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Delta 4-Heavy rocket takes its place atop launch pad
BY JUSTIN RAY
SPACEFLIGHT NOW

Posted: January 4, 2007

A massive Delta 4-Heavy rocket stood up on its Cape Canaveral launch pad Thursday morning to begin a three-month campaign of testing and preparations for blastoff carrying a critical military surveillance spacecraft.

 
Credit: Justin Ray/Spaceflight Now
 
Having been assembled horizontally in a nearby hangar, the 170-foot long vehicle was driven to pad 37B on Wednesday afternoon. The triple-wide rocket, creating a unique sight, traveled along the half-mile roadway and the curved incline to the pad overlooking the Atlantic Ocean.

Technicians then got to work readying the rocket to be raised vertically. The cradle-like pallets upon which the rocket rested were tied down to the erector platform on the pad's surface. The diesel-powered transporter used to haul the rocket to the pad then disengaged from the pallets and pulled away.

The erector, with its two hydraulic pistons, began lifting the rocket at about 11:07 a.m. EST. News media invited to cover the spectacle watched as the orange and white booster gracefully rose up and pointed skyward within a remarkably quick 15 minutes.

The mobile service tower stood by to become a cocoon for the rocket. The structure provides workers full 360-degree access during the pre-flight checkout process.

The pallets will be unhooked from the booster and the erector lowered back to the ground. The transporter then returns to retrieve the pallets, completing the rocket's pad delivery.

Must-see photo galleries are available:

Countdown rehearsals are planned for next week and again in early February. A complete launch day simulation that includes fueling the rocket's eight cryogenic propellant tanks is expected in mid-February.

The rocket's payload, the 23rd and final in the Defense Support Program (DSP) satellite series, will arrive at the launch pad in early March for attachment.

Officials are eyeing an April 1 liftoff during a four-hour launch window opening around 12 noon EDT (1600 GMT).

The rocket will fly directly into geostationary orbit 22,000 miles above Earth -- a trip lasting about six hours and featuring three firings by the upper stage -- to deploy the DSP spacecraft for its mission to detect enemy missile launches and nuclear weapon detonations.

The Northrop Grumman-built DSP satellites use infrared telescopes to spot the heat from missile and booster plumes against the Earth's background, giving the U.S. and allies early warning of impending attacks. The craft also detect nuclear explosions.

Recent DSP satellites rode aboard Titan 4 rockets. But that vehicle family has been retired in favor of the new-generation Atlas 5 and Delta 4 Evolved Expendable Launch Vehicles.

The Delta 4-Heavy is created by taking three hydrogen-fueled Common Booster Core stages and strapping them together, then adding a powerful upper stage to form a launcher capable of delivering hefty amounts of cargo into space. It is the biggest unmanned rocket available in the U.S. inventory today.


The rocket was driven to the pad Wednesday afternoon. Credit: Carleton Bailie for United Launch Alliance
 
This will be vehicle's first operational flight. Its one previous liftoff in December 2004 served as a demonstration test launch. The Air Force paid for the maiden mission, which carried just a satellite mockup, to uncover any problems with the Delta 4-Heavy before entrusting national security payloads to the complex rocket.

That decision proved wise.

The rocket suffered premature engine shutdowns on all three of its core boosters because of a condition in the liquid oxygen plumbing called cavitation. The phenomenon saw the super-cold oxidizer change from liquid to vapor within the feedlines running from the rocket's tanks to engines.

The bubbles fooled internal sensors into believing the boosters had run out of liquid oxygen and the engines were told to shut down several seconds early. That left the rocket with an underspeed too great for the upper stage to overcome, resulting in a final orbit far lower than planned.

"Analyses show that the cavitation originated at the entrance of the propellant feedline, where a filtration screen and turning elbow restrict the propellant flow as it accelerates leaving the tank. This feedline restriction has been present in all previous Delta 4 flights, but the unique combination of vehicle acceleration, liquid level in the tank, and propellant flow rate for this mission, reduced the fluid pressure enough to enable the creation of gaseous oxygen at this location as the tanks emptied," the Air Force said in a report about the launch.

 
The first Delta 4-Heavy rocket flies downrange on its test flight. Credit: Gene Blevins/LA Daily News
 
"Further draining of the liquid oxygen tank worsened the conditions at the feedline inlet, causing the cavitation effect to extend down the feedline until it reached the liquid depletion sensors and caused them to momentarily toggle 'dry.' This action was sensed by the flight computer, which initiated the sequence to throttle-down and shut off the main engines as it is programmed to do. Flight data shows that sufficient propellant remained in the tank to complete the planned first stage burn time."

Relieved that the incident occurred during the test flight and didn't jeopardize a real satellite payload, officials ordered corrective measures to prevent the problem from repeating in the future.

The Delta 4 rocket fleet, including Medium and Heavy rocket configurations, underwent updating with hardware and computer software changes aimed at increasing the pressure in the liquid oxygen tank to remove the potential of bubbles forming. Also, the time in which the onboard computer would begin accepting "dry" readings from the fuel-level sensors was moved later.

The changes were incorporated into the two Delta 4 rockets successfully flown last year from Vandenberg Air Force Base, California.

The upcoming DSP 23 launch will be the 8th for a Delta 4 vehicle and the first since Boeing and Lockheed Martin merged the Delta and Atlas programs into the United Launch Alliance joint venture.

Following the April flight, the team will ready another Delta 4-Heavy rocket to loft a classified spy satellite payload for the National Reconnaissance Office. Officials expect that booster to fly from Cape Canaveral approximately five months after the DSP mission.