Small Steps, Giant Leaps - Chapter 2, Part 3: From Skylab to Starlab
STS-1, being the first flight of the Space Shuttle, is often thought of as “the test flight”; however, this was not remotely the case. As with Mercury, Gemini, and Apollo before it, the Space Transportation System would have to perform multiple orbital tests before being officially certified by NASA as an operational system - the difference here being, due to the nature of Space Shuttle missions, every test would be a crewed flight unto itself.
Almost as soon as
Kitty Hawk rolled to a stop at Edwards Air Force Base at the end of STS-1, preparations were underway for STS-2. This mission would test important objectives like full-duration life support, payload deployment and retrieval, and orbital maneuvering, and would, rather crucially for the program, be the first re-flight of an orbital spacecraft.
After a triumphant return to Kennedy Space Center,
Kitty Hawk was offloaded from the Shuttle Carrier Aircraft and returned to the Orbiter Processing Facility. Initial inspections found the Space Shuttle Orbiter to be in remarkably good shape, the most notable and slightly concerning issue being damage to thermal tiles due to foam shedding from the External Tank during launch. Some of this was to be expected, but nevertheless preventative measures such as de-icing the External Tank and some minor design modifications to the tank itself would be implemented starting on STS-2 to lessen the impact of this issue going forward.
For STS-2, in addition to the Development Flight Instrumentation,
Kitty Hawk’s payload bay would contain two new payloads: Canadarm, and SPARTAN 101.
Canadarm, the primary Canadian contribution to the Shuttle program, was a robotic manipulator arm built by SPAR Aerospace and derived from robotic systems utilized in servicing Canadian nuclear reactors. Used for moving and grappling payloads in orbit, the system was capable of moving about 100 metric tons in microgravity.
SPARTAN 101, the first in a series of satellites bearing the name, was a satellite meant to be deployed from the Shuttle to carry out independent research before returning to the Shuttle and being stowed in the Payload Bay at the end of a mission. As a test article, SPARTAN 101 carried only basic telemetry equipment, but future versions would integrate a number of instruments and experiments, mainly focused on astronomy.
In addition to its “firsts”, STS-2 also had two rather notable “lasts”. Testing had revealed the Shuttle’s External Tank to be resilient enough to UV radiation to ditch its protective white paint, with the added benefit of over 100 kilograms of mass savings. All future External Tanks would be the now-iconic unpainted orange of the SOFI insulation, but STS-2’s tank was too far along in production, so the white-painted tank would fly for a second and final time on that mission.
STS-2’s second “last” was less visible, but nonetheless significant. While neither STS-1 nor STS-2 had been planned with an extravehicular activity in mind, all Shuttle flights would fly with spacesuits aboard in case of emergencies. With the new Extravehicular Mobility Unit suits still undergoing final certification at the time of its flight, STS-2 would be the final mission to fly with A7LB spacesuits aboard.[1]
STS-2 would reach the pad after 7 months’ turnaround from STS-1. The mission, commanded by Apollo 14 veteran Ken Mattingly and piloted by rookie Karol Bobko, lifted off on October 30, 1980, with
Kitty Hawk performing near-flawlessly for her second ascent to orbit.
Mattingly and Bobko spent Flight Day 1 checking Shuttle systems, including the newly-installed galley and “space toilet”, vastly improving both meal and hygiene quality, as well as crew morale surrounding both. Flight Day 2 saw Bobko power up Canadarm for the first time in space, expertly running it through a full range of motion and latching it onto its first payload, repeatedly grabbing and letting go of the still-secured SPARTAN 101. The crew also celebrated Halloween, with Mattingly revealing a miniature pumpkin and a collection of space-safe candy flown amongst his personal items and the crew wishing the country’s children good luck trick-or-treating during a television broadcast.
Flight Day 3 saw SPARTAN 101 deployed into space and
Kitty Hawk maneuvering to different orbits using its Orbital Maneuvering System and RCS thrusters. STS-2’s mission passed relatively uneventfully from there until Flight Day 6;
Kitty Hawk returned to her original orbit and rendezvoused once more with SPARTAN 101, retrieving the satellite and stowing it once more in the Payload Bay. Flight Day 6 also happened to be Election Day back on the ground; the crew of STS-2 could not vote from orbit, and instead had submitted absentee votes just prior to their flight.[2]
STS-2 concluded on Flight Day 8, with
Kitty Hawk deorbiting and returning safely to landing at Edwards Air Force Base. From there, she would be ferried once more back to KSC to begin preparations for STS-3, planned for February 1981.
Liftoff on STS-2, November 1980. Image credit: NASA SpaceFlight
STS-3 MET 2 DAYS, 19 HOURS
"Okay, Buzz, you're looking good. Right on the money."
