STS-93 SSME Nozzle Tube Rupture Investigation

STS-93 was launched on July 23, 1999. There was an anomaly at the end of the launch in that the main engines shut down 0.16 second early because sensors detected a low level of oxidizer in the LOX tank (actually the duct from the tank to the vehicle). This resulted in a cutoff velocity for the vehicle that was 16 ft/sec low. It should have been 25872 ft/sec. The OMS engines were subsequently used to achieve the proper orbit. An investigation was immediately initiated into the cause of this LOX tank low level cutoff. It was noticed during the launch that the turbine temperatures for Main Engine 3 (E2019) were approximately 100 F higher than the preflight prediction. Linear Engine Model matching of the data indicated that a nozzle leak best fit the data. Post launch review of the data showed, that at approximately five seconds into the start, numerous parameters indicated small anomalous shifts. These shifts were all consistent with a rupture of nozzle tubes. Post launch review of the films showed that just after Space Shuttle Main Engine (SSME) ignition and just prior to liftoff a streak is seen in the exhaust plume of E2019. Just after liftoff the streak can be seen emanating from the nozzle wall. This photo confirmed that a leak was coming from the nozzle tubes. Based on the photo, the axial location of the leak was estimated to be 28 in. from the aft end of the nozzle and in line with nozzle coolant feed line #1. The streak continued to be visible during the launch.