocket engines that generate a combined total thrust of some 680,000 lbs. The upper stage features a Castor 30 solid rocket motor with thrust vectoring. Antares can loft payloads weighing over 5000 kg to LEO.

The launch window opens at 3 p.m. and extends for a period of time since this initial test flight is not docking at the ISS, Orbital spokesman Barry Boneski told Universe Today.

Antares will boost a simulated version of the Cygnus carrier – known as a mass simulator – into a target orbit of 250 x 300 kilometers and inclined 51.6 degrees.

Antares A-One will fly on a southeast trajectory and the Cygnus dummy will be instrumented to collect flight and payload data.

The simulated Cygnus will separate from the upper stage 10 minutes after liftoff for orbital insertion.

“All launches are to the south away from population centers. Wildlife areas are nearby,” said Koehler.

The goal of the ambitious A-One mission is to fully demonstrate every aspect of the operational Antares rocket system starting from rollout of the rocket and all required functions of an operational pad from range operation to fueling to liftoff to payload delivery to orbit.

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 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)

Antares/Cygnus will provide a cargo up mass service similar to the Falcon 9/Dragon system developed by SpaceX Corporation – which has already docked three times to the ISS during historic linkups in 2012 and earlier this month following the tension filled March 1 liftoff of the SpaceX CRS-2 mission.

The Dragon is still docked to the ISS and is due to make a parachute assisted return to Earth on March 26.

The first stage of the privately developed Antares rocket stands on the pad at NASA's Wallops Flight Facility. Credit: Ken Kremer (kenkremer.com)
Antares rocket 1st stage and huge water tower at NASA’s Wallops Flight Facility. Credit: Ken Kremer (kenkremer.com)

Orbital has eight commercial resupply missions manifested under a $1.9 Billion contact with NASA to deliver approximately 20,000 kilograms of supplies and equipment to the ISS, Orbital spokesman Barry Boneski told me.

Tens of millions of American East Coast residents in the Mid-Atlantic and Northeast regions have never before had the opportunity to witness anything as powerful as an Antares rocket launch in their neighborhood.

Watch for my continuing reports through liftoff of the Antares A-One Test flight.

Ken Kremer

NASA Wallops Launch Control Center. Credit: Ken Kremer (kenkremer.com)
NASA Wallops Launch Control Center. Credit: Ken Kremer (kenkremer.com)
Ken Kremer & Antares rocket at NASA Wallops launch pad at the Virginia Eastern Shore.  Only a few hundred feet separate the pad from the Atlantic Ocean. Credit: Ken Kremer (kenkremer.com)
Ken Kremer & Antares rocket at NASA Wallops launch pad at the Virginia Eastern Shore. Only a few hundred feet of beach sand and a low sea wall separate the pad from the Atlantic Ocean and Mother Nature. Credit: Ken Kremer (kenkremer.com)

SpaceX Grasshopper Takes a Leap Into a ‘Ring of Fire’

The SpaceX Grasshopper during its test flight on March 7, 2013. Credit: SpaceX.

Last week, SpaceX’s Grasshopper took its highest leap ever, doubling its past flights. On March 7, 2013, the vertical and takeoff and landing (VTVL) vehicle, rose 24 stories or 80.1 meters (262.8 feet), hovered for approximately 34 seconds and then landed safely – and more accurately than ever before. The goal of Grasshopper is to eventually create a reusable first stage for SpaceX’s Falcon 9 rocket, which would be able to land safely instead of falling back into the ocean and not being usable again.

SpaceX CEO Elon Musk revealed this video this weekend during the South by Southwest (SXSW) festival in Austin, Texas, calling the Grasshopper’s flight a “Johnny Cash Hover Slam,” since the video includes Cash’s iconic song, “Ring of Fire.” A cowboy dummy was strapped to the side of the rocket for good measure (and perhaps good luck, since the previous test fight included the cowboy).

The test was completed at SpaceX’s rocket development facility in McGregor, Texas.

This is Grasshopper’s fourth in a series of test flights, with each test demonstrating exponential increases in altitude. Last September, Grasshopper flew to 2.5 meters (8.2 feet), in November, it flew to 5.4 meters (17.7 feet) and in December, it flew to 40 meters (131 feet).