"Thanks, Gordon. How's Skylab looking?"
"Skylab is lined up as well, docking port's still pointed right at us. We should be go for docking whenever Houston is ready."
"Copy,
Kitty Hawk. We're showing the same. You're cleared to take her in."
Although the rendezvous maneuvers had gone smoothly enough, the first docking of the Space Shuttle program was proving to be a bit awkward. The Shuttle's first operational payload, a modified Docking Module flight spare from Apollo-Soyuz, was perched precariously atop its docking port, blocking the docking camera. This forced mission Pilot Gordon Fullerton to float up by the upper windows in
Kitty Hawk's cabin, eyeballing in directions to Commander Buzz Aldrin at the controls. In addition, with the final approach having the unfortunate timing of occurring over East Asia, they were on a tight time limit for this first attempt: Once they passed out of range of the ground station in Japan, mission rules would require
Kitty Hawk to abort docking until contact could be regained over Hawaii.
"You're looking good, Buzz- a little to the left, now, there we go, now up a little- yeah, okay, zero out our lateral velocity- right down the centerline. What's our distance looking like?"
Buzz checked his console. "Rendezvous radar says 18 meters, closing rate of 0.2 m/s. Slowing down a little."
"Okay, we're still lined up, easy does it- move down now, okay, hold here, looks good. Ports look lined up."
"
Kitty Hawk, we're tracking the same. Houston is Go for docking."
Buzz pulsed
Kitty Hawk's RCS thrusters again, beginning a slow final approach to the waiting docking port.
"We've got contact! Looks like soft dock to me, what about you, Houston?"
"We confirm. Go for hard dock."
Latches that had gone unused for half a decade pulled in, and-
"Hard dock confirmed. Houston, be advised,
Kitty Hawk has caught herself a space station."
The final test flight of the Space Shuttle, STS-3, would prove to be the most demanding yet. With the Shuttle having proven itself capable of safely flying to and from orbit, supporting a crew, delivering and retrieving payloads, and performing rendezvous maneuvers, the only remaining test objectives were demonstrating docking with a space station and performing EVA operations. Under the mission plan,
Kitty Hawk would rendezvous and dock with Skylab using a modified Apollo-Soyuz Docking Module, and her crew would use the new EMU spacesuits for the first time to conduct an EVA inspection of the station.
STS-3, the last two-person mission of the Shuttle program, would be commanded by Gemini 12 and Apollo 19 veteran Buzz Aldrin. Similarly to STS-1 and STS-2, this would be Aldrin’s final spaceflight and the first for his Pilot C. Gordon Fullerton, with NASA planning to use the test flight Pilots and other early Shuttle fliers to gain more experienced astronauts to command future missions.
After a flawless launch on January 18th, 1981, the crew would spend their first day in orbit checking
Kitty Hawk’s systems and moving into a rendezvous orbit to reach Skylab. On Flight Day 2, Fullerton used the Canadarm to extract the Docking Module from the payload bay and mount it to
Kitty Hawk’s docking port, while Aldrin flew the Shuttle through additional maneuvers to continue the rendezvous.
The Docking Module is grabbed by Canadarm and maneuvered to Kitty Hawk’s APAS-79 docking port, January 19th, 1981. Image credit: beanhowitzer
Late on Flight Day 3, the crew made a smooth docking with Skylab, marking the first time the Space Shuttle had docked to another spacecraft and the first visit to Skylab since Skylab 5- the docked portion of the mission was designated as Skylab 6 internally to the Skylab program, in addition to the overall designation of STS-3. The crew would not enter Skylab immediately, instead resting while ground control verified that Skylab was in good condition to board.
On Flight Day 4, the astronauts opened up the hatch between the Docking Module and Skylab, and were greeted with an unwelcome surprise. The interior of the station was filled with mold, evidently caused by five years of abandonment leaving any mold spores that had escaped pre-launch sterilization and in-orbit cleaning to spread wildly. In addition to the general mess, the mold also made Skylab’s interior effectively unusable, meaning that experiments the crew had brought up on
Kitty Hawk to conduct on-station would have to be canceled. Without nearly enough supplies to deal with the problem, the crew evacuated and the hatches were quickly closed before the infestation could spread to the Docking Module. Although
Kitty Hawk was performing well, STS-3 would be cut short, with planned operations inside Skylab impossible.
