New Space and Tech

Elon Musk Says SpaceX Completed All Corrective Actions for Next Starship Launch

By Douglas Messier
SpaceRef
September 12, 2023
Filed under , , , ,
Elon Musk Says SpaceX Completed All Corrective Actions for Next Starship Launch
Starship during its first test launch.
Image credit: SpaceX webcast.

SpaceX CEO Elon Musk said on September 10 that the company has completed all of the corrective actions required by the Federal Aviation Administration (FAA) before it can conduct a second launch of its Starship/Super Heavy rocket.

Musk released images of a spreadsheet with the 63 corrective actions resulting from the failed maiden flight of Starship/Super Heavy on April 20, 2023. Six of the corrections were listed as future actions that Musk said SpaceX does not have to make before the next flight.

“Corrective actions include redesigns of vehicle hardware to prevent leaks and fires, redesign of the launch pad to increase its robustness, incorporation of additional reviews in the design process, additional analysis and testing of safety critical systems and components including the Autonomous Flight Safety System, and the application of additional change control practices,” the FAA said in a statement.

The first Starship launch in April ended, four minutes after launch, with an explosion that caused serious damage to the pad, sent debris flying into sensitive wildlife areas, and caused a fire that burned several acres of a state park (although it was reported to have not killed any of the area’s protected wildlife). The flight safety system also failed to immediately destroy the rocket when it veered off its planned trajectory.

The corrective actions came out of a SpaceX-led mishap investigation that was overseen by the FAA. The agency said it had also granted official observer status to representatives of NASA and the National Transportation Safety Board. A full list of the corrective actions, and their current status according to SpaceX, is below.

List of Corrective Actions
Starship/Super Heavy

Observation/DescriptionID #Corrective ActionStatus
Tank sensingC1Replace certain fittings with welds inside tankComplete
Aft end cavity environment failureC2Increase fire suppression capacity by 15xComplete
Booster leak mitigationC3Replace certain manifolds with dedicated drain per corresponding valveComplete
C4Replace certain flanges with better seals and improve joint designComplete
C5Replace certain fittings with welds in specific locationComplete
C6Replace accessible valves of a certain type of new designComplete
C7Replace certain flange bolts with higher strength bolts and increase torqueComplete
C8Disallow certain seal re-use, and add cameras to monitor all engines during ground operationsComplete
C9Increased scrutiny on leak checksComplete
C1090+ cameras added to detect leakage during operationsComplete
Raptor leak mitigationC11Add leak capture and drain hardware for valves of a certain typeComplete
C12Add leak check and screen for porosity on igniter unitsComplete
C13Improved igniter seal designFuture Action
C14Weld certain alignment bolt holds shutComplete
C15Reassess k-factor and torque for engine hot joint #1, add leak capture and route overboardComplete
C16Reassess k-factor and torque for engine hot joint #2Complete
C17Add safety cable to certain fluid lines on high risk locationsComplete
C18Add one methane sensor per engine bayComplete
C19Ground test campaign to better characterize typical engine leakageComplete
C20Improve structural FEA/fatigue analysis for all medium to high criticality linesComplete
Collateral damage from fireC21Add insulation to engine lines sensitive to thermally driven loadsComplete
C22Add insulation to avionic harnessingComplete
C23Add backup wire to specific harnessComplete
C24Improve thermal protection of avionics trayComplete
C25Change routing to flight computersComplete
Booster reliability improvementC26Replace sensor with more reliable unitsComplete
C27Cost gimbal assembly with lubricantComplete
C28Add pump temperature sensors to certain locationComplete
C29Add pump temperature sensors to certain locationComplete
C30Replace certain bolts, and increase torque for certain flangesComplete
C31New seal design for certain areas of boosterComplete
C32Add electric actuation systemComplete
C33Better manage engine bay pressure by increasing fire suppression capacity by 15xComplete
C34Change certain booster valve timingFuture Action
Raptor reliability improvementC35Add final leak checks for certain jointsComplete
C36Add support bracket for certain sensorComplete
C37Add support bracket for certain sensorComplete
C38Add check valves to certain areas of engineComplete
C39Improve oxygen valve designFuture Action
C40Improve oxygen valve seal designFuture Action
C41Improve design of hot manifoldFuture Action
C42Change nitrogen shutdown usageComplete
C43Change engine shutdown logicComplete
C44Increase capability for ground leakage mitigationComplete
C45Redesign fire suppression systemComplete
C46Change conditions around boltsComplete
C47Changing timing of specific valve actuationComplete
Avionics reliability improvementC48Eliminate certain type of connectorComplete
C49Redesign network architectureFuture Action
Risk ProcessC50Improve risk tracking processComplete
Safety SystemC51Implement improvements to safety systemComplete
C52Verify flight safety system design improvements using additional type of testing articleComplete
C53Verify flight safety system design improvements via analysisComplete
C54Perform component testingComplete
C55Review and improve operations surrounding flight safety systemComplete
Change ControlC56Improve CAD controlsComplete
C57Add engineering walkdownComplete
C58Improve use of change management systemComplete
Pad DesignC59Redesign of launch pad deckComplete
C60Improve assumptions for new pad deck designComplete
C61Add water cooled pad deckComplete
Pad Design ProcessC62Improve pad deck design documentationComplete
C63Improve pad design processComplete
Source: SpaceX.

Last week, the FAA announced it had closed the mishap investigation, meaning that officials were satisfied with the conclusions and actions SpaceX proposed to address the causes of the launch failure.

“The FAA conducted a final review of the mishap report, dated August 21, 2023,” the agency said in a letter to SpaceX. “The FAA has been provided with sufficient information and accepts the root causes and corrective actions described in the mishap report. Consequently, the FAA considers the mishap investigation that SpaceX was required to complete to be concluded.”

The FAA licensed SpaceX to conduct a single launch. The company must apply for a modification of the license and demonstrate compliance with all corrective actions before it can conduct a second launch.

Doug Messier

Douglas Messier is the founder of Parabolic Arc. He studied at George Washington University’s Space Policy Institute and is an alumnus of the International Space University.