Grasshopper stands 10 stories tall and consists of a Falcon 9 rocket first stage tank, Merlin 1D engine, four steel and aluminum landing legs with hydraulic dampers, and a steel support structure.

Image Gallery: Astronauts Capture a Dragon

The SpaceX Dragon capsule is snared by the International Space Station's Canadarm 2. Credit: NASA

Sunday was a big day in space, and astronaut Chris Hadfield captured the excitement in photos, and shared them via Twitter. “What a day!” Hadfield tweeted. “Reached & grabbed a Dragon, berthed her to Station & opened the hatch to find fresh fruit, notes from friends, and peanut butter.”

SpaceX’s Dragon spacecraft overcame a problem with its thrusters after reaching orbit on Friday, and on Sunday Dragon successfully approached the Station, where it was captured by Expedition 34 Commander Kevin Ford and crewmate Tom Marshburn using the station’s Canadarm2 robotic arm. Dragon was grappled at 5:31 a.m. EST, and was berthed to the Earth-facing port of the Harmony module at approximately 8:56 a.m. EST on March 3.

See more photos below. The image captions are Hadfield’s Tweets.

'Dragon comes into view - first sight this morning, sneaking up on us from behind the Progress solar array,' Tweeted Chris Hadfied. Credit: NASA/Chris Hadfield.
‘Dragon comes into view – first sight this morning, sneaking up on us from behind the Progress solar array,’ tweeted Chris Hadfied. Credit: NASA/Chris Hadfield.
'The Dragon spaceship high over Mount Etna - both spitting fire.' Credit: NASA/Chris Hadfield.
‘The Dragon spaceship high over Mount Etna – both spitting fire.’ Credit: NASA/Chris Hadfield.
The Dragon approaches the ISS over sub-Saharan Africa. Credit: NASA/Chris Hadfield.
The Dragon approaches the ISS over sub-Saharan Africa. Credit: NASA/Chris Hadfield.
Hadfield's self-portrait in the Cupola with rising Dragon below, Africa behind. Credit: NASA/Chris Hadfield.
Hadfield’s self-portrait in the Cupola with rising Dragon below, Africa behind. Credit: NASA/Chris Hadfield.
'Like a Praying Mantis, Canadarm2 poised to reach out and grab Dragon.' Credit: NASA/Chris Hadfield.
‘Like a Praying Mantis, Canadarm2 poised to reach out and grab Dragon.’ Credit: NASA/Chris Hadfield.
'Success! Canadarm2 holds Dragon by the nose, to drag it up and hook it on to a Station hatch.' Credit: NASA/Chris Hadfield.
‘Success! Canadarm2 holds Dragon by the nose, to drag it up and hook it on to a Station hatch.’ Credit: NASA/Chris Hadfield.
'Happy crewmember - Dragon securely snared by Canadarm2, ready to be lifted around, hooked into place, and opened up.' Credit: NASA/Chris Hadfield.
‘Happy crewmember – Dragon securely snared by Canadarm2, ready to be lifted around, hooked into place, and opened up.’ Credit: NASA/Chris Hadfield.

In this video, Hadfield provides a tour of the Robotic Workstation where the crew commanded Canadarm2 to capture and dock the Dragon:

Berth of a Dragon after Thruster Failure Recovery Establishes American Lifeline to ISS

SpaceX Dragon berthing at ISS on March 3, 2013. Credit: NASA

Kennedy Space Center – After overcoming a frightening thruster failure that could have spelled rapid doom on the heels of a breathtakingly beautiful launch, the privately developed Dragon spacecraft successfully berthed at the International Space Station (ISS) a short while ago, at 8:56 a.m. EST Sunday morning, March 3, 2013 – thereby establishing an indispensable American Lifeline to the massive orbiting lab complex.

Hearts sank and hopes rose in the span of a few troubling hours following Friday’s (Mar. 1) flawless launch of the Dragon cargo resupply capsule atop the 15 story tall Falcon 9 rocket from Cape Canaveral Air Force Station, Florida and the initial failure of the life giving solar arrays to deploy and failure of the maneuvering thrusters to fire.

