NASA launched STS-121, the second of their “Return to Flight” missions, to the ISS in 2006. The main purpose of the flight was to test the new safety and repair techniques following the Colombia disaster in February 2003. However, what many do not know, is that the space agency almost faced another catastrophe during takeoff.
Amazon Primes “Disasters in Space” claims that technicians inside Mission Control Houston were sent into a frenzy when things went south.
The 2016 documentary revealed: “Hundreds of systems are monitored by launch control engineers.
“Then, just 22 seconds into ascent, readings from a pressure transfuser went off the charts.
“Engineers watched helplessly for 60 seconds as the pressure hit levels never seen before – then went higher – so high they could no longer be measured.
The space shuttle suffered a pressure issue
The disaster occurred during a mission on Discovery
Somehow the blankets were installed over the drain lines, instead of behind
“The problem was at the front of the shuttle, threatening the crew just inches away.”
One minute and 14 seconds later the pressure recorded normally again, leaving engineers relieved, yet confused.
It was not until Discovery returned back to Earth on July 17, 2006, that scientists realised thermal blankets had been blocking the airways at the front of the shuttle.
The documentary continued: “Near the vent ports, Thermal Control System (TCS) blankets cover many surfaces in the Forward Reaction Control System (FRCS).
The astronauts were on their way to the ISS
“These protect the spacecraft’s surfaces from extreme heat and cold of space.
“They are located in front of the vent ports on an adjacent wall to the FRCS.
“The original blankets were installed underneath a Purge Vent and Drain (PVD) which keeps it in place.”
However, after a number of days inspecting the craft, the team realised the blankets had been removed and placed back incorrectly.
The series detailed: “The team accessed the FRCS from a topside electrical panel to get a better look.
Anthony Chambers revealed the mistake
“They made a breakthrough – somehow the blankets were installed over the drain lines, instead of behind.
“Testing confirmed without the drain line to hold them in place, the blankets could be sucked into the vent ports.
“This created a deadly build-up of pressure inside the FRCS.”
NASA then had to trawl through every record of Discovery’s life to determine when the mistake had happened, before finally making a breakthrough.
It was explained: “The FRCS was removed from Discovery after a successful mission in 2005.
The blankets were placed over their sealers
“it was then transported from the Orbiter Processing Facility to the Hypergolic Maintenance Facility to carry out repairs.
“This is when a dangerous mishap occurred that damaged the blankets.
“But, determined to send the FRCS back to the Orbiter Processing Facility on schedule, the team quickly replaced them.
“In the rush, the new blankets were installed wrong.”
Anthony Chambers, a NASA manager who oversaw the process, revealed the mistake was inexcusable, but plans should have been clearer.
He told the documentary: “The design intent, obviously, was to install the blanket underneath the line, that is why there are access slits.
“We typically install blankets against the structure, in almost all cases.
“A typical installation uses the access slips to do so.
“All I can say is the drawings should have been more clear.”