SpaceX Readies Booster 19 with Major Upgrades at Starbase for Upcoming Launch

SpaceX is making significant progress at its Starbase facility as it prepares for the return of Booster 19. The company has been conducting extensive tests, including deluge and load testing of the Ship Quick Disconnect (SQD) arm, in anticipation of the upcoming launch scheduled for May. This particular mission, designated as Flight 12, will feature the booster equipped with all 33 of its engines.

Efforts to improve turnaround times between flights have led to modifications of key components on the tower and launch mount, drawing on design insights gathered from Pad 1 operations. One notable development involves the SQD arm, which plays a critical role in connecting the Starship upper stage for propellant loading. Recently, engineers added steel reinforcements to the arm’s shoulder section, a move believed to bolster its structural integrity and expedite its retraction process during launches. A quicker retraction is essential to reduce potential damage from the powerful exhaust generated by the Super Heavy’s engines.

As preparations continue, the core enhancements to the SQD arm appear to be nearing completion, with scaffolding potentially being removed in the near future. Unusually, water bags were seen in use this week, likely simulating the downward forces on the arm during fuel loading and thrust from the rocket during liftoff.

In addition to the enhancements on the SQD arm, the tower’s new roof structure has been successfully installed and is undergoing final welding to secure it in place. This structure is designed to protect against the exhaust from the Starship’s engines during recovery operations. The process for recovering the Starship differs from that of the Booster, as the Starship employs a “flip and burn” maneuver during its approach for landing, sliding between the “chopsticks” or catch arms.

The exterior panels being installed on the tower will also provide protection for critical components, notably the drawworks system that operates the catch arms. Ensuring the functionality of this system especially important for the success of future recovery operations.

Simultaneously, work continues on the Orbital Launch Mount (OLM) at Pad 2. With Booster 19 currently housed in Mega Bay 1 for engine installation, scaffolding has returned around Booster Quick Disconnects (BQDs) for both liquid oxygen and methane. New proximity sensors have been fitted atop the BQDs to enhance the precision of the booster alignment, allowing for more efficient operations compared to the previous system used at Pad 1.

The dual BQDs offer multiple reference points for alignment, bypassing the manual adjustments of the past. In a further effort to bolster system reliability, SpaceX is relocating the newly installed sensors into protective housings to ensure they can withstand repeated operations.

Other recent activities at the OLM included the temporary removal and subsequent reinstallation of alignment hemispheres for modifications or inspections, potentially based on data from prior tests. Additional testing of the hold-down arms was also conducted to ensure optimal performance.

SpaceX has been actively testing the pad’s deluge system, including tests conducted in conjunction with NASA’s SLS/Artemis 2 mission activities. Recent deluge tests showcased quick, effective updates to the chopstick system, which has transitioned from hydraulic to electric actuation, resulting in improved speed and responsiveness.

These ongoing enhancements at Pad 2 exemplify SpaceX’s methodical approach to optimizing its Starship operational infrastructure. The improvements not only target potential wear and enhance alignment precision but also contribute to the overall robustness and efficiency crucial for the ambitious launch cadence envisioned for the Starship program. Further preparations are expected to lead to static fire tests with Booster 19 in the coming weeks, as both the Booster and Ship for Flight 12 are now equipped with their complete engine sets.