CAPE CANAVERAL, Fla. - Engineers probing the trouble
experienced on the Boeing Delta 4-Heavy rocket's test flight have cleared 40
potential causes of the main engines cutting off prematurely, leaving 9
scenarios on the table, including the leading theory that bubbles formed in the
liquid oxygen plumbing.
"The investigation team is making solid progress
in identifying the cause of the early engine shutdowns. The investment the Delta
4 team made in additional telemetry has helped support the engineers as they
narrow in on the cause of anomaly. I remain confident we will then be able to
find solutions that allow us to avoid this problem on future flights," said Col.
John Insprucker, Evolved Expendable Launch Vehicle program director at the Air
Force's Space and Missile Systems Center.
The shortened firing time of the main engines meant
the rocket failed to reach the proper altitude. Two student-made nanosats
hitching a ride on the rocket's demonstration test flight were lost and the
mission's primary payload -- an instrumented satellite mockup -- fell short of
its intended orbit. The launch served as a full-up test of the powerful new
booster before national security satellites are placed aboard the rocket in the
future.
The investigators are using a Fault Tree analysis,
which is a standard tool for such inquiries to pinpoint the root cause of an
incident. Parts of the rocket's propulsion system, avionics, launch environments
and other categories have been under suspicion as part of the Fault Tree, the
Air Force said.
"Forty of the 49 branches of the Fault Tree have been
reviewed, ruled out as potential causes of the anomaly and determined not to be
a factor. These Fault Tree closures continue to clear the flight control systems
(flight software and engine cutoff sensors), the RS-68 main engine and the basic
structure," the Space and Missile Systems Center said in a statement Friday.
It is believed the flow of super-cold liquid oxygen
in the rocket's three core boosters was disturbed, creating "bubbles" in the
oxidizer feed lines that tricked internal sensors into thinking the motors were
out of fuel and causing them to command an early engine shutdown.
The rocket's internal plumbing could have caused this
so-called cavitation where the liquid oxygen changed to gaseous oxygen near the
engine cutoff sensors. During the launch, the sensors registered the liquid
oxygen supply was depleted, triggering the engine cutoff sequence. But moments
later the sensors returned to "wet" conditions indicating the flow of liquid
oxygen. All three boosters experienced this same scenario.
"This
disruption of the smooth flow of liquid oxygen from the propellant tank to the
engine is caused by a unique combination of vehicle acceleration, liquid oxygen
level in the propellant tank, tank pressures and flow rates in the feed line
when the RS-68 engine is at full power. The engine cutoff sensors reacted to the
cavitation, indicating a depletion of liquid oxygen propellant. In reality,
there was adequate propellant in the tank to support the expected duration of
the RS-68 engine burns," Friday's Air Force statement said.
"Based upon progress to date, the combined Air Force
and Boeing investigation team aims to complete the Fault Tree closeout and
identify the cause by mid-February."
Computer simulations are being conducted to better
understand the liquid oxygen flow between the bottom of the propellant tank and
the engine cutoff sensors that are positioned about five feet downstream. This
testing and analysis could continue through March.
Ways to fix the Delta 4-Heavy vehicle to prevent the
cavitation bubbles on future launches won't be decided upon until the
investigation identifies the official root cause, the Air Force said.
"We're making great progress in working through our
Fault Tree," said Dan Collins, vice president of Boeing Expendable Launch
Systems. "Our Air Force and Boeing investigation team remains confident that we
will identify the cause of the early (main engine cutoff) in a timely manner and
determine an appropriate solution prior to our next scheduled Delta 4 launch
later this year."
The Air Force had planned to fly the first
operational Delta 4-Heavy rocket in the August-September time frame to deploy
the final Defense Support Program missile warning satellite. What, if any, delay
this launch could encounter remains unknown.