NASA Weighs Late Heat Shield Inspections for Shuttle Crews
By Tariq Malik
Staff Writer
posted: 15 July 2006
1:05 p.m. ET

http://space.com/missionlaunches/060715_sts121_lateinspect_disciss.html

HOUSTON – NASA managers are discussing whether a late heat shield 
inspection that has made an already busy flight even more so for six 
astronauts aboard the shuttle Discovery is worth the extra time and 
risk, a lead flight director said Saturday.

Tony Ceccacci, lead shuttle flight director for Discovery’s STS-121 
mission, said flight planners and heat shield experts closely monitored 
the current crew over the last two days to determine whether the data 
gleaned from an additional inspection merits the extra rigors placed on 
orbiter astronauts.

“What we’re trying to see is how difficult this is to do and whether 
it’s worth the risks of working the crew harder and such,” Ceccacci said 
during a mission update here at Johnson Space Center (JSC). “We’re using 
this as a good test to make sure we can accomplish this and accomplish 
this safely.”

The final inspections, which return up-close views of the reinforced 
carbon carbon (RCC) panels fixed to Discovery’s nose and wing edges, are 
aimed at determining whether micrometeorites or other orbital debris 
have damaged the orbiter’s heat shield during its eight days of docked 
operations at the International Space Station (ISS). If they turn up 
clear, Discovery will be given approval to land Monday, but if analysts 
find a large enough concern the orbiter’s crew could return to the ISS 
to seek shelter, NASA said.

At the same time, engineers continue to watch the tank pressure in one 
of the orbiter’s auxiliary power units (APU), which appears to be 
leaking either gaseous nitrogen or toxic hydrazine fuel. If the leak is 
hydrazine – it is not yet certain – and remains unchanged, it should not 
impact Discovery’s planned Monday landing.

Discovery’s STS-121 crew, commanded by veteran shuttle astronaut Steven 
Lindsey, undocked from the space station early Saturday at 6:08 a.m. EDT 
(1008 GMT). After pulling away from the station toward a station-keeping 
post some 40 nautical miles (74 kilometers) from the ISS, the shuttle 
astronauts went straight into a final inspection of Discovery’s 
starboard – or right – wing leading edge and nose cap using a 
sensor-equipped, 50-foot (15-meter) boom attached to the end of the 
shuttle’s robotic arm.

The crew completed a similar survey of the spacecraft’s port wing 
leading edge Friday, but delved about an hour into the sleep preparation 
to complete the task due to a delay caused by ISS robotic arm glitches.

Lindsey opted to push ahead with the task anyway, even when given the 
option to scrub it from the schedule altogether.

“We’re looking at the future flights to see what would be required to 
accommodate it,” Ceccacci said of the added inspections. “The more you 
take off the plate to complete the late inspection, now you’re taking 
that out of the mission timeline and now you have to find a place put 
that on a later mission. They may not all line up, and have like a 
domino effect.”

NASA has 15 planned shuttle missions, spread across its three remaining 
orbiters, to complete the ISS by 2010. The next flight, STS-115 to 
launch aboard Atlantis slated for a late-August launch, may also has 
room in its timeline for late heat shield inspections, Ceccacci said.

Discovery’s STS-121 mission is NASA’s second shuttle test flight since 
the 2003 Columbia accident, which one orbiter and seven astronauts were 
lost due to a heat shield breach in the spacecraft’s left wing leading 
edge caused by a 1.67-pound (0.7-kilogram) chunk of external tank foam 
the size of a briefcase.

NASA has since redesigned shuttle external tanks to minimize the amount 
of foam insulation shed during launch.

The largest area shed in Discovery’s STS-121 launch weighed less than 
one ounce total, covered a space slightly larger than a legal-size piece 
of paper and fell off in stages of six smaller pieces, NASA has said.

But the agency remains vigilant in on-orbit inspections for shuttle heat 
shields. Discovery’s current STS-121 astronauts and those of NASA’s 
first post-Columbia effort – STS-114 aboard the same orbiter – conducted 
intense, comprehensive scans of the shuttle’s wing edges, nose cap, 
thermal blankets and belly-mounted tiles for signs of damage on Flight 
Day 2 of their missions

Analysis teams on Earth pored over the resulting data and, in both 
flights, gave the crews follow-up targets for focused inspections.

Those earlier images – which allowed mission managers for to clear 
Discovery’s current spaceflight to reentry – will be used as a baseline 
for analysis of the new imagery from the STS-121 crew, NASA has said.

“We’re going to evaluate and see if the data we get from it and the crew 
time required justifies doing it for future flights,” Ceccacci said.

Discovery is currently slated to return to Earth after a 13-day 
spaceflight on July 17. The orbiter is expected to land at 9:14 a.m. EDT 
(1314 GMT) at Runway 33 of the Shuttle Landing Facility at NASA’s 
Kennedy Space Center in Cape Canaveral Florida.


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