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Clean Hydrogen Partnership

Explosion on a aerospace vehicle

Event

Event ID
30
Quality
Description
The last flight of the Space Shuttle Challenger ended 73 seconds after the launch in an explosive burn of hydrogen and oxygen propellants that destroyed the External Tank and exposed the Orbiter to severe aerodynamic loads that caused complete structural breakup. All seven crew members perished.
The two Solid Rocket Boosters flew out of the fireball and were destroyed by the Air Force range safety officer 110 seconds after launch.

According to the NASA version (Rogers President Commission): a steady flame coming (combustion gas leak) from the rocket booster impinged on the external tank which eventually failed, after which liquid hydrogen and liquid oxygen burnt in an explosive combustion.

There is another analysis by Chirivella: the ignited liquid hydrogen leaking from the external tank caused its structural deterioration and ignited its contents.
Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Fire Followed By An Explosion (No additional details provided)
Macro-region
North America
Country
United States
Date
Main component involved?
Lh2 Storage Vessel
How was it involved?
Rupture
Initiating cause
Material Degradation (Conventional Fire)
Root causes
Root CAUSE analysis
The INITIATING cause of the accident (according to the Rogers Commission)was the failure of the pressure seal in the aft field joint of the right Solid Rocket Booster.

The root cause of the failure was a faulty design unacceptably sensitive to a number of factors (effects of temperature, physical dimensions, materials properties, reusability, processing and the reaction of the joint to dynamic loading).

According to another version (Chirivella), the external tank experienced small undetected LH2 leakage (< 1.4 kg/s) which was ignited at early stage from the nearby burning rocket boosters.

Facility

Application
Non-Road Vehicles
Sub-application
Aerospace
Hydrogen supply chain stage
All components affected
on-board hydrogen storage, external fuel tanks (liquid and solid fuels)
Location type
Open
Location description
Airport Or Airborne
Operational condition
Pre-event occurrences
In the two external tanks there were 1575 m3 of LH2 and 550 m3 of LOX, which was part of the rocket fuel. The actual pressure was about 0.23 MPa. The potential ignition source was adjacent burning solid fuel rocket boosters. According to NASA, O-ring rubber pressure seal at one of the solid rocket boosters eroded by hot gases after approx. 60 s after lift-off. A steady flame developed which was directed towards the External Tank containing the LH2 and LOX.

Emergency & Consequences

Number of injured persons
0
Number of fatalities
7
Post-event summary
All shuttle flights were suspended, pending the results of the Rogers Commission investigation, after which NASA implemented investigation recommendations.
Emergency action
The fire brigade had no reason to intervene.

Lesson Learnt

Lesson Learnt

Rogers President's Commission issued a series of recommendations to NASA, the first and the most specific one was the redesign and replacement of the Solid Rocket Motor joint and seal.

Further, more general recommendations were:
1. The review of the whole Shuttle Program Structure
2. Bringing qualified astronauts into agency management positions
3. To re-design the shuttle safety panel
4. To establish an Office of Safety, Reliability and Quality Assurance
5. To improve communication and break management isolation
6. To improve the landing safety
7. To provide a crew escape system for use during controlled gliding flight
8. To establish a flight rate consistent with NASA resources, and to avoid commercial pressure.
9. To review and improve installation, test, inspection and maintenance procedures
rigorous

Event Nature

Release type
Liquid
Involved substances (% vol)
H2 100%
Release duration
0
Released amount
1575
Presumed ignition source
Open flame
Flame type
Flash fire

References

Reference & weblink

The Chapter 4 of President's Commission report<br />
http://science.ksc.nasa.gov/shuttle/missions/51-l/docs/rogers-commissio… />
(Accessed September 2020)

Part of the Chapter XI of President's Commission report, with recommendations<br />
http://science.ksc.nasa.gov/shuttle/missions/51-l/docs/rogers-commissio… />
(Accessed September 2020)<br />

JRC assessment