“Congrats to the @NASA/@SpaceX team. Great work getting #Dragon to the #ISS…our foothold for future exploration!” tweeted NASA Deputy Administrator Lori Garver.

Space station Expedition 34 crew members Kevin Ford and Tom Marshburn of NASA used the station’s 58 foot long Canadian supplied robotic arm to successfully grapple and capture Dragon at 5:31 a.m. Sunday as the station was flying 253 miles above northern Ukraine. See the grappling video – here.

SpaceX Dragon holding at 10m capture point. ISS crew standing by for "go" to perform grapple. Credit: NASA
SpaceX Dragon holding at 10m capture point. ISS crew standing by for “go” to perform grapple. Credit: NASA

“The vehicle’s beautiful, space is beautiful, and the Canadarm2 is beautiful too”, said station commander Kevin Ford during the operation.

The capsule pluck from free space came one day, 19 hours and 22 minutes after the mission’s launch.

Ground controllers at NASA’s Johnson Space Center in Houston then commanded the arm to install Dragon onto the Earth-facing port of the Harmony module – see schematic.

Schematic shows location of Dragon docking port for CRS-2 mission and ISS modules. Credit: NASA
Schematic shows location of Dragon docking port for CRS-2 mission and ISS modules. Credit: NASA

Originally, Dragon capture was slated only about 20 hours after launch. But that all went out the window following the serious post-launch anomalies that sent SpaceX engineers desperately scrambling to save the flight from a catastrophic finale.

The $133 million mission dubbed CRS-2 is only the 2nd contracted commercial resupply mission ever to berth at the ISS under NASA’s Commercial Resupply Services (CRS) contract. The contract is worth $1.6 Billion for at least a dozen resupply flights.

Following the forced retirement of NASA’s space shuttle orbiters in July 2011, American was left with zero capability to launch either cargo or astronauts to the primarily American ISS. NASA astronauts are 100% reliant on Russian Soyuz capsules for launch to the ISS.

Both the Falcon 9 rocket and Dragon spacecraft were designed and built by SpaceX Corporation based in Hawthorne, Calif., and are entirely American built.

The Falcon 9/Dragon commercial system restores America’s unmanned cargo resupply capability. But the time gap will be at least 3 to 5 years before American’s can again launch to the ISS aboard American rockets from American soil.

And continuing, relentless cuts to NASA’s budget are significantly increasing that human spaceflight gap and consequently forces more payments to Russia.

“Today we marked another milestone in our aggressive efforts to make sure American companies are launching resupply missions from U.S. shores,” said NASA Admisistrator Charles Bolden in a NASA statement.

“Our NASA-SpaceX team completed another successful berthing of the SpaceX Dragon cargo module to the International Space Station (ISS) following its near flawless launch on the Falcon-9 booster out of Cape Canaveral, Florida Friday morning. Launching rockets is difficult, and while the team faced some technical challenges after Dragon separation from the launch vehicle, they called upon their thorough knowledge of their systems to successfully troubleshoot and fully recover all vehicle capabilities. Dragon is now once again safely berthed to the station.”

“I was pleased to watch the launch from SpaceX’s facility in Hawthorne, CA, and I want to congratulate the SpaceX and NASA teams, who are working side by side to ensure America continues to lead the world in space.”

“Unfortunately, all of this progress could be jeopardized with the sequestration ordered by law to be signed by the President Friday evening. The sequester could further delay the restarting of human space launches from U.S. soil, push back our next generation space vehicles, hold up development of new space technologies, and jeopardize our space-based, Earth observing capabilities,” said Bolden.

ISS crew given GO for second stage capture of SpaceX Dragon with ISS on March 3, 2013.  Credit: NASA
ISS crew given GO for second stage capture of SpaceX Dragon with ISS on March 3, 2013. Credit: NASA

Dragon is loaded with about 1,268 pounds (575 kilograms) of vital supplies and provisions to support the ongoing science research by the resident six man crew, including more than a ton of vital supplies, science gear, research experiments, spare parts, food, water and clothing.

NASA says that despite the one-day docking delay, the Dragon unberthing will still be the same day as originally planned on March 25 – followed by a parachute assisted splashdown in the Pacific Ocean off the coast of Baja California.

