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Shuttles Grounded Once Again

PipianJ writes "After discovering that the piece of the shuttle that fell off mysteriously, not actually striking it, (as reported earlier) was a piece of foam insulation not unlike the piece that ended up in the destruction of Columbia, Yahoo News reports that NASA has once again grounded the shuttle fleet."

30 of 685 comments (clear)

  1. Remember... by daveschroeder · · Score: 5, Informative
    Jokes about the shuttle fleet being grounded while one is on orbit aside, things fall off the shuttles all the time during launch and reentry. This is expected. Foam insulation (during launch), insulating tiles, and so on. In the previous 113 missions, the shuttles have been hit with debris over 15,000 times, mostly during launch. Additionally, NASA replaces about 100 protective tiles after every flight and repairs hundreds more.

    The point is, now that we're looking intensely for problems in this area, we're going to find them. We're looking with eyes, cameras, satellites, lasers, sensors, robotic arms - all with unprecedented scrutiny. What do we expect to find? The shuttles are the most complicated pieces of machinery ever built, designed to launch into space with a controlled explosion, and then return to earth. Regardless of whether some here think the shuttle is junk, whether it's unnecessary, whether Air Force jocks doomed the program for the beginning, whether manned spaceflight is sentimental tripe, etc., the fact remains that flying something like the shuttle is a risky endeavor.

    It's all about smart management of risk. Eliminating risk, especially for something like the shuttle, is impossible. This focus on debris falling from the shuttle is nothing more than a reactionary CYA tactic in the midst of a media circus in case something else like this were to happen again. Doing get me wrong: it's wise to consider the problem, to attempt to prevent it, and to ensure there is not undue exposure. But that exposure cannot be eliminated, and this intense focus on debris in particular beyond anything else, even in light of Columbia, is unwarranted.

    NASA is operating in panic mode: one more catastrophic shuttle failure, and that's the end of the shuttle program, and essentially the practical end of the ISS and a lot of scientific research to boot. If you're paralyzed with fear, you're, well...paralyzed.

    This New York Times article, which I posted in the previous article on this, sums up the situation quite nicely, for those who may have missed it.

    Notable:

    ...all this inspection may be a mixed blessing. The more NASA looks for damage, engineers and other experts say, the more it will find. And the risks of overreaction to signs of damage while the shuttle is in orbit may be just as great as the risks of playing them down.

    "How do you distinguish - discriminate - between damage which is critical and damage which is inconsequential?" asked Dr. David Wolf, an astronaut who spent four months aboard the Russian space station Mir. "We could be faced with very difficult decisions, in part because of all this additional information that we will be presented with." ...if a crack is detected [...] "how is NASA supposed to explain that this is not a problem?"

    "...the harder they look, they'll find more things."

    "There is risk in anything you do."

    July 27, 2005

    Intense Hunt for Signs of Damage Could Raise Problems of Its Own

    By JOHN SCHWARTZ

    CAPE CANAVERAL, Fla., July 26 - Now that the Discovery is in orbit, the examination begins. Its 12½-day mission will be the most photographed in the history of the shuttle program, with all eyes on the craft to see if it suffered the kind of damage from blastoff debris that brought down the Columbia in February 2003.

    There were cameras on the launching pad, cameras aloft on planes monitoring the ascent, cameras on the shuttle checking for missing foam on the external fuel tank, and a camera on the tank itself. One camera caught a mysterious object falling from the shuttle at liftoff; radar detected another, about two minutes into the flight. Cameras aboard the shuttle and the International Space Station will monitor the Discovery until the end of its mission.

    But all this inspection may be a mixed blessing. The more NASA looks for damage, engineers an

    1. Re:Remember... by WhiteBandit · · Score: 2, Informative

      I can't remember the source, but when the shuttle was designed, I believe it was stated that every mission there was a 1 in 52 chance of critical failure. The shuttle has actually shown itself to be much more reliable than that, in fact. I don't see what the panic is, it isn't like the astronauts don't assume some risk when they take the assignments. Let's face it, hurling a chunk of metal into space going in excess of 12,500 MPH isn't ever going to be 100% safe.