Flight Day 5 would see the first EVA of the Shuttle program, with both crew members using the EMU suits and Shuttle airlock for the first time and conducting maneuverability tests in the payload bay and around Skylab; an EVA inspection of the station thankfully revealed everything to be in order, meaning that future missions would only have the mold to contend with. The crew would take a day off from strenuous activity and spend Flight Day 6 performing more testing and a truncated set of experiments in
Kitty Hawk’s crew cabin, while Flight Day 7 would see the second and final EVA of the mission. On EVA 2, the astronauts connected power cables and coolant lines from Skylab’s solar arrays and radiators to the Docking Module and replaced Roadrunner’s film canisters. The venerable ATM had spent five years dutifully gathering data on the Sun which astronomers were eager to have returned and developed. Finally, on Flight Day 8, the Shuttle would undock and make a successful landing at Edwards, bringing the Space Shuttle’s test program to a close.
Kitty Hawk docked to Skylab during STS-3, January 1981. Image credit: beanhowitzer
With the knowledge gained from STS-3, NASA finally determined Skylab’s long-term future. Once the mold was cleaned out, a task planned for the eventual second Shuttle-Skylab flight, Skylab would be used as a quiet, stable platform for experiments that needed to be returned via Shuttle but would otherwise be disturbed by the expected activity around Starlab, in a “Crew-Tended Free Flyer” configuration. Skylab would provide power, thermal control, control, and a pressurized environment if necessary to experiments that would otherwise have needed to fly on independent satellites such as the planned Long-Duration Exposure Experiment, saving NASA a considerable amount of money. Although not nearly as exciting as its upcoming replacement, Skylab would have a comfortable retirement mission for the foreseeable future.
With the Space Shuttle operational, there was no doubt as to what its first mission would be. Starlab was essentially ready for launch and had been for over a year by the time STS-3 launched, being simply an upgrade of the existing Skylab design rather than an entirely new system like the Shuttle. Both Starlab and Shuttle program managers wanted the station to fly as soon as possible; the former for somewhat obvious reasons, and the latter because Starlab’s launch would finally allow LC-39B to be converted for Shuttle use rather than remaining frustratingly in the Saturn configuration necessary to launch Starlab.
STS-4, flying with a full crew of 7 for the first time, was planned to launch just a day after Starlab. Like Skylab 2 before it, the crew would transform Starlab’s Orbital Workshop from an empty fuel tank into a home and laboratory in orbit and settle in as its first long-duration crew.
Kitty Hawk would leave five crew members in orbit to form the crew of Starlab 2 (with Starlab 1 being the station’s launch similarly to Skylab 1), while the Commander and Pilot would return home in the Shuttle. Starlab 2 was planned to occupy the station for six months, until STS-6 would retrieve them and drop off Starlab 3 to continue permanent habitation of the station. In addition to the first flight of the ESA-built Sortie Lab module, carrying additional supplies and equipment to outfit the station,
Kitty Hawk would also carry a special piece of cargo: the Apollo ACRV.
Even with Apollo-Soyuz as the final dedicated Apollo mission, the end was not yet to come for Apollo - it would live on at Starlab. By the nature of the Space Shuttle’s limited on-orbit lifespan, there would be long periods of no Shuttle on-station at Starlab, only briefly punctuated by resupply missions and crew rotations. In order to ensure a safe method of evacuation for a space station crew, Starlab would require an “Assured Crew Return Vehicle” present at all times in case a Shuttle was not present or could not be launched in time. Apollo could fill such a role easily without expensive development of a new system.
The Apollo Assured Crew Return Vehicle (ACRV) would be built largely out of spare parts, with a few new components ordered from Rockwell as needed from previously-mothballed tooling. The ACRV CSM would be stripped significantly from its previous role, with batteries charged from Starlab’s solar arrays replacing its fuel cells and a bare minimum of deorbit fuel loaded into the SM. With seats arranged in the “Skylab Rescue” configuration, it could safely return five crew members, setting the limit for Starlab’s crew capacity. Luckily, an Apollo CSM of standard proportions was small enough to easily fit in the Space Shuttle’s payload bay, providing a natural launch vehicle with the retirement of the Saturn IB. The Shuttle would deliver the ACRV to orbit and rotate out vehicles as needed, with the CSMs being returned in the payload bay for refurbishment.[3]
Three ACRV CSMs would be built for the Starlab program. Although two were new-build CSMs using spare parts and tooling, CSM-119 was the long-grounded Skylab Rescue CSM, offered a new lease on life. Together, CSMs 119, 123, and 124 would provide Starlab with a critical crew return capability, and continue Apollo’s legacy into the 1980s.
Kitty Hawk and the last Saturn IB prepare for Starlab’s launch, spring 1981. Image credit: Talv / Jess
OV-099 Challenger is rolled out of the Palmdale plant for delivery to NASA in spring 1981, a sign of things to come for the Shuttle Program. Image credit: NASA History Office