Hans Koenigsmann, Vice President of Build and Flight Reliability at SpaceX later said that sensors detected an unusual pressure rise in gas generators on two Merlin engines. “When we looked at the data, we saw that two of the engines attempted to start early, and the auto abort prevented that. By doing that, it prevented a possible hard start that could have been damaging to the engine hardware.”
The Merlin engine is powered by RP-1 kerosene and liquid oxygen, one of the oldest-used mixtures in the aerospace industry. To ignite the engine, a green-colored compound known as TEA-TEB (triethylaluminium-triethylborane) is used. TEA-TEB is a pyrophoric mixture, meaning it combusts in exposure to air.
Koenigsmann added, “You need to introduce these liquids in the right order. If you do this in the wrong order, or if you happen to throw in the liquid oxygen and the RP-1 and the igniter fluid, then what would happen is… we call it a hard start. A hard start would rattle the engine in most cases but could cause damage. So in general, you don’t want that. You want a good startup.”
“If we see the pressure rise too early, then we know the liquid is in there, and it shouldn’t be there,” he said. “And software in the engine controller then stops the whole process.”
Oops
Teams were able to analyze the engines’ startup behavior, and additional inspections found a blockage in a narrow line leading to a relief valve on the gas generator.
The vent port, which is just one-sixteenth of an inch wide, was obstructed by hardened masking lacquer. Koenigsmann described it as similar to red nail polish.
The gas generator on each Merlin engine drives a turbopump feeding RP-1 kerosene and liquid oxygen to the main combustion chamber.
Engineers at SpaceX’s McGregor test site also demonstrated that the engines performed normally after removing the blockage from the vent valve. Koenigsmann said that the issue was “very subtle,” but could’ve had some negative impact on the engine operation.