      You have it backwards. The shuttle was INITITIALLY thought to be extraordinarily safe. Before the Challenger explosion, the odds were put at 1 in 100,000 of a critical failure happening. Then the Challenger accident occured. They raised it to something like 1 in 52 chance. As more shuttles launched, they lowered the estimate again to around 1 in 200. Columbia happened.

      The latest estimates put the risk of failure at 1 and 100. However, the ACTUAL statistic, based on successful missions vs disasters is 1 in 57. So the bottom line is that the Shuttle has shown to be quite a bit less reliable than we originally thought.

  2. Embedded Systems? by Beardo+the+Bearded · · Score: 4, Informative

    I guess you've never heard of an embedded system.

    Those can't ship with bugs. Try applying a patch to several hundred 512 byte micros that are controlling the charging systems on the shock paddles in hospitals.

    --

    ---
    ECHELON is a government program to find words like bomb, jihad, plutonium, assassinate, and anarchy.
    1. Re:Embedded Systems? by exp(pi*sqrt(163)) · · Score: 2, Informative
      Let me think about some embedded systems I have personal experience of:
      1. Linksys network storage device - firmware updates downloadable to fix bugs
      2. Garmin GPS - firmware updates available to fix bugs (does shoddy filtering count as a bug?)
      3. Calculators - most new ones bugs of one sort or another. Some have firmware updates.
      4. Palm. Is that en embedded system? It's buggy as hell.
      5. Game consoles - definitely have bugs but this time game developers find workarounds. Of course the games ship with bugs.
      6. Steering control on 1st gen Priuses - buggy at low speeds. Fixable with firmware upgrade.
      7. Climate control in my Saab 93 - a disaster of engineering - I thought PID controllers were textbook material. Probably fixable with firmware upgrade, I haven't asked.
      8. My 2nd gen iPod. Ironically, battery charging control completely f**ked. Firmware upgrades f**k it more.
      9. Oven. Aha! An embedded system that seems 100% reliable.
      Maybe when you're writing code that's 512 bytes long you can keep the bug count down.
      --
      Doesn't it make you feel good to know that our freedoms are protected by politicans, lawyers and journalists.
    2. Re:Embedded Systems? by Anonymous Coward · · Score: 0, Informative

      I believe I would count only 3 of your examples embedded systems, since most of them were fundamentally computers. How about:

      microwave oven
      dishwasher
      dryer
      POTS telephone
      coffee pot

      The automotive ones are probably the most familiar examples, though-climate and cruise control, fuel injection controls, exhaust controls, brakes...

      Embedded systems are small and modular specifically because they need to be bulletproof. Unix tools used to be the same way.

  3. Parent is NOT INFORMATIVE by Anonymous Coward · · Score: 0, Informative

    The Parent poster is cracking a joke, referring to the science fiction show "Stargate: Atlantis". There is no such thing as a "Zero Point Module" yet.

    1. Re:Parent is NOT INFORMATIVE by Anonymous Coward · · Score: 1, Informative

      It was the Deadless needed to bring a Zero Point Module (ZPM) to Atlantis. If you're going to insult a show, at least do it right.

  4. Re:Go back to painted external tanks by NOLAChief · · Score: 4, Informative

    Nice idea, but it won't work. Ice formation on the tank has nothing to do with it. The trouble with hand-laid foam insulation(which is what this was) is that large air pockets can form during the forming process. These air pockets are at atmospheric pressure (14.7 psi). As the craft climbs higher into the atmosphere, the surrounding air pressure drops, causing that pocket to expand. Eventually the pocket can pop like a balloon, knocking off a chunk of foam. Were the tank painted, the paint would just come off along with the rest of the piece.