Dragon will spend 22 days docked to the ISS. The station crew will soon open the hatch and unload all the up mass cargo and research supplies. Then they will pack the Dragon with about 2,668 pounds (1,210 kilograms) of science samples from human research, biology and biotechnology studies, physical science investigations, and education activities for return to Earth.

Canadian built robotic arm grapples SpaceX Dragon on March 3, 2013.  Credit:
Canadian built robotic arm grapples SpaceX Dragon on March 3, 2013. Credit:

Dragon is the only spacecraft in the world today capable of returning significant amounts of cargo to Earth.

Orbital Sciences Corp also won a $1.9 Billion cargo resupply contract from NASA to deliver cargo to the ISS using the firm’s new Antares rocket and Cygnus capsule.

NASA hopes the first Antares/Cygnus demonstration test flight from NASA’s Wallops Island Facility in Virginia will follow in April. Cygnus cargo transport is one way – to orbit only.

“SpaceX is proud to execute this important work for NASA, and we’re thrilled to bring this capability back to the United States,” said Gwynne Shotwell, President of SpaceX.

“Today’s launch continues SpaceX’s long-term partnership with NASA to provide reliable, safe transport of cargo to and from the station, enabling beneficial research and advancements in technology and research.”

The SpaceX CRS-3 flight is slated to blast off in September 2013.

Ken Kremer

Falcon 9 SpaceX CRS-2 launch on March 1, 2013 ISS - shot from the roof of the Vehicle Assembly Building.  .  Credit: Ken Kremer/www.kenkremer.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com

Video: Dragon Grappled and Berthed at Space Station

The Dragon approaches the ISS over sub-Saharan Africa. Credit: NASA/Chris Hadfield.

SpaceX’s Dragon spacecraft has arrived at the International Space Station! After overcoming a problem with its thrusters after reaching orbit on on Friday, today, Dragon successfully approached the Station, where it was captured by Expedition 34 Commander Kevin Ford and crewmate Tom Marshburn using the station’s Canadarm2 robotic arm. Dragon was grappled at 5:31 a.m. EST, and was berthed to the Earth-facing port of the Harmony module at approximately 8:56 a.m. EST on March 3.

Below, Canadian astronaut Chris Hadfield snapped a photo of Dragon as it approached the station over sub-Saharan Africa. “A surreal juxtaposition,” Hadfied said via Twitter.

SpaceX Dragon Recovers from Frightening Propulsion System Failure – Sunday Docking Set

Launch of SpaceX Falcon 9 on CRS-2 mission on March 1, 2013 from Cape Canaveral, Florida. Credit: Jeff Seibert

Kennedy Space Center – Barely 11 minutes after the spectacular Friday morning, March 1 launch of the SpaceX Falcon 9 rocket and unmanned Dragon capsule bound for the International Space Station (ISS), absolute glee suddenly threatened to turn to total gloom when the mission suffered an unexpected failure in the critical propulsion system required to propel the Dragon to the Earth orbiting outpost.

An alarming issue with the Dragons thrust pods prevented three out of four from initializing and firing.

For several hours the outlook for the $133 million mission appeared dire, but gradually began to improve a few hours after launch.

“It was a little frightening,” said SpaceX CEO Elon Musk at a Friday afternoon media briefing for reporters gathered at the Kennedy Space Center, commenting on the moments after the glitch appeared out of nowhere.

“We noticed after separation that only one of the four thruster pods engaged or was ready to engage,” Musk explained. “And then we saw that the oxidizer pressure in three of the four tanks was low.”

Launch of SpaceX Falcon 9 on CRS-2 mission on March 1, 2013 from Cape Canaveral, Florida. Credit: Jeff Seibert
Launch of SpaceX Falcon 9 on CRS-2 mission on March 1, 2013 from Cape Canaveral, Florida. Credit: Jeff Seibert/Wired4Space.com

The situation progressed onto the road to recovery after SpaceX engineers immediately sprang into action and frantically worked to troubleshoot the thruster problems in an urgent bid to try and bring the crucial propulsion systems back on line and revive the mission.

