Assessment of the hydrogen external tank pressure decay anomaly on Space Transportation System (STS) 51-L

Following the Challenger tragedy, an evaluation of the integrated main propulsion system flight data revealed a premature decay in the hydrogen external tank ullage pressure. A reconstruction of predicted ullage pressure versus time indicated an inconsistency between predicted and measured ullage pressure starting at approximately 65.5 seconds into the flight and reaching a maximum value between 72 and 72.9 seconds. This discrepancy could have been caused by a hydrogen gas leak or by a liquied hydrogen leak that occurred either in the pressurization system or in the external tank. The corresponding leak rates over the time interval from 65.5 to 72.9 seconds were estimated to range from 0.28 kg/s (0.62 lbm/s) + or - 41 percent to between 0.43 and 0.51kg/s (0.94 and 1.12lbs/s) + or - 1 percent for a gas leak and from 72.9 kg/s (160.5 lbs/s) + or - 41 percent to between 111.6 and 133.2 kg/s (245.8 and 293.3 lbs/s) + or - 1 percent for a liquid leak. No speculation is made to ascertain whether the leak is liquid or gas, as this cannot be determined from the analysis performed. Four structural failures in the hydrogen external tank were considered to explain the leak rates. A break in the 5-cm (2 in) pressurization line, in the 13-cm (5 in) vent line, or in the 43-cm (17 in) feedline is not likely. A break in the 10-cm (4 in) recirculation line with a larger structural failure occurring in the 72 to 73-second time period, the time of the visibly identified premature pressure decay, does seem plausible and the most likely of the four modes considered. These modes are not all-inclusive and do not preclude the possibility of a leak elsewhere in the tank.