Lessons Learned from the Space Shuttle Engine Cutoff System (ECO) Anomalies

The Space Shuttle Orbiter's main engine cutoff (ECO) system first failed ground checkout in April, 2005 during a first tanking test prior to Return-to-Flight. Despite significant troubleshooting and investigative efforts that followed, the root cause could not be found and intermittent anomalies continued to plague the Program. By implementing hardware upgrades, enhancing monitoring capability, and relaxing the launch rules, the Shuttle fleet was allowed to continue flying in spite of these unexplained failures. Root cause was finally determined following the launch attempts of STS-122 in December, 2007 when the anomalies repeated, which allowed drag-on instrumentation to pinpoint the fault (the ET feedthrough connector). The suspect hardware was removed and provided additional evidence towards root cause determination. Corrective action was implemented and the system has performed successfully since then. This white paper presents the lessons learned from the entire experience, beginning with the anomalies since Return-to-Flight through discovery and correction of the problem. To put these lessons in better perspective for the reader, an overview of the ECO system is presented first. Next, a chronological account of the failures and associated investigation activities is discussed. Root cause and corrective action are summarized, followed by the lessons learned.