By late Saturday afternoon sufficient recovery work had been accomplished to warrant NASA, ISS and SpaceX managers to give the go-ahead for the Dragon to rendezvous with the station early Sunday morning, March 3.

“The station’s Mission Management Team unanimously agreed that Dragon’s propulsion system is operating normally along with its other systems and ready to support the rendezvous two days after Friday’s launch on a Falcon 9 rocket from the Cape Canaveral Air Force Station in Florida,” NASA announced in a statement on Saturday, March 2.

A failure to ignite the thrusters within 1 or 2 days would have resulted in unacceptable orbital decay and a quick and unplanned fiery reentry into the earth’s atmosphere, said Musk.

Reentry would cause a total loss of the mission – carrying more than a ton of vital supplies, science gear, research experiments, spare parts, food, water and provisions to orbit for the stations six man crew.

Shortly after the Dragon achieved orbit and separated from the second stage, the solar arrays failed to deploy and the live webcast stopped prematurely.

Falcon 9 SpaceX CRS-2 launch on March 1, 2013 ISS - shot from the roof of the Vehicle Assembly Building.  .  Credit: Ken Kremer/www.kenkremer.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013 to the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Ken Kremer/www.kenkremer.com

During the course of the Friday afternoon briefing, Musk and NASA officials received continuous updates indicating the situating was changing and slowly improving.

Musk confirmed that SpaceX was able to bring all four of Dragon’s thruster pods back up and running. Engineers were able to identify and correct the issue, normalizing the pressure in the oxidation tanks.

The problem may have been caused by stuck valves or frozen oxidizer in the lines. Dragon has four oxidizer tanks and four fuel tanks.

“We think there may have been a blockage of some kind or stuck check valves going from the helium pressure tank to the oxidizer tank,” Musk hypothesized. “Whatever that blockage is seems to have alleviated.”

Three of the four thruster pods must be active before the Dragon would be permitted to dock, said Mike Suffredini, NASA program manager for the ISS. There are a total of 18 Draco thrusters.

SpaceX and the ISS partners conducted a thorough review process to assure that the thrusters will work as advertised and allow the Dragon to safely enter the stations keep out zone and physically dock at the berthing port onto the Earth-facing port of the Harmony module.

“SpaceX said it has high confidence there will be no repeat of the thruster problem during rendezvous, including its capability to perform an abort, should that be required,” NASA said in a statement.

Dragon is now slated to be grappled early Sunday morning at 6:31 a.m. by NASA Expedition 34 Commander Kevin Ford and NASA Flight Engineer Tom Marshburn – that’s one day past the originally planned Saturday morning docking.


Video: Falcon 9 SpaceX CRS-2 launch on March 1, 2013 bound for the ISS – shot from the roof of the Vehicle Assembly Building. Credit: Matthew Travis/Spacearium

NASA says that despite the one-day docking delay, the Dragon unberthing and parachute assisted return to Earth will still be the same day as originally planned on March 25.

There are numerous docking opportunities available in the coming days if SpaceX and NASA determined that more time was needed to gain confidence that Dragon could safely carry out an attempt.

Musk said the Dragon could stay on orbit for several additional months if needed.

We have to review the data with NASA before docking to make sure it’s safe, Musk emphasized on Friday.

Falcon 9 SpaceX CRS-2 launch on March 1, 2013.  Credit: Mike Killian/www.zerognews.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013. Credit: Mike Killian/www.zerognews.com

The mission dubbed CRS-2 will be only the 2nd commercial resupply mission ever to berth at the ISS. SpaceX is under contract to NASA to conduct a dozen Dragon resupply flight to the ISS over the next few years at a cost of about $1.6 Billion.

NASA TV coverage of rendezvous and grapple on Sunday, March 3 will begin at 3:30 a.m. EST. Coverage of berthing operations on NASA TV will begin at 8 a.m.

SpaceX’s live coverage at http://www.spacex.com/webcast begins at 6:00 a.m. Eastern.

Ken Kremer

Falcon 9 SpaceX CRS-2 launch on March 1, 2013.  Credit: Mike Killian/www.zerognews.com
Falcon 9 SpaceX CRS-2 launch on March 1, 2013. Credit: Mike Killian/www.zerognews.com