  5. Re:Ummm,.... What about Discovery by NOLAChief · · Score: 2, Informative

    The mission continues. Likely, if a problem surfaces, Atlantis would still be sent up after them. There's no sense in bringing down the orbiter until the assessments they already had planned for this mission can be completed. Right now, the shuttle does not appear to be damaged; it was a close call. Once Discovery lands, though, that's it until the tank's fixed.

  6. watch it grow... by alkaloids · · Score: 3, Informative

    so, Thom Patterson - CNN reported last night that it was a 1.5" piece of tile. MARCIA DUNN, AP Aerospace Writer - on the yahoo! news - says that it's a "sizable chunk of foam insulation -- the very thing that doomed Columbia" - but then later says that it was indeed a 1.5" piece of tile while in the latest report from yahoo! it's simply "a large piece of foam insulation broke." interesting to see this evolve. at least it's not being sensationalized...

  7. Re:What about modified jets? by Planesdragon · · Score: 2, Informative

    In the mid-to-late 1980s there was a USAF program called NASP--National Aero-Space Plane. It was supposed to do exactly what you're describing.

    NASP was eventually scrapped as "unworkable", and its successor project -- IIRC, the X-33 -- did not fare much better, even though it was actually built.

    The short answer for why we haven't done it is "fuel is heavy." I'm not qualified to give the long answer, but a straight shot right into the atmosphere really is the cheapest way to get a given weight into orbit.

    And, btw, the Space Shuttle *IS* hydrogen powered. The two solid-fuel boosters aren't, but that big foam-covered tank is just a shell carrying two parts H to one part O, which is what burns out of the shuttle's main engines.

  8. Re:speed along a replacement by cmowire · · Score: 4, Informative

    Not really.

    The X-33 was over-budget, late, and suffering major development problems. The performance was getting worse and worse. And then you would have had to hope that Lockheed-Martin was willing to put up their portion of the funds to build the production booster.....

    And, at the same time, Iridium was bankrupt, "Dark Fiber" was eating into comsat requirements, etc.

    And worst of all the Skunk Works had said, "Hey, we've been building all kinds of classified stuff all these years. I know that nobody in the public field can make a multi-lobed composite hydrogen tank, but we can pull one off, winkwinknudgenudge" So when it was shown that they couldn't, people lost faith. Especially because the only actually novel, testable parts of it was that multi-lobed composite hydrogen tank and the linear aerospike... everything else wasn't going to be getting a proper workout because it wasn't going to have enough speed to really properly test the metal skinned TPS or much else.

    The problem was the X-33 was the riskiest design of the three contenders. So it was mostly doomed from the start....

    No, they'll probably figure out how to dust off the shuttle yet again and fly it. Remember, it's just the PAL ramp that's the problem, so they might just be able to change it to using a metal cover.

  9. Re:FP? by vought · · Score: 5, Informative
    Ok, a better question....WHY IS IT MADE OF FOAM?

    I'm going to treat this as if you were serious...

    Liquid hydrogen (the stuff in the big, brown tank, along with liquid oxygen) has a boiling temperature of about -434 degrees fahrenheit.

    The launch site is next to the ocean and bounded by swamps and rivers. Humidity at the launch site is quite high. The surface of the external tank, if exposed to the atmosphere without the foam, would develop a very thick layer of ice - a material with considerably higher density than foam.

    Now, which would you rather flake off of your orbiter during climbout: ice, or foam?

  10. Harmless foam loss by A+nonymous+Coward · · Score: 4, Informative

    The foam in question insulates the disposable fuel tank so ice doesn't form on it. It does not reach orbit and is not part of the shuttle. The problem with the previous shuttle was that the foam hit the shuttle tiles as it fell off. Since this foam did not hit the shuttle, there is no problem with it.

  11. Re:Conspiracy Theory? by Jon+Abbott · · Score: 5, Informative

    Northrop Grumman and Boeing are getting prepped for the CEV, the successor to the space shuttle. According to this page, they are expecting flight demos in 2008 and manned CEV flight by 2014. If Griffin (the new NASA administrator) has his way, this will be fast-tracked to 2010. Exciting times are ahead...

