CAPE CANAVERAL, Fla. - Investigators are theorizing
that the flow of super-cold liquid oxygen in the three core boosters of Boeing's
first Delta 4-Heavy rocket could have been disturbed, creating "bubbles" that
tricked internal sensors into thinking the motors were out of fuel and causing
them to command a premature engine shutdown, the Air Force said Friday.
The heavy-lift rocket, topped with a instrumented satellite mockup, was
launched from Cape Canaveral December 21 on a test flight for the U.S. military.
The mission's goal was demonstrating the vehicle's capabilities and identifying
any problems before actual national security payloads are entrusted to the
rocket.
The Delta 4-Heavy features three Common Booster Cores
(CBCs) strapped together to provide 1.9-million pounds of thrust at liftoff. The
Rocketdyne RS-68 main engine on each booster consumes liquid hydrogen and liquid
oxygen.
During the ascent, the outer two boosters shut down
their engines and separated eight seconds early after sensing the fuel supply in
each stage had been depleted. The center booster had its firing cut nine seconds
short by the same problem.
Sensors temporarily indicated "dry" fuel conditions
despite the stages having plenty of propellant remaining to accomplish the
scheduled firing time. The sensors returned to "wet" readings after the shutdown
sequence was activated on each booster.
"An Anomaly Investigation Team of engineers from the
Boeing Company and the Air Force, supported by the Aerospace Corporation, has
not yet determined the root cause of the premature shutdown as it continues its
disciplined process of evaluating the flight data," the Air Force said in a
statement Friday.
"The leading candidate is some type of disturbance of
the flow of liquid oxygen in the area of the engine cutoff sensors. The liquid
oxygen flow conditions appear to be very similar in each of the CBCs at the time
of premature engine cutoff commands, which further supports the assessment that
the problem was common to all three Heavy demonstration boosters.
"A subteam of Air Force and industry experts is
constructing computer simulations of the liquid oxygen flow between the bottom
of the propellant tank, and the engine cutoff sensors, approximately five feet
downstream.
"The investigation team will assess whether the
design of the liquid oxygen feed system could be creating a cavitation
(localized change from liquid to vapor) under the flow conditions unique to the
Heavy demonstration mission. If so, these cavitation 'bubbles' could have
signaled a change from 'wet' to 'dry' by the engine cutoff sensors, triggering
the premature shutdown sequence.
"The investigation goal is to understand this
premature shutdown, and to correct any deficiencies and mitigate risk prior to
flying an operational mission. Possible mitigations will be examined once the
investigation team has determined the root cause. Although there have been
reports in the media that Boeing and the Air Force will make software and timing
changes in the design, specific corrective actions have not yet been chosen."
The early engine shutdowns left the Delta rocket's
upper stage and attached payload traveling much slower than planned. Although
the upper stage fought to make up the lost ground by firing its engine longer,
the motor ran out of fuel and reached a final orbit 10,000 miles lower than
targeted.
"This was the first flight of the Delta 4 HLV, the
largest rocket ever in the Air Force arsenal. A Senior Review Team, chartered by
the Under Secretary of the Air Force deemed this the greatest technological
launch challenge since the first space shuttle," the Air Force statement
noted.
"Because of the challenges, the Air Force teamed with
the Boeing Company to make this first flight a demonstration. As part of the
demonstration, the Delta 4 HLV carried a dummy payload (Demosat)."
A formal post-flight review of the launch data is
scheduled for late-January, the Air Force said.
"We collected an unprecedented amount of data that
we're thoroughly analyzing to reduce risk and fine-tune our plan for the first
operational Heavy mission," said Col. John Insprucker, Evolved Expendable Launch
Vehicle Program Director, Space and Missile Systems Center, and the Air Force
mission director for the demonstration launch.