SpaceX pushes forward with Booster 19 amid challenges from Booster 18 failure and tight timelines for Flight 12

Following a recent setback with Booster 18, SpaceX is moving forward with the development of Booster 19 and the evaluation of the Block 3 test tanks. Despite this progress, a high number of tasks remain before the anticipated Flight 12 can take place, particularly the construction of a new booster and the completion of a new launch pad.

Last week, Booster 18 faced a significant disruption during a gas system pressure test, where SpaceX attempted to load gaseous Oxygen, Nitrogen, and possibly Helium to conduct pressure checks on the main propellant tanks and associated systems. This testing led to a catastrophic failure, resulting in a breach in the side of the booster, attributed to a likely explosion of a Composite Overwrapped Pressure Vessel (COPV). Fortunately, SpaceX reported that no personnel were injured, and efforts commenced quickly to secure the test site. The aftermath of the anomaly has seen the removal of various components, including the Liquid Methane tank and parts of the Liquid Oxygen tank.

Following the incident, SpaceX is expected to finalize the scrapping operations after the Thanksgiving holiday. Once all remnants of Booster 18 are extracted from the thrust simulator cryogenic stand, repairs will be needed on the stand itself, as some hydraulic systems sustained damage during the test. The stand is anticipated to be operational again in time for the cryogenic proof testing of Booster 19.

Booster 19, which is set to take the reins as the first Block 3 booster for Flight 12, is currently being assembled in Mega Bay 1. With its stacking process underway as of November 27, SpaceX aims to have Booster 19 ready for testing by December. This timeline suggests a rapid preparation period of just three to four weeks, a pace that would mark a historic achievement for SpaceX in its Starship program.

Nonetheless, the ambitious timeline for Booster 19 faces some historical context; SpaceX has not previously constructed and tested any ship or booster within a month. The fastest any previous booster has been prepared was three months, indicating that achieving such a rapid turnaround could be challenging.

In addition to the work surrounding Booster 19, Flight 12 must also contend with important milestones concerning two booster test tanks, named B18.1 and B18.3, currently being tested at Masseys. B18.1, a Block 3 booster aft test tank, has undergone extensive cryogenic proof testing while B18.3 has not yet reached the same level of completion. SpaceX is currently also constructing a structure intended for upcoming testing on grid fin sockets.

As critical components of Flight 12, Ship 39 and its associated test tank, S39.1, pose another challenge. Fully assembled within Mega Bay 2, Ship 39’s next phase involves cryogenic proof testing, which is currently impeded by S39.1 occupying the thrust simulator cryogenic stand. The testing of S39.1 requires modifications to further interface with a can crusher, complicating the timeline.

Moreover, the operational readiness of Pad 2 is essential, as it will serve both testing and eventual flight needs. Progress has been made with the installation of the ship quick-disconnect arm, but several components remain, including a critical liquid methane pump and various blast doors that need to be installed.

As SpaceX approaches the pivotal moments leading to Flight 12, both its launch infrastructure and vehicle readiness are still under significant development. With various testing protocols to complete and multiple components awaiting final adjustments, the team faces a demanding schedule ahead.