  12. Re:Huh now? by CharlieG · · Score: 5, Informative

    How about switching back to the older foam that shead less. NASA switched to an "envrionmentally friendly" foam a few years back, even though they have an exemption...

    --
    -- 73 de KG2V For the Children - RKBA! "You are what you do when it counts" - the Masso
  13. Re:what do we expect to find? by EvanED · · Score: 2, Informative

    the root of Moores' Law states, fundamentally, that the more you use a technology, the better it gets.

    Actually, Moore's law doesn't even directly talk about performance at all.

    It is specific to integrated circuits and says that the complexity will double roughly every two years.

    Complexity roughly corresponds to number of transistors which certainly roughly corresponds to performance.

    See Wikipedia.

  14. Can we use Freon again? by michaelmalak · · Score: 2, Informative
    Feb. 4, 2003 Orlando Sentinel article:
    In one presentation last year at Tulane University, a Lockheed Martin external tank researcher wrote that a change in the foam formula led to "unanticipated program impacts, such as foam loss during flight." The change was prompted by environmental concerns over using freon to spray on the foam.

    [...] Hundreds of the heat-resistant tiles were damaged during a Columbia flight in 1997 when chunks of the foam broke off and hit the spacecraft. Some of the gouges were 15 inches long.

    During that event and in the incident from October that Dittemore cited Monday, the foam came loose from a ridged part where the tank's liquid oxygen and liquid hydrogen sections are joined together.

    Technicians traced at least part of the problem to a chemical called HCFC 141b, which Lockheed Martin began using in the mid-1990s as a replacement for the freon gas used to help spray on the foam.

    The new chemical may have contributed to "popcorning," which happens when the tiny cells within the tank's foam start to expand and break loose from the rest of the material.

    The cells expand as the outside pressure decreases during the shuttle's ascent and the temperature rises from air friction and hot exhaust gases. The chemicals in the foam may also vaporize, increasing the pressure.

  15. Re:FP? by WhiplashII · · Score: 2, Informative

    Actually, if ice were the problem they would ignore it - they typically do not bother to insulate LOX tanks, for example, because they form an ice layer that is a very effective insulator (the ice falls off during launch, but in a normal rocket nothing is below the tank to hit!).

    The problem with LH is that it condenses oxygen from the atmosphere onto it. That does two really bad things - first, you now have lox all over the place turning everything around it into a high explosive (pratically any porous substance, like concrete or asphalt, becomes a high explosive when saturated with LOX), and this is not a good thing to have around when lighting up a rocket. Second, condensing the LOX adds a lot of energy into the LH, boiling it, possibly raising the pressure enough to rupture the tank - KABOOM! (Remember that LOX sitting around outside the tank? Great stuff!)

    Even if the LH tank doesn't rupture, you would never get the tank full enough to fly...

    --
    while (sig==sig) sig=!sig;
  16. Just so we're clear on "big bucks" by jpellino · · Score: 4, Informative

    Astronauts are on government pay scales GS-11 thru GS-14.
    The lowest step of GS-11 is $45K per year, the highest step of GS-14 is $99K per year.

    Another way to look at it is that they do it in spite of the middling bucks, because that's the sort of person they are.

    --
    "Win treats sysadmins better than users. Mac treats users better than sysadmins. Linux treats everyone like sysadmins."
  17. Re:A suggestion by dthx1138 · · Score: 2, Informative

    You'd be suprised

    thermal problems are one of the most difficult on a space mission. solar radiation, cryogenic fuels, and of course, the vacuum of space make keeping all your parts in a 20 or 30 degree range a huge pain in the ass.

    foam is the simplest option, as its totally passive. what happens if your giant foam net doesn't detatch from the shuttle properly and rips off a section of the shuttle underbody during launch?

    --
    I just found the box to change my sig. Um.... [timeless witticism].
  18. You are correct. by jd · · Score: 1, Informative
    Example: London Ambulance Service decided to computerize, in the 1980s. The digital exchange dropped calls at random, the computer listing the calls would go into infinite loops, and all sorts of other disasters struck. It was a total disaster. Estimated deaths, due to an inoperable emergency service in a major city: 100-200


    Example: Airbus' fly-by-wire system, designed to override a pilot when a dangerous decision was made, erroniously concluded a forest was a runway after a very low pass was made over it. Deciding the speed was too high, it cut the engines. Both pilots and something like 18 journalists were killed. Airbus blamed the pilots - a safe decision as the pilots couldn't answer back, being dead and all, and the only one they could have made. Blaming the computer could have put them out of business.


    ALMOST an example: Electromagnetic interference, caused by badly-screened and improperly-earthed electronics throughout Manchester, caused the computers operating Manchester Ringway's Radar system to shut down. Given that it is one of Britain's busiest international airports and that temperature inversions will often cause some really nasty orange/yellow smog, that could have caused more than a delay.


    New York's phone system shut down, one time, due to a digital exchange propogating a negative number of users through that area. As routing worked by picking the least-congested path, the exchange suffered the telephony version of a Slashdot Effect. This included an effective shutdown of 911 services. It is unclear how many died as a result, if any, but the potential for a real disaster was there.


    Many of the cascading power blackouts that have occured since the 1950s (there have been four or five in the US, and at least a couple in the UK) have been due to bugs in the design of the response systems. It is arguable as to whether this is quite the same as a system crash, but the effect was the same. It's not clear how many died from those, either, but the mid 100s to low 1000s would not be unreasonable.

    --
    It's a small world and it smells funny; I'd buy another if it wasn't for the money; Take back what I paid (SoM)
    1. Re:You are correct. by Gerhardius · · Score: 5, Informative

      The facts of the crash are not as cut and dried as either of you state and many are wrong. The pilot survived, along with most of the people on board, and was found guilty of manslaughter in the 3 fatalities connected to the crash. The funny thing is that two primary claims of the pilot in his defence were Operational Engineering Bulletins from Airbus Industrie regarding:

      OEB 19/1 Engine Acceleration Deficiency at Low Altitude
      OEB 06/2 Barometric Cross Setting Check

      In a nutshell, the bulletins state that the engines didn't respond "normally" to throttle input and that barometric altitude indicator did not comply with airworthiness regulations. Air France chose not to share this information with the pilots. Naturally, this is the kind of thing that the data recorders could shine some light on. The data supported the claims that it was pilot error and the case was closed.

      In 1998 it was determined that the data that was supposedly from the flight had been compromised. The flight data and cockpit voice recorders had been tampered with during a 10 day period when they were not in the hands of the magistrate's office. They were in the hands of the French Civil Aviation Authority (DGAC), contrary to their own regulations. The funniest thing is that one of the boxes presented as coming from the crashed A320 spontaneously changed its markings during the interim. An independent body from Switzerland determined that there had been a switch by comparing photos of the CVR being recovered from the crash site with the one presented as evidence.

      While the "official" verdict was pilot error there is enough evidence to call that verdict into question. Who lost the least with the verdict? Airbus was introducing an advanced aircraft and attempting to challenge Boeing, and they were selling the "advanced" electronics of the 320 series: even admitting that there may be an issue with the system would have had devastating consequences.

      The onboard computers did lead to a few incidents with the A320. In 93 a Lufthansa pilot made a landing with a very low sink rate, so low the flight computers would not allow the deployment of thrust reversers or brakes for a number of seconds. The plane ended up going off the runway. I guess you could make too soft a landing.

      Admittedly they seem to have solved those problems, and I have no qualms flying in an Airbus but then again I flew Aeroflot a couple of times.

  19. Hello? Do you read the news? by iamlucky13 · · Score: 4, Informative
    Ummm....NASA pretty much decided that 2 years ago. You're a little behind the time. As soon as the ISS is finished, the Shuttle is going to be retired, and we'll have a lapse in the availability US manned launching until the Crew Exploration Vehicle is ready, which will be based on current heavy lifting technology and a reusable crew capsule. Payload will be handled seperately. In case you have to ask, the Shuttle has to be used to finish the station because most of the components have already been designed and even built around the shuttle's payload bay, rather than the Delta IV's.
    All the other space countries are still using rockets.
    As opposed to our warp drives?
  20. Re:Hate to Bore You... by donscarletti · · Score: 4, Informative
    Hell, it could be argued that the US has one of the MOST stable political systems in the world.

    Considering it's been 360 years since the last English Civil war and 140 years since the last American Civil war, I'd be inclined to say that the American system is fairly stable, but doesn't look set to be breaking any records quite yet. I come from Australia where the last thing that looked like it could have become a civil war (but didn't) happend in Ballarat 160 years ago and so even that beats America's current record.

    --
    When Argumentum ad Hominem falls short, try Argumentum ad Matrem
  21. Re:FP?-Brick on a stick. by J05H · · Score: 5, Informative

    >You're limited in how much and what size by doing that. In case you all haven't noticed. The orbiter plus the solid rocket boosters form a powered triangle. A more stable formation for carrying a big load, say a telescope.

    You're kidding, right, AC? The Shuttles can carry at most 28 tons of cargo. Saturn V could lob 118 into LEO. Proton can boost almost as much as Shuttle, for far less money, including a series of integrated space station components (Zarya, Zvezda, Mir baseblock). Maybe the trunnion pins were great for launching Hubble, but that is the exception. Your "triangle" thing doesn't make sense, inline thrust structure is more efficient, less mechanically complex and makes trajectory calculation simpler.

    >And siting on top of a roman candle is safe?

    Yes, comparatively. For manned flight, a rocket under the crew is far safer than having components next to them. Launch escape towers are safe, accurate tools for keeping crews safe from an exploding "candle". There is footage online of a Soyuz capsule popping off the rocket right above the pad, the rocket failed but the crew lived. The same can't be said for low-altitude launch problems with Shuttle.

    Capsules, rockets and tugs for station components make sense. Buck Rogers spaceplanes don't.

    --
    gigantino.tv - Heavy but weighs nothing.
  22. Re:So they still haven't learned... by HappyMeal · · Score: 2, Informative
    NASA was not required to take the EPA up on this.

    In fact, the EPA actually offered a waiver for NASA/Space Shuttle Program.

    You can see a letter from NASA in response to the EPA firmly stating they *need* to continue to use CFCs for the Space Shuttle Program, specifically.

    http://www.nasa.gov/pdf/45329main_hcfc4_001.pdf

  23. Free as in beer by suteri · · Score: 2, Informative

    Check this link. There's a plenty of cool pictures available for free, just not on a CD. (hey, that rhymes :-)

  24. Re:poor design by Retric · · Score: 2, Informative

    ... Fuel costs are a low % of the total cost of each launch. So optimizing things to reduce fuel costs is almost a waste of time.

    The goal was to build something so you could just refuel it each time you want to send it up thus saving a lot of $ but a large % of the ship is not reusable and they have to inspect / disassemble the rest of the thing each flight which is why it's so expensive. They should have build a ship that can do low temp reentry and can do horizontal takeoff and landing not some sort of rocket where you have to rebuild build 90% of it for each launch.

  25. Re:Huh now? by DerekLyons · · Score: 2, Informative
    How about switching back to the older foam that shead less. NASA switched to an "envrionmentally friendly" foam a few years back, even though they have an exemption...
    That's partly truth and partly fiction. The 'enviromentally friendly' foam is used for acreage foam (and has lead to the 'popcorn' problems). The ramp that broke off was made from the older "enviromentally unfriendly" foam. At any rate, Columbia flew with an older tank, all if it's insulation was the older "unfriendly" foam.

    Much has been made of the two types of foam, but it's a non-issue in reality.